MOST Specifications For Road & Bridges

Ministry of Surface Transport (Roads Wing)
SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

(Third Revision)
Published by Indian Roads Congress New Delhi 1997

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Ministry of Surface Transport (Roads Wing)
SPEd FICATIONS FOR ROAD AND BRIDGE WORKS

(Third Revision)
LIBRARY & DOCUMENTATION CENTRE

LARSEN & TOUBRO LTD.
EGG CONSTRUCTION GROUP
P.B. No. 979 MOUNT PC~NAMALLEEROAD MANi~riKKAM,CHENNAI-600 089 RecE Acc. No.
r~
...
Published by the Indian Roads Congress on behalf of the Govt. of India, Ministry of Surface Transport (Roads Wing)
Copies can be hadfrom the Secretary, indian Roads Congress, Jamnagai House, Shahjahan Road, New DelJzi.119 Oil
NEW DELHI-lgg7 Prk~e 400/Rs. Plus packing & postage charges
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First Published
Reprinted First Revision Reprinted Reprinted Reprinted Second Revision Reprinted

Reprinted
April, 1973 November, 1975 May, 1978 September, 1981 October, 1983 April, 1986 February, 1988
August, 1988
Reprinted Reprinted Reprinted

Third Revision Reprinted
April, 1990 June, 1992 February, 1993

July, 1993
Reprinted
Reprinted Reprinted
Repri ntccl
April, 1995 January, 1997 (Incorporates Corrigendum NoJ &2andCol. 12&l5ofp.662) January, 1998 January, 1999 May, 1999 February, 2000
(The Rights of Publication and Translation are rese,ved)
Printed at M/s Dec Kay Printers, New Delhi-hO 015 1000 Copies
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PREFACETO THE THIRD REVISION
Specifications for Road and Bridge Works first published in 1973 has already undergone two revisions in the past. With the advent of the externally aided projects based on international contract documents and modernisationofHighway Construction, it became necessary to revise the Specifications to be consistent with equipment based construction techniques. Many of these revised specifications were included in the bidding documents of individual projects. The specifications have now been completely revised incorporating all the changes required to take into account the latest construction practices and the suggestions received from various users. A few additional chapters on topics not covered earlier have also been added. Revision of these specifications could be carried out in a short time only due to the concerted efforts of officers of the Roads Wing and the consultants whowere intimately connected with this work. I wish to record my appreciation of the efforts put in by all concerned. As with all specifications, the Third Revision of the Specifications wilt also no doubt need furtherupdating in course of time. Feed back and suggestions (or improvement would be welcome from all users of the document.
New Delhi November, 1994.
M. V. SASTRY Director General ( Road Development)
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CONTENTS
SECTION NO. 100 SECTION TITLE GENERAL CLAUSE NO. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 CLAUSE TITLE IN1RODUCTION DEFINITIONS MATERIALS AND TEST STANDARDS SIEVE DESIGNATIONS SCOPE OF WORK CONSTRUCTION EQUIPMENT CONTRACT DRAWINGS SITE INFORMA11ON SET11NG OUT PUBLICUTILITIES PRECAUTIONS FOR SAFEGUARDING THE ENVIRONMENT ARRANGEMENT FOR TRAFFIC DURING CONSTRUCTION GENERAL RULES FOR THE MEASUREMENT OF WORKS FOR PAYMENT SCOPEOFRATHS FOR DIFFERENT ITEMS OF WORK METHODOLOGY ANDSEQUENCE OF WORK CRUSHED STONE A~GGREGAThS APPROVAL OF MATERIALS SUPPLYOFQUARRYSAMPLES USE OFSURFACES BY CONSTRUCTION TRAFFIC SITE OFFICE FOR ENGiNEER AND OTHER SUPERVISORY STAFF FIELD LABORATORY SFTE RESIDENTIAL ACCOMMODATION FOR ENGINEER AND OTHER SUPERVISORY STAFF PROVIDING AND MAINTAINING WIRELESS COMMUNICATION SYSTEM PROVIDING AND MAINTAINING VEHIQ..ES FOR THE ENGINEER SUPPLY OF COLOUR RECORD PHOTOGRAPHS AND ALBUMS SUPPLY OF VIDEO CASSETIES PAGE NO. 3 3 6 6 7 8 9 9 10 11 13 14 17 19 21 21 21 21 22 22 26 30
123 124 125 126
32 33 35 36
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11
Contents
SECTION NO. 200
SECTION TITLE SITE CLEARANCE
CLAUSE NO. 201 202
CLAUSE TITLE CLEARING AND GRUBBING DISMAN1UNG CULVERTS. BRIDGES AND OTHER STRUCFURESIPAVEMENTS EXCAVATION FOR ROADWAY AND DRAINS BLASTING OPERATIONS PRESPLITI1NG ROCK EXCAVATION SLOPES EXCAVATION FOR STRUCTURES EMBANKMENT CONSTRUCTION SOIL EROSION AND SEDIMENTATION CONTROL TURFING WITH SODS SEEDING AND MULCHING SURFACE/SUB-SURFACE DRAINS PREPARATION AND SURFACE TREATh(ENTOF FORMATION WORKS TO BE KEPT FREE OF WATER WATER COURSES ATCULVERTS CONSTRUCTiON OF ROCKFILL EMBANKMENT GRANULAR SUB-BASE LIME TREATED SOIL FOR IMPROVED SUB-GRADE/SUB-BASE CEMENT TREATED SOIL SUBBASE/BASE WATER BOUND I ACADAM SUB-BASE/BASE CRUSHED CEMENT CONCRETE SUB-BASE/BASE WET MIX MACADAM SUB-BASE! BASE SHOULDERS, ISLANDS AND MEDIAN CEMENT CONCRETE KERB AND KERB WITH CHANNEL FOO11~ATHS AND SEPARATORS CRUStIER-RUN MACADAM BASE PREPARATION OF SURFACE PRIME COATOVER GRANULAR BASE TACK COAT BITUMINOUS MACADAM BITUMINOUS PENETRATION MACADAM BUILT-UP SPRAY GROUT
PAGE NO. 41 44
300
EARTHWORK~ EROSION CONTROL AND DRAINAGE
301 302 303 304 305 306 307 308 309 310 311 312 313
49
57
61 63 67 83 85 87 90 94 95 95 96 101
400
SUB-BASES, BASES (NONBITUMINOUS) AND SHOULDERS
401 402 403 404 405 406 407 408 409 410
105 109 112 121 123 128 130 132 133 139
145
500
BASES AND
SURFACE COURSES (BITUMINOUS)
501 502 503 504 505 506
148 149
157
160
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Contents SECTION NO. SECTION TITLE CLAUSE NO. 507 508 509 510 511
512
ill
CLAUSE TITLE DENSE BITUMINOUS MACADAM SURFACE DRESSING OPEN GRADED PREMIX CARPET MIX SEALSURFACING SEMI-DENSE BITUMINOUS CONCRETE BITUMINOUS CONCRETE SEAL COAT SUPPLY OF MINERAL AGGREGATES FOR PAVEMENTCOURSES BITUMEN MASTIC SLURRY SEAL RECYCLING OF BiTUMINOUS PAVEMENT DRYLEANCEMENTCONCRETE SUB-BASE CEMENT CONCRETE PAVEMENT ROLLED CEMENT CONCRETE BASE GEOSYNTHETICS IN ROAD AND BRIDQE WORKS GEOTEXTILES IN SUB-SURFACE DRAINS REINFORCED EARTH GEOSYNTIIETICS FOR HIGHWAY PAVEMENTS PROTECTION WORKS WITH GEOSYNTHETICS TRAFFIC SIGNS OVERHEAD SIGNS ROAD MARKINGS I-IECTOMETREJIULOMETRE STONES ROAD DELINEATORS BOUNDARY STONES FENCING TUBULAR STEEL RAILING CONCRETE CRASH BARRIER METAL BEAM CRASH BARRIER ROAD TRAFFIC SIGNALS GENERAL CONTROL OF ALIGNMENT LEVEL AND SURFACE REGULARITY QUALITY CONTROL TESTS DURING CONSTRUCtiON
PAGE NO. 163 170 177 185 186 189 192 194
197
513 514 515 516 517 600 CONCRETE PAVEMENT 601 602 603 700 GEOSYNTHETICS 701 702 703 704 705 800 TRAFFIC SIGNS, MARKINGS & OTHER ROAD APPURTENANCES 801 802 803 804 805 806 807 808 809 810 811 901 902 903
202 204
211
220 247 255 257 259 263 266 273 278

282 288
289 289 289 290 291 292 295 299 301 305
900
QUALITY CONTROL FOR ROAD WORKS
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iv SECTION NO. 1000 SECTION TITLE MATERIALS FOR CLAUSE NO. 1001. CLAUSE TITLE
Contents PAGE NO. 323 323 323 323 324 324 325
STRUCTURES
1002. 1003. 1004. 1005. 1006. 1007. 1008. 1009.

1010. 1011. 1012. 1013. 1014. 1015.
GENERAL SOURCES OF MATERiAL

BRICKS
STONES CAST iRON CEMENT COARSE AGGREGATES SANtVFINE AGGREGATES STEEL WATER TIMBER CONCRETE ADMLXTURES REINFORCED CONCRETE PIPES STORAGE OF MATERIALS TESTS AND STANDARD OF ACcEPTANCE DESCRIPIlON SUIT-SURFACE INVESTIGATION TYPE OF PILES MATERIALS TEST PILES PRECAST CONCRETE PILES
CAST.!N.SITU CONCRETE PILES
326
326 329 330 330 331 331 334
1100
PILE FOUNDATIONS
1101. 1102. 1103. 1104. 1105.
339 339
340
340 341 341 344 347 348 348 349 352 353 353
1106.
1107. 1108.
1109.
1110. 1111. 1112. 1113. 1114. 1115.
STEEL PILES TIMBERPILES

DRIVING EQUIPMENT DRIVING
RAKER (INCLINED) PILES

P1LETESTS
PILECAP
IMPORTANT CONSIDERATIONS, INSPECTION/PP..ECAU11ONS FOR DIFFERENT TYPES OF PILES TOLERANCES TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENTS FOR PAYMENT RATE
354
356 357 357 358 361 361 362 364 364 365 366
1116. 1117. Ills. 1119. 1200. WELL FOUNDATIONS 1201. 1202. 1203, 1204. 1205.
DESCRIPTION
GENERAL SElliNG OUT AND PREPARATIONS FOR SINKING CUlliNG EDGE WELL CURB WELL STEIN ING WELL SINKING
1206.
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1207.
Contents SECTION NO. SECTION TITLE CLAUSE NO.
CLAUSE TITLE BO11OM PLUG

SANDFILLING
PAGE
NO. 375 376 376 376
1208 1209.
1210. 1211. 1211 1213, 1214. 1215. 1300
TOPPLUG WELLCAP TOLERANCES . TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENT FOR PAYMENT
RATE
377
377
377
377 381 381 381 381 382 382 382 383 383 384 384 384 386 386 386 387 391
BRICK MASONRY
1301. 1302. 1303. 1304.

1305.
1306, 1307,
130&
1309,
1310. 1311. 1312. 13 13. 1314.
DESCRIPTION MATERIALS PERSONNEL CEMENT MORTAR SOAKING OF BRICKS JOINTS LAYING JOINTING OLD AND NEW WORK CURING
SCAFFOLDING
EQUIPMENT
FINISHING OF SURFACES ARC}IITEC11JRAL COPING FOR
1315.
1316. 1400
WING/RETURNiPARAPET WALL ACCEPTANCE OF WORK MEASUREMENTS FOR PAYMENT

RATE
STONE MASONRY
1401.
1402. 1403. 1404, 1405. 1406. 1407,

1408.
DESCRIPTION MATERIALS PERSONNEL TYPE OFMASONRY CONSTRUCTION OPERATIONS ARCHITECTURAL COPING FOR WING/RETURN/PARAPET WALLS TESTS AND STANDARD OF ACCEPTANCE MEASUREMENTS FOR PAYMENT
RATE
391 391
391 391 397
397 397
398 401 401 401
1409.
1500 FORMWORK 1501, 1502.
DESCRIPTION
MATERIALS DESIGN OF FORMWORKE
1503. 1504. 1505. 1506. 1507.
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WORKMANSHIP FORMED SURFACE AND FINISH PRECAUTIONS PREPARATION OF FORMWORK BEFORE CONCRETING
402
403
404 404
Ti
(.on ten Is SECTION TITLE CLAUSE NO. 1508. 1509. 1510. 1511. 1512. 1513. CLAUSE TITLE PAGE NO. 405
SECTION NO.
REMOVAL OF FORMWORK RE-USE OFFORMWORK SPECIALISED FORMWORK TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENTS FOR PAYMENT
406 406 407 407 407

411 411 411 411 412 413 415 415 415 419 419 419 42! 424 424 425 426 427 428 428 430 431 432 433 433 435 435 439 439 441 441 445 445 446
RATE DESCRIPTION
GENERAL PROTECTION OF REINFORCEMENT BENDING OF REiNFORCEMENT PLACING OF REINFORCEMENT BAR SPLICES TESTING AND ACCEPTANCE MEASUREMENTS FOR PAYMENT RATE DESCRIPTION MATERIALS GRADES OF CONCRETE NOPORTIONING OF CONCRETE ADMIXTURES SIZE OF COARSE AGGREGATE EQUIPMENT MIXING CONCRETE TRANSPORTING, PLACING AND COMPACTION OF CONCRETE CONSTRUCTION JOINTS CONCRETING UNDER WATER ADVERSE WEAThER CONDITIONS PROTECTION AN!) CURING FINISHING TOLERANCES TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENTS FOR PAYMENT RATE DESCRIPTION
1600
STEEL REINFORCEMENT (UNTENSIONED)
1601. 1602. 1603. l6O~ 1605.
1606.
1607. 1608. 1609. 1700 STRUCTURAL CONCRETE 1701. 1702. 1703. 1704. 1705. 1706. 1707. 1708. 1709. 1710. 1711. 1712. 1713. 1714. 1715. 17 16. 1717. 1718. 1800 PRESTRESSINC 1801. 1802. 1803. 1804. 1805. 1806. 1807.
MATERIALS
TESTING OF PRESTRESSING STEEL AND ANCHORAGES WORKMANSHIP SUPERVISION TENSIONING EQUIPMENT POST.TENSIONING
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(on t~ n
vii
SECTION CLAUSE CLAUSE TITLE NO. PAGE NO.
SECTiON NO.
T1TLE
1808.
1809. 1810. 1811, 1812. 1813. 1814. 1815. 1900 STRUCTURAL STEEL 1901. 1902.
GROUTING OF PRESTRESSEI) TENDONS PRE-TENSIONING SAFETY PRECAUTIONS

DURING TENSIONING TRANSPORTATION ANI) STORAGE OF UNITS TOLERANCES TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENTS FOR PAYMENT RATE
447 447 450 451

451 451
451
452 455 455 455 458 471 481 488 488 489 493 493 493 498
DESCRIPTION
GENERAL
1903. 1904. 1905. 1906.

1907. 1908.
MATERIALS
FABRICATION
ERECrION
PAINTING TESTS AND STANDARDS OF ACCEPTA ICE MEASUREMENFS FOR PAYMENT RATE DESCRIPTION GENERAL STEEL BEARINGS SPECIAL BEARINGS ELASTOMERIC BEARINGS
1909.
2000 BEARINGS
2001. 2002. 2003. 2004. 2005. 2006. 2007. 2008. 2009.

2010.
500
513 519 519 519 519 523 523 523 523 525 526
POT BEARINGS INSPECTION AND TESTING TESTS AND STANDARDS OF ACCEPTANCE

MEASUREMENTS FOR PAYMENT
RATE DESCRIPTION
MATERIALS
2100
OPEN FOUNDATIONS
2101. 2102. 2103. 2104. 2105.
GENERAL
WORKMANSHIP TESTS AND STANDARDS OF
2106,
2107. 2108. 2200. SUB-STRUCTURE 2201.
ACCEPTANCE TOLERANCES MEASUREMENTS FOR PAYMENT

RATE
52.6
526 529 529
2202.
DESCRIPTION MATERIALS
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Contents SECTION TITLE CLAUSE NO. 2203. 2204. 2205. 2206. 2.207. 2208. CLAUSE TITLE PAGE NO. 529 529 530
SECTION NO.
2209.
2210. 2300 CONCRETE SUPERSTRUCTURE 2301. 2302. 2303 2304. 2305.
GENERAL PIERS AND ABUTMENTS PIER CAP AND ABUTMENT CAP DIRT/BALLAST WALL, RETURN WALL & WING WALL TESTS AND STANDARDS OF ACCEPTANCE TOLERANCES IN CONCRETE ELEMENTS MEASUREMENTS FOR PAYMENT RATE DESCRIPTION
531
531 531 532 532 535
MATERIALS
GENERAL REINFORCED CONCRETE CONSTRUCTION PRESTRF.SSED CONCRETE CONSTRUCTION TOLERANCES TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENTS FOR PAYMENT RATE GENERAL PR! 1 IMINARY INVISTIGA I tON DETAILED EXPLORATION EXPLORATION FOR BRIDGE FOUNDATIONS RESTiNG ON ROCK BORING RECORDS OF BORINGS AND TRIAL PITS METHODS OF SAMPLING PROCEDURE FOR TAKiNG SAMPLES PROTECTION, HANDLING AND LABELLING OF SAMPLES TESTS FOR EXPLORATION OF SHALLOW FOUNDATIONS OF BRIDGES TESTS FOR EXPLORATION FOR DEEP FOUNDATIONS OF 1RIDGES
535
535 535
536 538 538 539 539 543

~41
2:306.
2307. 2308.
2309,
2400 SURFACE AND ,UB ~URFA( F GEOTECEJNICAL EXPLORATION 2401. 2402
2403.
2404,
546 547
550 550 551
2405. 2406. 2407. 2408. 2409. 2410.
552
554
555
555
2411.
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CEontents
SECTION NO. SECTION TITLE CLAUSE NO. 2412.
5
CLAUSE TITLE
ix PACE NO. 556
TESTING OF MATERIAL FOR GUIDE BIJND AND HIGH

EMBANKMENT AND ITS FOUNDATIONS.
2413. 2414. 2500 RIVER TRAINING WORK AND PROTECTION WORK 2501. 2502. 2503. 2504 2505

RATE
559
559 563 563 564 566 569
DESCRIPTION
GUIDE BUND APRON PITCHING/REVEThIENT ON SLOPES RUBBLE STONE/CEMENT
CONCRETE BLOCK FLOORING OVER CEMENT 2506.

2507. CONCRETE BEDDING DRY RUBBLE FLOORING CURTAIN WALL AND FLEXIBLE APRON TESTS AND STANDARDS OF 570 570 571 571 571 575 575 576 577 578 578 583 587 587 587 591 591 592
2508.
2509. 2510. 2600 EXPANSION JOINTS 2601. 2602. 2603. 2604. 2605. 2606. 26p7. 2608.
ACCEPTANCE MEASUREMENTS FOR PAYMENT

RATE DESCRIPTION GENERAL
REQUIREMENTS STEEL PLATE SLIDING

EXPANSICdtJOINTS FILLER JOINTS ELASTOMERIC SLAB SEAL EXPANSION JOiNT STRIP SEAL EXPANSION JOINT TESTS AND STANDARDS OF ACCEPTANCE
2609.
2610. 2700 WEARING 2701. COAT AND 2702. APPURTENANCES 2703, 2704. 2705. 2706. 2707. 2708. 2709.

RATE DESCRIPTION
WEARING COAT
RAILINGS APPROACH SLAB DRAINAGE SPOUTS WEEP HOLE TESTS AND STANDARDS OF ACCEPTANCE MEASUREMENTSFOR PAYMENT RATE
593
594 595 595 595 595
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x
SECTION NO. 2800 SECTION TITLE REPAIR OF STRUCTuRES CLAUSE NO. 2801. 2802. 2803, 2804. CLAUSE TITLE
CEontents PAGE NO.
DES~R1PTION GENERAL SEALING OF CRACKS BY INJECTION OF EPOXY RESIN EPOXY MORTAR FOR REPLACEMENT OF SPALLED
599
599 599
606
609 609 612 614 615 616 617 617 618 621 621
CONCRETE
2805. 2806. EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE CEMENT GROUTING GUNITING/SHOTCRETE REPLACEMENT/RECTIFICATiON OP BEARINGS DISMANTLING OF CONCRETE WEARING COAT EXTERNAL PRESTRESSING TESTS ANDSTANDARDS OF ACCEPTANCE MEASUREMENTS FOR PAYMENT RATE SCOPE MATERIALS EXCAVATION FOR PIPE BEDDING FOR PIPE LAYING OF PIPE JOINTING BACKFILLING HEADWALLS ANI) OTHER ANCILLARY WORKS
2807.
2808.
2809.
2811). 2811. 2812. 2813. 2.900 PIPE CU1.,VEST S. 2901. 2902. 2903.
2904.
2905.
2906.
2907. 2908.
621 622 622 623

623
624 624 624

624 627 627 628 629
2909.
2910. 2911. 3000 MAINTENANCE OF ROA [) 3001. 3002. 3003.
OPENING TO TRAFFiC
MEASUREMENTS FOR PAYMENT RATE GENERAL RESTORATION OFRAIN.CUTS MAINTENANCE OF EARTHF.N SHOULDERS BITUMINOUS WORK IN CONNECTiON WITH MAINTENANCE AND REPAIRS MAINTENAINING OF CEMENT CONCRETE ROAD
3004. 3005.
631
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xi SECTiON
NO. A PPFEN DEC ES APPENDIX I.
SECTION
HIITLE
C1.,AIJSE
NO.
(ELAL SE TITLF,
PAGE NC).
LIST OF I.R,C, PUBI.ICATIONS

RIIIRRID1OIN IIIFSPFUIKAI1ONS CODES& STANDARDS
637
APPENDIX
1,15 OF INDIAN AND FOREIGN SIANDARDSRIZIRRFDTOI\ 1IlESPFCEIFICATIONS Ni F.flRlI) OF SIEVING FOR VQI 1 SOlES IODFIIRMINI nil DEGREE OFPCELVERISATION GEIDEI.JNES ON SELECTION OFT BE GRADE OF BFTIJMEN
640
~\PEI.ENDI\ 3.
647
APPENDIX 4.
648
APPENDIX 5.
ANTI STRIPPING AGENTS USFEI) FOR BITUMINOUS MATFERIALS AND MiXES

1 (X)i-1 IE)RAFF DOCUMENT ON ISC 9077-1979 CODE 01 PRA( 1 ICI FOR CORROSION PRO EEC lION OF STEEL REINFORCEMENT ZN RB AND RCC (EONSTRUCTION (REVISED) HISTOR N GE SINKING Oi~ \\rI.:I .1. P1 ANOI WEll NOS 111:1 & SPIEL IN )~rEIINOS. INFORM ATION 1O BE SEPPLTEI) TO Ti] F MANt I k( 111(1 RI, UI PROPRII 1 NRN SYSTIJ.MS SPECIEICAJI( IN FOR CONSTRUCTiON JOINTS PF.R.MF.ABIL1TY TESI EFESTS ON SIIEAIIIING DCEC1S PRESTRESSING REPORT SPFECIFICA11ONS FOR GROUTING OF POSTTENSIONED CABLES TN PRESTRESSED CONCRETE GROUTING RECORD
6 0
APPENDIX
655
APPENDIX
1 2oO/I~ P00/I 2 200/LI 500/I
666 661 662 663
APPI EN~DIX
A PP1EE\ iTX
I 700/I 1700/TI 1800/I 18(X)/tI 1800/Ill I 8(X)/IT
665 667 668 674 675 681
APPENDIX
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General
100
General
<<
General 101.. INTRODUCTION
Section 100
These Specifications shall apply to all such road and bridge works as are required to be excctltecl under the Contract or otherwise directed
by the F:~ngineer-in-Charge(hereinafter referred to is the Fngineer). in every case, the work shall be carried out to the satisfaction of the
Engineer and conform to the location, lines.., dimensions., grades and crosssections shown on the drawings or as indicated by the Engineer. Tic quality of materials, processing of materials as may be needed at the ,site,saiient features of the construction work and quality of finished work shall comply with the requirements set forth in succeeding sections. Where the drawings and Specifications describe a portion of he. work in only general terms, and not in complete detail, it shall be: understood that only the best general practice is to prevail, materiab and
workmanship of the best quality are to be employed and instructions of the Engineer are to be fully complied with, A lisl of Indian Roads Congress Specifications and Recommended Codes of Practice which have been made use of in the preparation of these Specifications is given at Appendix-i. The latest e,dition of all Specifications/Standards till 30 (thirty) days before the final dale of submission of the tender, shall be adopted. 102. DEFINITiONS
The words like Contract, Contractor, Engineer (synonymous with Eng.neer-in-charge), Drawings, Employer, Government, Works and \Vcrk Si to used in these. Specifications shall he considereti to have the meaning as understood Ironi the definitions of these terms given in the Genera Conditions of Contract, The following abbreviations shall have the meaning as seI be low E
ASS I ITO 45151 PS Cml PlC IS American Association of State highway and Iran~Ei~!.~t.oioo i)IticiaE; American Society for Testing and Materials British Standard published by the British Startddrls Institutior c~ur~~j~ Ratio Bearing Indian Roads Congress IncIi~aStandard published by he Bureau of Indian SLindari
The various elements in the cross-section of a road re.ferrHi

these Specifications are shown in the cross-sections in Figs. 0 ~.
~
100-2,
l
<<
General
hh
U
E
U U
-~
.~ .~
C I)
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a
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2
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~8
2
.a
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-~
a
I0~
C
U U 5) 5) -C C
-~
t5
C
.5 E.~
General
C
WUJ ~
~ECJ~
U~.C
/
/
C
~ C, (C
C U
E
U C 0 U U
0
U
-~
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U U U -a
0
C 0
CC,
U U U CU .0 C
.5 LU Ui
0 C S
0 LU LU
F
U C LU
9
~.5
C C
CC
N
5
Section 100
General
Treated shoulders shown in the cross-section

(I) Hanf~ shoulders which have select granular layer or bricks.
shall be of two typesEconip~scsed
gravel/moorsam, any other
Paved :shouiders which have a hiruminou, surfacing over granular layers.
103. MATERIALS AND TEST STANDARDS

The relevant standards for materials, as well .as the tesling procedures, have been indicated at appropriate places in the Spec ifieations. A list of these slandards with their full title and the year of publication applicable is included at Appendix-2.
104. SIEVE DESIGNATIONS

Thesieve designations referred to in the Specifications correspond to those specified by Bureau of Tndian Standards in IS: 460. Tahie IOU-I gives the list of the commonly used IS sieves. TABLE 100-1. DESIGNATION OF TEST SIEVES iS Designation conforming to IS: 464)
u iron) * 125 106
*
(in micron) 850

*
710
600
90 75 63 53 45
~ 500
*
425
355
300
*
375
*
250
212 31.5
26.5
180 1St) 125 106

90 75
224 19.0
~ 16..O 13.2 11:2 9_So

*
63 53
45
8.00
6.70
<<
General
*
Section 100 5.60 4.75 400 3,35 2.80 2.36 2.00 1.70
1,40 Its 1.00 1. 2. 3.

~ _______________
Noses
are the principal sizes stated in 1SO~565 and are preferred. Sieve sizes given in BS:410 & ASTM -E 11 are same as in 15:460 Only sieves with square openings shall be used.
105. SCOPE OF WORK 105]. The work to be carried out under the Contract shall consist
of the. various items as generally described in the Tender Documents as well as in the Bill of Quantities furnished in the Tender Documents.
105.2. The works to be performed shall also include all general works preparatory to the construction of roads, bridges.., canal crossings, drainage and all other related works, The works shall include work of any kind necessary for the due and satisfactory construction, completion and maintenance of the works to the intent and meaning of the drawings and these Specifications and further drawings and orders that may he issued by the Engineer from time to time. The scope of work shall include compliance by the Contractor with all General Conditions of Contract, whether specifically mentioned or not in the various clauses of these Specifications, all materials, apparatus, plant, equipment, tools, fuel, water, strutting, timbering, transport, offices.,.stores, workshop, staff,labour and the provision of proper and sufficient protective works, diversions, temporary fencing, and lighting. It shall also include: safety of workers, first-aid equipment, suitable accommodation for the staff and workmen with adequate sanitary arrangements, the effecting and maintenance of all insurances, the payment of all wages, salaries, fees, royalties, duties or other charges arising out of the erection of works and the regular clearance of rubbish, reinstatement and clearing-up of the site as may be required on completion of works, safety of the public and protection of the works and adjoining land.
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Section 100
General
105.3. The Contractor shall ensure that all actions are taken to build in quality assurance in the planning and execution of works. The quality assurance shall cover all stages of work such as setting out, selection of materials, selection of construction methods, selection of equipment and plant, deployment of personnel and supervisory staff, quality control testing, etc. The work of building in quality assurance shall be deemed to he covered in the scope of the work. 105.4. The Contractor shall furnish, at least 15 days in advanc.e, his programme of commencement of item of work, the method of working he intends to adopt for various items of work such as site clearance, construction for embankment, sub-base, base, surfacing, culverts, bridges,
retaining walls, well-sinking, cast-in-situ piling, construction of cast-insitu prestressed concrete simply supported girders, cantilever construction of prestressed concrete superstructure, and such other items for which the Eagineer demands the submission of the method of working. He shall provide information regarding the details of the method of working and equipment he proposes to employ and satisfy the Engineer about the adequacy and safety of the same. The sole responsibility for the safety and adequacy of the methods adopted by the Contractor will, however, rest on the Contractor, irrespective of any approval given by the Engineer.
i06. CONSTRUCTION EQUIPMENT In addition to the general conditions indicated in the Contract Documents, the following conditions regarding use of equipment in works shall be satisfied:
(a) The Contractor shall he required to give a trial run of the equipment for establishing their capability to achieve the laid clown 5peciflc.atior~and tolerances to the satisfaction of the Engineer before commencement o~the work;
~h) All equipmcnt provided shall be of proven efficiency and shall he operated and maintained at all times in a manner acceptable to the Engineer; (c) All the plant/equipment to be deployed on the works shall be got approved from the Engineer for ensuring their fitness and efficiency before commence rnent of work; Any material or equipment not meeting the approval of the Engineer shall be removed from the site forthwith; No equipment will be removed from site without and permission of the Engineer;
(4) (e) (1)
The Contractor shall also make available the equipment for site quality control work as directed by the Engineer~
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General
Section 100
107. CONTRACT DRAWINGS 107.1. The Contract Drawings provided for tendering purposes shall be as contained in the Tender Documents and shall be used as a reference only. The Contractor should visualise the nature and type of work contemplated and to ensure that the rates and prices quoted by him in the Bill of Quantities have due consideration of the qualitative and quantitative variations, as may be found at the site and complexities of work involved during actual execution/construction. 107.2. The tendered rates/prices for the work shall be deemed to include the cost of preparation, supply and delivery of all necessary drawings, prints, tracings and negatives which the Contractor is required to provide in accordance with the Contract, 107.3. Two copies of drawings, on the basis of which actual execution of the work is to proceed, shall be furnished free. of cost to the Contractor by the Engineer progressively according to the work programme submitted by the Contractor and accepted by the Engirteer. Drawings for any particular activity shall be issued to the Contractor at least 30 days in advance of the scheduled date of the start of the activity. 107,4. Examination and for approval by the Engineer of any drawings or other documents submitted by the Contractor shall not relieve the Contractor of his responsibilities or liabilities under the ~ontracL 108, SITE INFORMATION 108.1.. The information about the site of work and site conditions in the Tender Documents is given in good faith for guidance only hut the Contractor shall satisfy himself regarding all aspects of site conditions. 108.2. The location of the works and the general site particulars
are as generally shown on the Site plan/Index plan enclosed with the
Tender Documents. 108.3. Whereas the right-of-way to the bridge sites/road works shall he provided to the Contractor by the Engineer, the Contractor shall have to make his own arrangement for the land required by him for site offices, labour camps, stores, etc. 108.4. The quarry charts enclosed with the Tender Documents indicate the location of quarries and other sources from which naturally occurring materials are available, for guidance of the Contractor. The leads indicated in the said charts are only approximate. It is assumed
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that the. Contractor has inspected the quarries, borrow areas etc , hefore quoting his rates for the work to assess the availability of con,stnict ion materials in required quantity and quality.
109.
SETTING OUT
1091. The Contractor shall establish working Bench Marks tied wtth the Reference Bench Mark in the area soon after taking possession of the site, The Reference Bench Mark for the area shall he as indicated tn the Contract Documents and the values of the same shall he obtained
hy the Contractor from the Engineer. The working Bench Marks shall be at the rate of four per km and also at or near all drainage structures,
over.hndges and underpasses. The working Bench Marks/levels should he got approved from the Engineer. Checks must he made on these Bench Marks once every month and adjustments, ii any, got agreed ec it the Engineer and recorded. An up-to-date record of all Bench Marks including approved adjustments, if any, shall he maintained by the Contn.ictor and also a copy supplied to the Engineer for his record
1092. The lines and levels of formation, side slopes., drainage works, earriageways and shoulders shall he care lully set out and frequently checked, care being taken to ensure that correct gradients and crosssections are ohtained everywhere.
109.3. In order to facilitate the setting out of the works, the centre
of the carriageway or highway rntist be accurately c ieiblished by the Contractor and approved by the Engineer. It must theit he accurately referenced in a manner satisfactory to the Engineer, every 50 in intervals in plain and rolling terrains and 20 in intervals in Ii illy terra in and in all curve poinis as directed by the Engineer, with marker pegs and chainage hoards set in or near the fence line, and a schedule of reference dimensions shall be prepared and supplied by the Contractor to the Engineer. These markers shall he maintained until the works rea.ch finished formation level and are accepted by the Engineer line
109A. On construction reaching the formation level stage, the centre line shall again he set out by the Contractor and when approved by the
iEngineer, shall be accurately referenced in a manner satisfactory to the Engineer hy marker pegs set at the outer limits of the formation,
109.5. No reference peg or marker shall he moved or withdrawn without the approval of the Engineer and no earthwork or structural work shall be commenced until the centre line has been referenced, 199,6. The Contractor will 6e the sole responsible party for safe-
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Sieetion
100
guarding all survey monuments, bench marks, beacons, etc. The Engineer wtll provide the Contractor with the data necessary for setting out of the centre line, All dimensions and levels shown on the drawings or mentioned in documents forming part of or issued under the Contract shall he verified by the Contractor on ihe site and he shall immediately inform the Engineer of any apparent errors or discrepancies in such dimensions or levels The Contractor shall, in connection with the staking c.iut of the centre line, survey the terrain along the road and shall subniit to the Engineer for his approval, a profile along the road centre line and cross-sections at intervals as required by the Engineer.
109.7. After obtaining approval of the Engineer, work on earthwork can commence and the profile and cross-sections shall form the basis
for measurements and payment. The Contractor shall he responsible for ensuring that all the basic traverse points are in place at the comniencement of the contract and if any are missing, or appear to have been disturbed, the Contractor shall make arrangements to re-establish these points. A Survey File containing the necessary data will he made available for this purpose. If in the opinion of the Engineer, design modifications of the centre line or grade are advisable, the Engineer will issoe detailed instructions to the Contractor and the Contractor shall perform the modifications in the field, as required, and modify the groand levels on the cross-sections accordingly as many times as required. There will he no separate payment for any survey work performed by the
Contractor. The cost of these services shall he considered as being included in the cost of the items of work in the Bill of Quantities. 109,8. The work of setting out shall be deemed to be a part of general works preparatory to the execution of work and no separate payment shall he made for the same. 109.9. Precision automatic levels, having a standard deviation of 2mni per kin, and fitted with micrometer attachment shall he used for all double run levelling work. Setting out of the road alignment and measurement of angles shall be done by using Iheodolite with traversing target, having an accuracy of one second. Measurement of distances shall be done preferably using precision instruments like Distomat.
110. PUBLIC UTILITIES 110.1. Drawings scheduling the affected services like water pipes,
pipelines, cables, gas ducts etc. owned by various authorities including Public Undertakings and Local Authorities included in the
sewers, oil
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~t Doe ~mentsshall be verified by the Contractor for the accuracy of uie information prior to the commencement of any work.
110.2.
Notwithstanding the fact that the information on affected
services may not be exhaustive, the final position of these services within the works shall be supposed to have been indicated based on the information furnished by different bodies and to the extent the bodies are familiar with the final proposals. The intermediate stages of the works
are, however, unknown at the design stage, these being dictated by the
Contractors methods of working. Accordingly, the Contractors programme must take into account the period of notice and duration of diversionary works of each body as given on the Drawings and the Contractor must also allow for any effect of these services aad alterations upon the Works and for arranging regular nieetings with the various hodies at the commencement of the Contract and throughout the period of the Works. in order to maintain the required co-ordination. During the period of the Works, the Contractor shall have no objection if the public utility bodies vary their decisions in the execution of their proposals in terms of programme and construction, provided that, in the opiniou of the Engineer, the Contractor has received reasonable notice thereoF before the relevant alterations are put in hand. 110.3. No clearance or alterations to the utility shall be carried out unless specially orde.red by the Engineer.
110.4, An~ services affected by the Works must be temporarily supported by the Contractor who must also take all measures reasonahly required by the various bodies to proteci their services and propert) during the progress of the Works,
110.5. The Contractor may be required to carry out certain works tor and on behalf of the various bodies and he shall also provide, with the prior approval of the Engineer, such assistance to the various bodies as may be authorised by the Engineer,
liM. The work of temporarily supporting and protecting the public utility services during cxecuiion of the Works shall be deemed to be part of the Contract and no extra payment shall be made for the same.
110.7. The Contractor may he required to carry out the removal or shifting of certain servieesfutilities on specific orders from the Engineer for which payment shall be made to him, Such works shall be taken up by the Contractor only after obtaining clearance from the Engineer and ensuring adequate safety measures.
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Section
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111. PRECAUTIONS FOR SAFEGUARDING THE ENViRONMENT 111.!. General The Contractor shall take all precautions for safeguarding the environment during the course of the construction of the works. He shall abide by all laws, rules and regulations in force governing pollution and environmental protection that are applicable in the area where the
works are situated.
111.2. Borrowpits For Embankment Construction Borrowpits shall not be dug in the right-of-way of the road. The stipulations in Clause 305.2.2. shall govern. 111.3. Quarry Operations The Contractor shall obtain materials from quarries only after the consent of the Forest Department or other concerned authorities is
obtained. The quarry operations shall be undertaken within the purview
of the rules and regulations in force. 111.4. Control of Soil Erosion, Sedimentation and Water Pollution The Contractor shall carry out the works in such a manner that soil er.osion is fully controlled, and sedimentation and pollution of natural water course,s, ponds, tanks and reservoirs is avoided. The stipulations in Clause 306 shall govern. 111.5. Pollution from Hot-Mix Plants and Batching Plants Bituminous hot-mix planis and concrete batching plants shall be located sufficiently away from habitation, agricultural operations or industrial establishments. The Contractor shall take every precaution
reduce the levels of noise, vibration, dust and emissions from his plant and shall he fully responsible for any claims for damages caused to the owners of property, fields and residences in the vicinity.
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111.6.
Substances Hazardous to Health
The Contractor shall not use or generate any materials in the works which are hazardous to the health of persons, animals or vegetation. Where it is necessary to use some substances which can cause injury to the health of workers, the Contractor shall provide protective clothing or appliances to his workers.
111.7. Use of Nuclear Gauges Nuclear gauges shall be used only where permitted by the Engineer.
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Section ItS)
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The (.ontraetc.ir shall provide the Engineer with a copy of the regulations govern ir~g the. safe use of nuclear gauges he intends to employ arid shall abide by such regulations, 111,8, The Contractor must take all reasonable steps to minimise dust nuisanc.e during the construction of the works.
111.9. All existing highways and roads used by vehicle of the Con uaeti.:ir or any of his sub-contractors or suppliers of materials or plant, and similarly any new roads which are part ot ihe works and which are being u sed by traffic, shall be kept clean and clear of all dust/mud or other exiraneous materials dropped by the said vehicles or their tyres. Sinularly, all dust/mud or other extraneous materials from the works spreading on these highways shall he immediately cleared by the Contractor. 111.10. Clearance shall be effected immediately by manual sweeping and removal of debris, or, if so directed by the Engineer, by mechanical sw~.e ping and clearing equipment, and all dust, mud an 1 other debris shEll I he removed entirely from the road surface. Addi donally, if so directed by the Engineer, the road surface shall he hosed or watered using suitable equipment. 111.11. Any
the Contractors any extra cost. structural damage caused to the existing roads by (EonstrlliL:i on rqaipnlent shall be made geo.:t without
ill. 12. Compliance with the foregoing wilt not relieve the Contractor of any responsibility for complying with the requirenients of any Highway Authority in respect of the roads used by hi in, 112. ARRAN(WMENT FOR TRAFFIC DURING CONSTRUCTION General
112.1.
The Contractor shall at all times carry out work on the highway in a manner creating least interference to the flow of traffic while consistent with the satisfactory execution of the same. For all works involving improvements to the existing highway, the Contractor shall, in accordance with the directives of the Engineer, provide and maintain, during execution of the work, a passage for traffic either along a part of the existing carriageway under improvement, or along a temporar) diversion constructed close to the highway. The Contractor shall take prior approval of the Engineer regarding traffic arrnn~!ementsduring construction
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112.2. Passage of Traffic along a part of the Existiug Carriageway under Improvement
For widening/strengthening existing carriageway where part width of the existing carriageway is proposed to be. used for passage of traffic, treated shoulders shall be provided on the side on which work is not in progress. The treatment to the shoulder shall consist of providing atleast 150 mni thick granular base course covered with bituminous surface dressing in a width of atleast 1.5 m and the surf.ace shall he. n dintamed throughout the period during which traffic uses the same to the satisfaction of the Engineer. The continuous length in which such work shall he carried out, would he limited normally tt.500 m a.t a place. However, where work is allowed by the Engineer in longer stretches passing place...s atie.ast 20 m long with additional paved width of 2.5 m shall be. provided at every 0.5 km interval. In case of widening existing two-lane to four-lane, the additional two lanes would he constructed first and the traffic diverted to it and only thereafter the required treatment to the existing carriageway would ht. carried out, However, in case where on the request of the Contractor, work on existing two-lane carriageway is allowed hy the Engine.e.r with traffic using part of the cx isting carriageway, stipulations as in para ahove shall 01)131 y. After obtaining permission of the Engineer, the treated shoulder shall be. dismnr.ntled, the debris disposed of and the area cleared as per the direction of the Engineer. 112.3, Passage of Traffic along a Temporary Diversion in stretches where. it is not possible to pass the traffic on part width of the carriageway, a temporary diversion shall be constructe.d with 7 mu carriageway and 2..5 m.. earthen shoulders on each side (total width of roadway 12 m) with the following provision for road crust in the 7 in widthE
(I) (ii) 200 miii (compacted) granular subbase; 225 mm (compacted) granular base course; and
CoamlMix Seat Surracing. The alignment and longitudinal section of diversion including junctions and temporary cross drainage provision shall he as approved by the Engineer.
ciii) Premix carpet with Seal
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112.4. Traffic Safety and Control
The Contractor shall take all necessary measures for the safety of traffic during construction and provide, erect and maintain such barricades, including signs, markings, flags, lights and flagmen as may he required by the Engineer for the information and protection of traffic approaching or passing through the section of the highway under improvement. Before taking up any construction, an agreed phased programme for the diversion of traffic on the highway shall be drawn up in consultation with the Engineer.
The barricades erected on either side of the carriageway/portion of the carriageway closed to traffic, shall be of strong design to resist
violation, and painted with alternate black and white stripes. Red lanterns
or warning lights of similar type shall he mounted on the harricades at night and kept lit throughout from sunset to sunrise. At the points where traffic is to deviate from its normal path (whether on temporary diversion or part width of the carriageway) the channel for traffic shall be clearly marked with the aid of pavement markings, painted drums or a similar device to the directions of the Engineer. At night, the passage shall be delineated with lanterns or other suitable
light source. One-way traffic operation shall be established whenever the traffic is to be passed over part of the carriageway inadequate for two-lane
traffic, This shall be done with the help of temporary traftic signals or fiagmen kept positioned on opposite sides during all hours, For regulation of traffic, the flagmen shall be equipped with red and grec.n flags and lanterns/lights. On both sides, suitable regulatory/warning signs as approved by the Engineer shall be installed for the guidance of road users. On each approach, at least two signs shall be put up, one close to the point where transition of carriageway begins and the other 120 m away. The signs shall be of approved design and of reflectory type, if so directed by the Engineer. 112$, Maintenance of Diversions and Traffic Control Devices Signs, lights, barriers and other traffic control devices, as well as the riding surface of diversions shall be maintained in a satisfactory condition till such time they are required as directed by the Engineer. The temporary travelled way shall be kept free of dust by frequent applications of water, if necessary.
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112.6. Measurements for Payment and Rate

All arrangements for traffic during construction including provision of temporary cross drainage structures, if required, and treated shoulder as described in Clause 112.2 including their maintenance, dismantling and clearing debris, where necessary, shall be considered as incidental to the works and shall be the Contractor*s responsibility. The construction of temporary diversion including temporary cross drainage structures as described in Clause 112,3, shall be measured in linear metre and the unit contract rate shall be inclusive of full compensat~on for construction (including supply of material, labour, tools etc.), maintenance, final dismantling, and disposal. 113, GENERAL RULES FOR THE MEASUREMENT OF
WORKS FOR PAYMENT 113.1. General

All measurements shall be made in the metric system. Different items of work shall be measured in accordance with the procedures set forth in the relevant sections read in conjunction with the General Conditions of Contract. The same shall not, however, apply in the case of lumpsuri contracts. All measurements and computations, unless otherwise indicated, shall be carried nearest to the following limits:
(I) (iii length and breadth height, depth or thickness of earthwork, subgrade, sub-bases, bases, surfacing and structural members 10 nun
5 mm 001 sq. rn.
(ia) areas (iv) cubic contents
aoi cu. m.
In recording dimensions of work, the sequence of length, width and height or depth or thickness shall be followed.
113.2.
Measurement of Lead for Materials
Where lead is specified in the Contract for construction materials, the same shall be measured as described hereunder:
Lead shall be measured over the shortest practicable route and

not the one actually taken and the decision of the Engineer in this regard shall be taken as final. Distances upto and including 100 m shall be measured in units of 50 m, exceeding 100 m but not exceeding 1 km in units of 100 m and exceeding 1 km in units of 500 m, the half
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and greater than half of the unit shall be reckoned as one and less than half of the unit ignored. In this regard, the source of the material shall be divided into suitable blocks and for each block, the distance from the centre of the block to the centre of placing pertaining to that block shall be taken as the lead distance. 113.3. Measurement of Pavement Thickness for Payment on Volume Basis The finished thickness of sub-base, base and bituminous courses to he paid on volume basis shall be computed in the following manner: Levels shall be taken before and after construction, at grid of points 10 m centre to centre longitudinally in straight reaches but 5 m at curves. Nornally, on two-lane roads, the levels shall be taken at four positions transversely, at 0,75 and 2.75 m from either edge of the carriageway; and on single lane roads, these shall be. taken at two positions transversely, being at L25 in from either edge of the carriageway. For multilane roads, levels shall be taken at two positions transversely for e.ach lane at locations specified by the Engineer. S. uitahlc references for the transverse grid lines should be left in the form of embedded bricks on either ends or by other means so that it is possible to locate the grid points for level measurements alier each successive course is laid. For pavement courses laid only over widening portions, atle.ast one lire of levels shLill he taken on each strip of widening, or more depending on the width .~fwidening a.s decided by the Engineer. Notwithstanding the above, th.e measurements may he taken a.t closer mtervals also, if SO desired by the Engineer, the need for which may arise particularly in the case of estimation of the volume of the material br profile. corrective cours.e (levelling course). The. average thickness of the pavement course. in any area shall he the arithmetic mean of the difference. of levels before and after constfliclion at all the grid points falling in that area, provided that the thickness of finished work shall he. limited to those shown on the drawings or approved by the Engineer in writing. As supplement to level measurements, the Engineer shall have the option to take cores/make holes to check the depth of construction. The holes made and the portions cut for taking cores shall be made good by the Contractor by laying fresh mix/material including compacting as required at no extra cost immediately after the measurements are recorded.
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Checking of Pavement Thickness for Payment Oil Area Basis Where payment for any bituminous course in Section 500 is allowed to be made on area basis, the Engineer may have its thickness checked with the help of a suitable penetration gauge at regular intervals or
other means as he may decide. 113.5. Measurement of Bituminous Courses for Payment on Weight Basis Plantmixed bituminous materials for pavement courses where des~ ignated to be paid on weight basis shall be weighed on accurate scales approved by the Engineer. Approved scales shall me~in scales that are of size, capacity, kind and type suitable for the weighing to he done, and these shall be properly and adequately installed and maintained. Prior to the use. of the scales and as frequently thereafter as the Engineer may deem necessary to ensure accuracy, the scales shall be checked and approved by the Engireer, or the Engineer may direct the Contractor to have the scales checked by other competent agency at the cost of the Contractor. Location of the scales shall he as designated by the Pngineer. Trucks used for hauling the material to he weighed shall be weighed empty daily at such times as the Engineer directs, and each truck shall bear a plainly leg ible identification mark. For materials specified to be measured by weight, the Engineer will have the option to make measurements of the finished work by volume in accordance with Clause 113.3 and such volumes shall he converted into weight for payment purposes. The factor for conversion from volume measurement to weight measurement shall be computed from the.. representative density of the compacted material at site deterniined at locations approved by the Engineer.
113.4.
114. SCOPE OF RATES FOR DIFFERENT ITEMS OF WORK 114.1.. For item rate contracts, the contract unit rates for different items of work shall be payment in full for completing the work to the
requirements of the Specifications including full compensation for all the operations detailed in the relevant sections of these Specifications under Rates. In the absence of any directions to the contrary, the rates are to be considered as the full inclusive rate fir finished work covering all labour., materials, wastage, temporary work, plant, equipment, over-
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Section 100
General
hew] charges and profit as well as the general liabilities, obligations,
insurance and risks arising out of General Conditions of Contract, 114,2. The item rates quoted by the Contractor shall, unless otherwise specified, also include compliance with/supply of the following
(i) (ii) General works such as setting out, clearance of site before setting out and clearance of works after completion; A detailed programme for the construction and completion of the work(using CPM! PERT techniques) giving, in addition to construction activities, detailed netwo:rk activities for the submission and approval of materials, procurement of critical materials and equipment, fabrication of special products/equipment and their tn~ stallation and testing, and for all activities of the Employer that are likely to affect the progress of work, etc., including updating of all such activities on the basis of the decisions taken at the periodic site review meetings or as dirceted by the Engineer;
(ii) Samples of various materials proposed to Ft used on the Work for conducting tests thereon a.s required as per the provision:s of the Contract; (iv) Design of mixes as per the relevant Clauses of th.e Specifications giving proportions of ingredients, sources of aggregates and binder along with accompanying trial mites as per the relevant Clautes of these Specifications to he submitted to the. Engineer for his approval before use on the Works; ~v) Detailed design calculations and drawings for all Temporary Works (such as form.. work, staging, centering; specislised constructional handling and launchins, equipment and the like); (vi) Detailed drawings for temptatcs, support and end anchorage, details for ~ restressing e:ahle profiles, bar bending and cutting schedules for reinforcement, matrrial lists (or fabrication of stnsctssral steel, mc; (sir) Mill test reports for all mild and high tensile steel and. cast steel as per the relevant provisions of the Specifications; (sitti Testing of various finished items and materials including bitumen, cement, concrete, bearings as required under these Specifications and furnishing test rexsrtsfeertifieates; (is) Inspection Reports irs respect of fo nnwork, staging, reinforcement items of work as per the relevant Specifications; (a) and other
Any other data which may he required. as per these .Speeiiieasions or the Conditions of Contract or any other annexures/sehedules forming part of the (.ontract;
(xi) Any other item of work which is not specifically provided in the Bill of Quantities hut which is necessary for complying with she provisions of she Contract; (,sii) All tesnporary works, formwork and false work; (xiii) listahlishing and running a laboratory with facilities for testing for various items of works as specified in Section 9~)and other relevant Clauses, where there is no separate item in the Bill of Quantities for establishing and ntnning a laboratory;
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(xiv) Cost of in~buihprovisions for Quality Asaurance; (xv) Cost of safeguarding the environment; and
Section 100
(xvi) (ost of providing aa-boitt drawings in original and two sets of prints.
114.3, Portions of road works beyond the Limits and/or any other work may be got constructed by the Employer directly through other agencies. Accordingly, other agencies employed by the Employer may be working in the vicinity of the Works being executed by the Contractor. The Contractor shall liaise with such agencie.s and adjust his construction programme br the completion of work accordingly and no claim or compensation due to any reason whatsoevcr will be entertained on this account. The Employer will he indemnified by the. Contractor for any claims from other agencies on this account.
115, METHODOLOGY AND SEQUENCE OF WORK
Prior to start of the construction activities at site, the Contractor shall, within 30 days after the date of the Letter of Acceptance, submit io the. Engineer for approval, the detailed construction methodology including tnechanica.l equipment proposed to be used, sequence of vari~ ous activities and schedule from start to end of lhe. project. Programme relating to pavement and shoulder construction shall be. an integrated EtCEl.ivity to he done~ sii~~ultancouslyin a coordinated manner, The nielho.dology and the sequence. shall he.so planned as to provide proper safety, drainage and free flow of traffic..
116. CRUSHED STONE AGGREGATES \Vhere, the terms crushed gravel/shingle, crushed stone, broken stone or stone aggregate appear in any part of the Tender Documents or Drawings issued for work, they refer to crushed gravel/crushed shm pIe/crushed stone aggregate obtained from. .integrated crushing plant having appropriate primary crusher, secondary crusher and vibratory screen. 117. APPROVAL OF MATERIALS Approval of all sources of material for work shall be obtained in writing from the Engineer before their tise on the project. 118. SUPPLY OF QUARRY SAMPLES Raw and processed samples of the mineral aggregates from the approved quarry shall be submitted by the Contractor at no extra cost.
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119. USE OF SURFACES i.Y CONSTRUCTION TRAFFIC
119,1. Ordinarily, no construction traffic shall be allowed on pavement under construction unless authorised by the Engineer, Even in that case the load and intensity of construction traffic should be so regulated that no damage is caused to the subgrade or pavement layers already constructed. Where necessary, service roads shall be constructed for this purpose and the same shall be considered as incidental to the work, 119.2. The wheels or tracks of plant moving over the various pavement courses shall be kept free of deleterious materials, 119.3. Bituminous base course shall be kept clean and uncontaminated as long as the same remains uncovered by a wearing course or sEurface treatment. The only traffic permitted access to the base course
shall be that engaged in laying and compacting the wearing course or
that engaged on such surface treatment where the base~course is to be blinded and br surface dressed. Should the base course or tack coat on the base course become contaminated, the Contractor shall make good by clearing it to the satisfaction of the F.~~ngineer, if this is and
impracticable, by removing the layer and replacing it to Specification
without any extra cost. 120. SITE OFFICE FOR ENGINEER AND OTHER SUPERVISORY STAFF
120.1. Scope
The work covers the construction and provision of furnished site office. acommodation for the supervisory staff of Engineer and maintaining the same.
120.2. Description The Contractors hail arrange to provide fully furnished office accommodation constructed as shown in drawings. Work includes providing electric supply, all electrical items like lights, fans and complete wiring, providing water supply including all pipes, flttings, tanks, tube well, pumps, valves etc. complete,. septic tank, sewer lines., drains, fencing, internal surfaced roads etc. complete as shown on the drawings. The. Contractor shall provide the office accommodation within 4 months from the date of the commencement of work or 3 months from the. date of providing the land .and the working drawings for the construction of office accommodation, whichever is later. List of furniture to he
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Section 100
provided and maintained for Engineers site office shall be as in Table I O&-2.
Table IOO~2. LIST OF FURNITURE TO BE PROVIDED AND MAINTAINED FOR ENGINEERS SITE OFFICE SNo. item 01 Executive table (for the Engineer) Executive chair (for the Engineer~ Table 11or Site Engineer, Aecountant and Head Clerk) Ordinary chair Type I(For the Engineer, Accountant, Read Clerk and visitors) Table (for all other staff) Ordinary ehair~Type II (for all other staff and visitors) Stool SpecifIcations Make - Godrej Model No, T-I08 or equivalent Make-Godrej Model No, PCH-701 or equivalent Make-Godrej Model No. T-104 or equivalent. Nos. Reqd.*
02.
03.
04,
Make-Godrej Model No. CHR-6 or equivalent.
05.
Make~OodrejModel No T-i0l or equivalent Make-Codrej Model No. CITR-6 or equivalent
06.
137.
Make-Godrej Model No. ST-2 or equivalent. Make-Oodrej Model No.1 Storewel plain or equivalent ilakoGodrej Model Minor p1 ant or ccitt iv alent
OS
Steel Almirah 1980mm a 915mm a 485mm Steel Atmirtth 1270mm a 765 rum a 440 mm Racks 5 Tie.r 1800 mm a 900 mm x 355 mm Typewriter
09.
11).
Made of slotted angles and MS. Sheets of Godrej make ElectronicBilingual (English & Rindi) Network make or equivalent.
Il.
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Section 100 S.No. Item 12. Steel Cash Chest of size 1.5 x 1.5 @50 mm s 450 mm) (approx.) Air Coolers Specifications Make-Cktdrej Storewel or equivalent Nos. Reqd.
General
0
13.
The coolers shall have 24 (60cm) size fan with suitable pump and shall be of either GEC, Khaitan or Cool Home make or equivalent The heaters shall be of 2(100 W capactty - Bajaj make or equivalent Ceiling fans shall be of approved make and colour
1 4.
Room Heaters
5.
Ceiling Pans 1400 mm sue CEompu cr with printer
16.
PC 486 with hard disc capacity

230 MB, Maths eoprocessor, Two disc drives of 5.25 (132 mm) and 3.5 (88 mm), 14 (350 mm) size colour VGA monitor letterquality dotmatnEx pritster of 132 columns and 101 Key board Make RICOH Model FT 4065 or equivalent requirements of the Project.
7.
Phoroc:opier
Numbers to be decided by the Engineer as xrr
120.3.
Ownership
The sile office with all services, furniture anti fittings shall he the property of the Employer. The land for the site office shall he provided by the Engineer and the location shall he as indicated in the Drawings. 120.4, Maintenance The Contractor shall arrange to maintain the site office until the issue. of Taking over Certificate for the complete work, Maintenance includes the day to day upkeep of the building and the surroundings, attending to repairs to various parts of the building, furniture, fittings, office equipment and the connected services as and when necessary.,. including the periodic white/colour washing of building and painting of wood work, steel work, replacing the broken window/door/ventilator
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General
Section 100
glasses, furniture and other hardware and maintaining necessary watch and ward during day and nighL The Contractor shall arrange to provide uninterrupted supply of electricity and water for the office building. In case of failure of main power/water supply, alternate source shall be available for providing uninterrupted supply. All sources, tappings and connected equipment and fittings, piping, tanks, wiring and all accessories of the main alternate power/water supply, for the site office accommodation shall be the property of the Employer. 1.29.5. Measurements for Payment The measurement for construction and provision of site office shall be in square metres of the plinth area of the office accommodation and the payment shall be made after the completion and handing over of the buildings with connected services fully furnished including office., equipment for occupation. if the Contractor fails to hand over the furnished office accommoda.tion within the period stipulated under Clause 1202, an amount oURs. 15,000 per month or part thereof shall be debited to the Contractors account for the period of delay. The. measurement for maintenance of F..~ngin~rs site office ac commodation shall be on maintenance months and shall be niade on completion of satisfactory maintenance every month, if at any stage, the Contractor fails to carry out the required maintenance satisfactorily, an amount of Rs. 5000 per month or part thereof shall be debited to the Contractors account. In addition, the month/months during which the Contractor fails to carry out the required maintenance satisfactorily shall not be measured for payment. If the Contract works are not completed within the stipulated period or within the granted extended time of completion, maintenance of site office accommodation in accordance with Clause 120.4 shall be carried out by the Contractor at his own cost and as such no payment shall he made for thc same. In case of any failure by the Contractor to do so, an amount of Rs, 15,000 per month or part thereof shall be debited to the Contractors account. 1.20,6. Rate lhe Contract unit rate f.or constructing and providing Ihe site office accommodation shall include the expenses of all the operations involved
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25
Section 100
General
in construction of the building including all services, fittings, fixtures, furniture, fencing, internal surfaced roads, as mentioned under Clause 120.2. The Contract unit rate for maintenance shall include expenses
towards all items of works detailed in Clause 120.4 including power and water charges for supply from the mains and for providing uninterrupted supply of power and water from alternate sources in case of failure of main supply. 121, FIELD LABORATORY 121.1. Scope The work covers the provision and niaintenance of an adequately equipped field lab.mtory as required for site control on the quality of materials and the works.. 121,2. Description The Contructor shall arrange to provide fully furnished and adequately
equipped field laboratory constructed as shown in drawings. The fold laboratory shall preferably be located adjacent to the site office of the Engineer and provided with amenities like water supply, electric. supply etc. as for the site office of the Engineer in Clause 120.2. The floor space requirement for the feld laboratory shaU he. as indicated in the drawing It shall include office space for the Materials
.,
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Engineers, one from the Contractors side and another from the Engineers side and a store for the storage of samples. The remaining space shall be provided for the. installation of equipment, laboratory tables and cupboards, working space for carrying out various laboratory tests, besides a. wash basin, toilet facility and a curing tank fOr the curing of samples, around 4m x 2m x im in size and a fume chamber. The, furnishing in each of two offices of the Materials Engineers shall he as provided for the Site Engineer in Table 100-2.. Wooden/concrete working table with a working platform area of about Tm x TOm shall he provide.d against the wails, also providing wooden cupboards above and below the working tables to store accessories such as sample moulds etc. Atleast 4 racks of slotted angles and! MS. sheets as at SINo. ID of Table 100-2 and atleast 6 stools for laboratory test operators as at Sl,No 7 of Table 100-2 shall also be provided. 121.3. Laboratory Equipment The. following items of laboratory equipment shall he provided in the field laboratory.. 26
General 121.3.1. General

(I)
Oven - Electrically operated, thermostatically controlled, range opto 200C sensitivity 1C Platform balance 300 kg capacity Balance 20 kg capacity-self indicating type Electronic Balance 5 kg capacity accuracy 0.5 gm Water bath-electrically operated and thennostatically controlled with adjustable shelves, sensitivity 1C Thennometers: Mercury-in-glass thermometer range 0 LO 250c Mercury-in-steel thermometer with 30 cm stem, range upto 300C Kerosene or gas stove or electric hot plate Glasswares, spatulas, wire gauzes, steel scales, measuring tape, casseroles, karahis, enamelled trays of assorted sizes, pessle.mortar, porcelain dishes, gunny bags, plastic bags, chemicals, digging tools like pickaxes, shovels etc. Set of IS sieves with lid and pan: 450 mm diameter: 63 mm, 53 mm, 37.5 mm, 26.5 mm, 13.2 mm, 93 mm, 6.7 mm and 4.75 nun size 200 mm diameter: 2.36 sum, 2.0 mm, 1.18 mm, 6(1) micron, 425 micron, 300 micron, 150 micron, and 75 micron
Section 100
1 No.
1 No. 1 No. 2 Nos. 1 No.
(ii) (iii) (iv) (v)
(vi)
4 Nos.
(vii) (viii)
1 Nn, As required
(it)
1 set
2 sets
(4
(xi)
Water testing kit Hrst aid box
i set 1 set
121,3,2.
(i) (ii,)
For soils and aggregates

I No.
Riffle Box Auerhcrg Limits (liquid and plan ic limits) determination apparatus
1 set
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27
Sechost 100 (iii) C~ompaetion Tess Equipment both 2.5 kg and 4.5 kg rammers (1..ight and Heavy compactive efforts) Dry Bulk D.nsisy Test apparatus (sand pouring cylinder, tray, can etc.) complete Speedy Moisture Meter complete with chemicals Post ~hole Auger with extensions Core cutter apparatus 10 cm dia, 10/IS cm height, complete with dolly, rammer etc. Aggregate Impact Value Test apparatus/Los Angeles Abrasion Test apparatus Flake ess and Elongation Test Gatiges Standard measures of 30, 15 and 3 litres capacity alongwith standard tar ping rod California Bearing Ratio test apparatus l.;scoifined compression test apparatus I set
General
(iv)
I set I set 1 set
(v) (vi) (vii)
I set
(viti)
I set I set
)is) (x)
1 set 1 set I set
lsi) (tii)
121.3,3.
(i)
For bitumen and bituminous mixes

I set 1 No. small size
Fcnetronseter with standard needles Riffle box
(ii)
(iii)
Centrifuge type bitumen extractor, hand operated, complete wish petroh/cosssmereial henzene Marshall stability te.st apparatus, witis all accessories complete
I set
(iv)
I set
(v)
l.:ic,ld density bottle aiongwith cutting tray, chisel, hamnscr and standard sand 3 rn straight edge Camber hoard Core cuttistg machine witls 10 an dia diansond cutting edge Vacuum pump and El specific gravity bottles
2 Nos. I No. I No. I set
(vi) (vii) (viii)
(is)
I set
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28
General 121.3.4,
(i) (ii) (iii)
Section
100
For cement and cement concrete
Vicat apparatus for testing setting times I set Slump testing apparatsts 4 mets Compression and Fleitttral strength testing machine of 200 ton.ne capacity with additional dial for flettssral testing 1 No. (is) Needle Vibrator 2 Nos, (v) Air Meter 1 No, (vi) Vihrating hammer for vibrating dry mix as for Dry Least Cement concrete stab-base I No. r.~rote .~ The items and their numbers listed shove in this Clause shall be decided by she Engineer as per reqstirements of the Project and modified accordingly.
121,4,
Ownership
if provided as a separate payable item in the Bill of Quantities, the field lab. ratory building and equipment shall be the property of the. Employers and the land for laboratory will he provided by the Employer. 121.5. Maintenance if trovide.d for as a separate payable item in the Bill of Qttanti ties, the Contractor. shall .t.rrange. to maintain the field laboratory ~n a saltsfac.tory rnanne.r until the. issue of Taking Over Certificate for the coniplete. work, Maintenance includes all activities described itt Clause 120,4, 121.6. Measurements for Payment If provide..d a..sa separate payable item in the Bill of Quantities, the. measurement for payment for the constrtsction of the field laboratory shall be on square metres of plinth area.
lhe sttpplv of testing equipment, the erection, running the. sante shall he on a lump sum basis.
maintenance and.
121.7. Rate If provide.d in the Bill of Quantities as a separate payable item, thd~ contract unit rate for constructing and providing the field laboratory shall include, expenses of all operations involved in construction of the httilding including all services, fittings, fixtures, furniture and fencing as mentioned in Clause 121.2, The Contract unit rate for maintenance shall include expenses towards all items of works and equipment in Clauses. .121.2 and 121.3 including power and water charges for supply from the mains and for providing uninterrupted supply of power and water from alternate sources in case of failure of main supply.
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29
Section 100
General
The. Contract lumpsum rate for the supply, erection, maintenance
and running of testing equipment s,hall include cost of supply, installation

and running including all consumables like chemicals and reagents. 122. SITE RESIDENTIAL ACCOMMODATION FOR
ENGINEER AND OTHER SUPERVISORY STAFF

122.1. Scope The work covers the provision and maintenance of unfurnished sile residential accommodation for the Engineer and other supervisory staff. The Contractor shall arrange to provide residential accommodation constructed as shown in the drawings, Work includes providing electric supply, all electrical items like wiring, switches, all fittings, lights, fans, etc. complete; providing water supply and sanitation including all pipes, littings, tanks, tube well, pumps, valves etc. complete; septic tank, sewer lines, drains, fencing, internal roads etc.., complete as shown in the drawings. 122.2. Ownership The. site residential accommodation with all services and fittings etc., shall he the property of the Employer. The land for the residential acconi modat ion shall be provided by the Engineer and the location shall be as indicated by the Engineer. The Contractor shall provide the residential accotnmodation within 4 months from the date of commence~ me.nt of the. work or 3 months from the date of providing land and the working drawings for the construction of residential accommo~ dation, whichever is later. 122.3. Maintenance The Contractor shall arrange to maintain the supervisory staff residential accommodation until the issue of Taking Over Certificat.e fbr the complete work. Maintenance includes attending to repairs to various parts of the building, fittings etc. and the connected services as and when necessary, including the annual white/colour washing of the building and periodic painting of wood and steel work; replacing the broken window/door, ventilator glasses and other hardware; and maintenance of internal roads. The Contractor shall arrange to provide uninterrupted supply of electricity and water for the buildings. In case of failure of main water or power supply, suitable alternate arrangement shall be made for
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30
General
Section
100
providmg uninterrupted supply. All sources/tappings and connected enuipment and flttings, piping, tanks, wiring and all other accessories of the. main and alternate power/water supply for the residential accommodation shall be the property of the Employer.
122,4,
Measurement for Payment
The measurement for construction of the residential accommodation shalt be on square metres of piinth area of the accommodation. The payment shall be made after the residential accommodation, complete with all services, fencing etc., is constructed and handed over for occupation. If the Contractor fails to complete and hand over the complete residential accommodation within the period stipulated under Clause 122.2, an amount of Rs. 50,000 per month or part thereof shall be. debited to the Contractors account for the peiiod of delay. The measurement for mnaintenance of supervisory staff residential accommodation shall be in maintenance months and shall be made on completion of satisfactory maintenance every month. If at any stage the Contractor fails to carry out the required maintenance satisfactorily, an a.mount of R.s, 25,000 per month or part thereof shall he debited tc.~ the Contractors account. In addition, the month/months during winch the tontractor fails to carry out the required maintenance satisfactorily shall not be measured for payment. If the Contract works are not comnpleted within the stipulated period or within the granted extended time of completion, maintenance of re.siden ti~d accommodation in accordance with Clause 122.3 shall be carried out by the C.ontractor at his own cost and as such no payment shall he. made. for the same. in case of any failure by the Contractor to do so, an amount of Rs, 60,000 per month or part thereof shall be debited to the Contractors account. 122.5. Rate The Contract unit rate for constructing and providing residential accommodation for the Engineer and other supervisory staff shall inelude cost of all the. operations involved in construction of buildings and connected services and fittings, fencing etc. complete. The Contract unit rate for maintenance shall include the expenses for all items of work detailed in Clause 122.3 including provision
of uninterrupted supply of power and water.
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31
Section 100
General
123.
PROVIDING AND MAINTAINING WIRELESS COMMUNICATION SYSTEM
123.1. Scope The work covers the provision and maintenance of wireless coin
munieation systems with necessary mobile/base trans-receivers and other accessories,
123.2,
Supply
The Contractor shall arrange to supply, install and commission the eimplete wireless systeni of approved quality suitable for a range of upto 65 km. The system shall consist of the foltowingE
(a) Mobile trans.~receiversuitable for mounting on 4 wheelers with Microphone st... sembly, Mobile Antenna with Oable and External Speaker assembly (3 \V audio output) with all necessary fittings and accessories - IC sets. Base Trans-receivers with Microphone assembly suitable Antenna, csternat speaker tush (3 SY audio output) with all necessary fittings a.r,.d accessories - 3 sets, I-land held radio sets
..
(h)
to Not, The Contractor shall provide the complete wireless system within 12 months from the date of commencement of work or 8 months from the ttate. on which frequency is allotted to him by the Coy L Department, whichever is later. FTc shall submit a guarantee for replacement of any d,e.feclive. trans-receiver/trans-receivers during the hurrency of the. con---tract.
(c)
123.3. Approval The Contractor shall. arrange to obtain all necessary statutory approvals From various Government bodies for operating the system,. He shall also fulfil the requirements laid down hy various Government Departments and obtain the frequency to operate the wireless system. 123.4. Maintenance The Contractor shall arrange to maintain the entire wireless system including the mobile and base transreceivers and all accessories until the issue of the Taking Over Certificate for the complete work, He shall replace any Trans-receiver or accessory which goes out of order, at his own cost and provide all necessary spares and attend to all repairs necessary for keeping the complete system in satisfactory working condition, On issue of the Taking Over Certificate after obtaining clearance from the Engineer, the Contractor shall dismantle the complete wireless system and hand over to the Engineer.
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32
General
Section 100
1233. Measurements for Payment The measurement for supply and installation of wire:iecs system shall be on lumpsum basis for the complete system as described in the preceding pans. If the Contractor fails to commission and hand over the complete wireless system in the stipulated time, an amount of Rs, 10000 per month or part thereof shall be debited to the Contractors account.! The measurement for maintenance of the wireless system shall be on maintenance months and shall be made on completion of satisfactory maintenance every month. If the Contractor fails to carry out the required maintenance as directed by the Engineer at any stage of work, an amount of Rs, 5000 ~er month or part thereof shall be debited to the Contractor. In addition, the month/months during which the Contractor fells to carry out the required maintenance shall not be measured for payment! if the Contract Works are not completed within the stipulated period or within granted extended time of completion, the maintenance of wireless system in accordance with Clause 1214 shall be carried out
by the Contractor at his own cost and as such, no payment shall be made for the same. In case of any failure by the Contractor to do so, an amount of Rs. 8000 per month or part thereof shall be debited to the Contractors account. 1216. Rates The Contract unit rate for the supply and installation of wireless system shall cover all the expenses towards the supply oF all necessary items and expenses towards obtaining statutory approvak and operating trequency erection omm isaoning ~nd h mud~ o~ n U it inn c or replacement of the trans~receiverftrans-receivcs (which arc frmund defec~ r the) during the currency of the Contract md all other incidentals, The Contract unit rate for the maintenance of wireless system shall be payment in full for carrying out periodic servicing and checking of the system!!, replacement of components, attending to all necessary repair, payment of taxes, if any, and other inddentals to keep the complete system in satisfactory working condition.
124. PROVIDING AND ML% INTAI:NENG VEHICLES FOR

THE ENGINEER 124.1. Scope The work covers prnvtd~ngand maintaining of hard top ~es~cnger
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3:1
Section 100
(ieneral
cars and br hard top leeps for use by the Engineer as described under the Bill of Quantities, 124,2, Description
The passenger cars shall be petrol or diesel driven and may he Am. hassador or equivalent having cylinder capacity of minimum 1400 cc The hard top jeeps shall be 4 \V Drive either petrol or diesel driven and may be Maruti Gypsy Model MG 410, Mahindra & Mahindra leep Model MM 540/MM~440or equivalent. The number of vehicles to h1 pm idc.d by the Contractor shall be decided hy the Engineer at vanno limes, out of the total provision in the B ill of Quantities and md tEnted in writing. The Contractor shall provide within one month from the due of order by the Engineer, vehicles as indicated above, lhe vehicless hal I he provided and maintained unhl issue of the Taking Over (ertifitEatL fix the complete Work. Initially, new vehicles shall he provided, in case of vehicles of Indian make. a velt ide shall be replaced with a new xrchiclt~after a maxim tim run of 75,001 km or two years whiche ci is earlier, in case ot vehuEles of lbreign make approved b~ the Engineer the vehicle shall be replaced with a new vehicle after a maximum run uI 1,00,0110 km er three Lears u~hicheveris earlier. All necessary taxes for operating the vehie ic shall he hilly prod anti all necessary papers ,shal be pros ided as reru red hy prevailing Motor Vehicles Act tvi th iEomprrhensivc in~u rance :ov er for the vehicles. The vehicles shall he provided da> and night ai required by the Engineer The Contractor shall also makE as ailEd~lc. ~lnvrrs hEEivmne valid licence at such tunes and or such duration as I nstruER d by the Engineer.
124.3. Ma i ritena mit

The vehicles shall hi Pain tainet:l in a smooth rurning condoinn \l I expenses required ha kec ping the vehicles in smooth runnine tEui](lltil)fl such as fusl, luhrieati.eu oil and oi her consumables, necessarx o tee antI maintena.rtte, dri,ers, rep:.iirs and rei:dacenient etc. are to IL ni hy the Coiitraetor. In the evcx I of any xrhiele being off the reid br main lenan ?s or on acEe 01 tnt of breakdown the Contractor shall pro V di substitute vehicic(s) immediately, If the Contractor at any time tah s provide vehicle(s) or substitute vehic Ic(s) as specified above, an anion i~t of Es. 500 per day dir part thereef for each vehicle (that the Contra trir failed to pro~~ shall he del i ted U the Contractors account. Also the tie) numher of days for which the sehicle(sl were not prov iderl shalt not he mel tided for pay me nt.
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.34
Ocncrat
Secuon (Xi)
If the Contract Works are not completed within the stipulated penod or within the granted extended lime of completion, provision and maui tcnance of vehicles in accordance with Clause 124.,! through 124 4 shall be carried oot by the Contractor at his own cost and no payment shall he made for the same. In case of any failure by the Contractor to
do so an amount of R s, 700 per clay or part thereof per vehicle sft ill
he debited to the Contractors account. 124.4. Withdrawal of Vehicles the Contractor shall withdraw particular cc hide/vehicles fbr the non-use by the Engineer if so directed by the Engineer. In such ca~e~ the instructions for non-use of vehicle shall be given in writing 15 c1a~
in advance and the withdrawal of vehicles shall not be for a period H le.ss than 1,5 days continuously at a time.
124.5. Measurements for Payment

The payment for providing and maintaining vehicles shall b1 vehicle clay basis for actual number of clays the vehicles were prn;
ri satisfiictory working order, No payment shall be male for the ~:~e

of withdrawal as per Claus..: IN ~1irrespective of the fact wlte:hc
~rehiclewas available or not 124,6. Rates

lhe Contract unit ratc tor providing and maintaining vehicle: Engineer shall include all expenses towards providing and eelI!ng lLhL, vehicles in smooth running condition including taxes dc rn ni i
I ri
the. preceding paras. 125. SUPP[.X OF COLOUR RECORD PF1OTOG RAPIIS AND ALBUMS 125.1. Scope The work covers the s ippl of photographs, negat i e~ ani I all in
~. ~ ~
to serve a.s a permanent re c orit of various stages/1acet c; I he c~ ~r neecled br an authentic dricu men tat ion as approved b~ h a r ng I
125,2. Description
The Contractor shall arrange to take colour photograph sacv stages/facets of the worl: including interesting and no H (cat res of the work as desired h) the Engineer. The. photograph.;; shalt he acceptable quality and they shall he tal:en by a professior ally ci rrrrpe .en photographer with caineri having the facility ro reeori I te U t 1
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Section 1(X)
General
photographs taken in the prints and negative. The Contractor shall supply
two colour prints of each of the photographs taken to the standard postcard size mounted in albums of acceptable quality. Also the negative in 35 mm size shall be supplied for each photograph. Each photograph in the album shall be suitably captioned. 125.3. Measurements for Payment
Supply
the albums
of two copies of colour record photographs mounted in and the negative thereof shall be measured in number
of record photographs supplied.

measured in number of additional prints
Supply of additional prints of cokiur record photographs shall be supplied. 125.4. Rate The rate for the supply of record photographs shall include the cost
of taking the photographs. developing and obtaining colour prints cost of album, mounting of photographs and captioning the same etc. The rate for additional colour prints shall similarly include all ensis incurred.. The photographs and materials including negatives shall form a part of the records of the Department and the prints o..f the same cannot he supplied to anybedv else or published without the written permission of the [)epartment 126.
SUPPLY OF VIDEO CASSETTES
126.1. i)escription The work conskts of taking video films of important activities of the work as directed by the Engineer during, the currency of the proiect and editing them to a vidpo film of playing time not less than 60 minutes md upto 180 minutes as directed by the Engineer. It shall contain naiTation of thene tivities in English by a competent narrator. The edition of the video 1dm and the script for narration shall be as approved by the Engineer. The video cassettes shall be of acceptable quality and the film shaL he capable of producing: colour pictures. 126.2. Measu renients for Payment The nleaanement shall be by number of sets of edited master cassettes each with four copies thereof.
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36
General
Section 11)0
Rates
126.3.
The contract unit rate shall include all expenses for making video films with the help of a professionally competent photographer, editing, narration and supplying the final edited master cassette aiongwiih tour copies thereof..
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Site Clearance
200 Site Clearance
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Site Clearance
Section
200
201. CLEARING AND GRUBBING

201.1. Scope
This work shill consist of cutting,,, removing and disposing of all materials such as Lrees, hushes, shrubs, stumps, roots, grass, weeds, top organic soil not exceeding 150 mm in thickness, nibbish etc., which in the opinion of the Engineer are unsudable for incorporation in the works, fnmi the. area of road land containing road embankment, drains, cross drainage, structures and such other areas as may be specifIed on the drawings or by the Engineer. it shall include necessary excavation, backlilling of pits resulting from uprooting of trees and stumps to required compaction, handling, salvaging, and disposal of cleared materials, Ck.arin,g and grubbing shall be performed in advance of earthwork operations and in accordance with the requirements of these Specifications.
20L2.
Preservatkni of Property/Amenities
Roadside trees, shrubs, any other plants, pole lines, fences, signs, monuments, buildings, pipelines., .sewer~ all highway facilities within and or adjacent to the highway~.vhich not to be disturbed shall be protected are from injury or damage. The Contractor shall provide and install at his own expense, suitable safeguzuds approved by the Engineer for this purpose.
During clearing and grubbing, the Contractor shall take all adequate precautions against soil erosion, water pollution, etc., and where required, undertake additional works to that effect vide Clause 306. Before start
of operations, the Contiactor shall submit to the Engineer for approval, his work plan including the procedure to be followed for disposal of waste materials, etc.., and the schedules for carrying out temporary and permanent erosion control works as stipulated in Clause 306.3. 2013, Methods, Tools and Equipments Only such methods, tools and equipment as are approved by the Engineer and which will not affect the property to be preserved shall be adopted for the Work. If the area has thick vegetation/roots/trees, a crawler or pneumatic tyred dozer of adequate capacity may be used for clearance purposes. The dozer shall have ripper attachments for removal of tree stumps, All trees, stumps, etc., falling within excavation and fill lines shall be cut. to such depth below ground level that in no ease these fall within 500 mm of the subgrade. Also, all vegetation such as
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41
Section 200
Site Clearance
roots, indeNgrowth, grass and other deleteriotis matter unsuitable for incorporation in the embankment/subgrade shall be removed between fill lines to the satisfaction of the Engineer. On areas beyond these limitiE, trees and stumps required to be removed as directed by the Engineer shall be cut down to I m below ground level so that these do not present an unsightly appearance. All branches of trces extending above the trimmed as directed by the Engineer. roadway shall he
All excavations below the general ground level arising out of the removal of trees, stumps, etc., shall be filled with suitable material and compacted thoroughly so as to make the surface at these points conform to the surrounding area. Antli ills both above and below the ground, as are liable to collapse and obstruct free subsoil water flow shall be removed and their workings, which may extend to several metres, shall be suitably treated.
201.4. Disposal of Materials All materials arising from clearing and grubbing operations shall
he the property of Government and shall he disposed of by the Contractor
a.s hereinalter provided or directed by the F...ngineer.

Trunks, branches and stumps of trees shall be cleaned of limbs and roots and stacked, Also boulders, stones and other materials usable in road construction shall be neatly stacked as directed by the Engineer. Stacking of stumps, boulders, stones etc., shall he done at specified. .spots with all lifts and upto a lead of 1000 m. All products of clearing and grubbing which, in the opinion of the Engineer, cannot be used or auctioned shall be cleared away from the roadside in a manner as directed by the Engineer. Care shall he taken to see that unsuitable waste materials are disposed of in such a manner that there is no likelihood of lhese getting mixed up with the materials meant for embankment, subgrade and road construction. 20 1,5. Measurements for Payment Clearing and grubbing for road embankment, drains and crossdrainage structures shall be measured on area basis in terms of hectares. Clearing and grubbing of borrow areas shall be deemed to he a part of works preparatory to embankment construction and shall be deemed to have bee.n included in the rates quoted for the embankment construction item and no separate payment shall he made for the same. Cutting of
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42
Site Clearance
Section 20()
trees upto 300 mm in girth including removal of stumps and roots, and trimming of branches of tmes extending above the roadway shall be considered incidental to the clearing and grubbing operations. Removal of stumps left over after trees have been cut by any other agency shall also be considered incidental to the clearing and grubbing operations. Cutting, including removal of stumps and roots of trees of girth above 300 mm and hackfilling to required compaction shall he measured in ten-os of number according to the sizes given below:i) ii) fl) iv) Above Above Above Above 3(X) mm to to 6()0 900 1800 mm mm mm
6(X)
mm
9(X) mm to 1800 mm
For this purpose, the girth shall be measured at a height of 1 metre above ground or at the top of the stump ii the height of the stump is less than one metre from the ground.
201.6.
Rates
201.6.1, The Contract unit rates for the various items of clearing and grubbing shall be payment in full for carrying out the required operations including full compensation for all labour, materials, tools, equipment and incidentals necessary to complete the work, These ~vi1 1 also include removal of stumps of trees less than 300 mm in girth as well as stumps left over after cutting of trees carried out by another ag:ncy, excavation and back-filling to required density, where necessary, and handling, salvaging, piling and disposing of the cleared materials with all lifts and upto a lead of 1000 m. 201.6.2. The Contract unit rate for cutting (including removal of stumps and roots) of trees of girth above 300 mni shall include excavation and hackfilling to required compaction, handling, salvaging, piling and disposing of the cleared materials with all lifts and upto a lead of 1000 m. 201.6.3. Where a Contract does not include separate items of clearing and grubbing, the sa.me shall be considered incidental to the earthwork items and the Contract unit prices for the same shall be considered as including clearing and grubbing operations.
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.:j 1
Section 200
Site Clearance
21)2. DISMANTLING CULVERTS, BRIDGES AND
OTHER STRUCTURES/PAVEMENTS 21)2.1. Scope

This work shall consist of removing, as hereinafter set forth, existing culverts, bridges, pavements, kerbs and other structures like guard~rails., fences, utility services., manholes, catch basins, inlets, etc.~~) hich are w in place but interfere with the new construction or are not suitable to remain in place..~, nd of salvaging and disposing of the resulting materials a and back filling the resulting trenches and pits. Existing culverts, bridges, pavements and other structures which are within the highway and which are designated for removal, shall be removed upto the limits and extent specified in the drawings or as indicated by the Engineer. Dismantling and removal operations shall he carried out with such equipment and in such a manner as to leave undisturbed, adjacent pavement, structures aud any other work to be left in place. All operations necessary for the removal of any existing structurc which might endanger new construction shall be completed pnor w. the start of new work. 20L2. Dismantling Culverts and Bridges The structures shall be d~srnantled carefully and the resuh my materials so removed as not to cause any damage to the serviceable materials to he salvaged, the part of the structure to be retained and any other properties or structures nearby. Unless otherwise specified, the superstnicture portion of eulvcrts/ bridges shall he entirely removed and other parts removed below the ground level or as necessary depending upon the interference, they cause to the new construction. Removal of overlying or adjacent material, if required in connection with the. dismanding of the structures,.~shall be incidental to this item. Where existing culvert.sfbridges are to be extended or otherwise incorporated in the new work, only such part or parts of the existing structure shall he removed as are necessary and directed by the Engineer to provide a proper connection to the new work. The connecting edges shall be. cut, chipped and trimmed to the required lines and grades without weakening, or damaging any part of the structure to be retained, Due care should he taken to ensure that reinforcing bars which are to he
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44
Site Clearance
Section 200
left in place so as to project into the new work as dowels or ties are not injured during removal of concrete, Pipe culverts shall he carefully removed in such a manner as to avoid damage to the pipes. Steel structures shall, Unless otherwise provided, be carefully dismantled in such a manner as to avoid damage to members thereof. If specified in the drawings or directed by the Engineer that the structure is to be removed in a condition suitable for re-erection, all rnemhers shall be match-marked by the Contractor with white lead paint before dismantling; end pins, nuts loose plates, etc., shall be similarly marke.d to indicate their proper location; all pins, pin holes an.d machined surfaces shall be painted with a mixture of white lead and tallow and all loose parts shall be securely wired to adjacent members or packed in boxes, Timber structures shall he removed in such a manner as to avoid damage to such timber or lumber as is designated by the. Engineer to be salvaged. 202.3. Dismantling Pavements and Other Structures In removing pavements, kerhs, gutters. and other structures like guard-rail;, f~.nces,manholes, catch basins, inlets, etc., where portions of the c~istingconstruction are to be leSt in the finished work, the same thall be removed to an existing joint or cut and chipped to a true line, with a face perpendicular to the surface of the existing structure, Sufficient removal shall be made to provide for proper grades and connections with the new work as directed by the Engineer AU concrete pavements, base courses in carriageway and shoulders desoEnate.d for removal shall he broken to pieces whose volume shall not scce.d 0 02 cu. m, ~mci stockpiled at designate.d locations if the material is to he used later or otherwise arranged for disposal as directed (see Clause 202,5)
i.acE.
.
202.4.
Back-filling
eons
Holes anti depre
LEaused by dismantlin,g operations shall he
hackfilled with ~
292.5.
,OE other approved materials and compacted to required density as dire~ by the Engineer. ted
Disposal of Materials
..
All materials obi unto by disin totlu Governnitnt lJnless oth twi o s;
di h
II
th
ot
s imE~,
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Section 2110
Site Clearance
value shall he placed in neat stacks of like materials within the righ o cThway, as directed by the Engineer with all lifLs and upto a lead of 1000 Pipe t: ulverls that are removed shall he cleaned and neatly piled on the nght~of~wayt points designated by the Engineer ss ith all lifts a and lead upto 1000 in. Struc tura.i steel removed from old structures shall, unless otherwise speci bed or directed, he stored in a neat and presentable manner on blocks in locations suitable for loading. Structures or portions thereof which are specified in the Contract for re~erectionshall he stored in separate ~i1e~, Timber or lurn her from old structures which is desig naled by the E: ng ineer as rnateri a Is to he salvaged shall have all nails and bolts rem ove. il theretroin and shall be stored in neat piles in locations suitalElle for loading. Al I ma teria.ls obtained from dismantling operati 015 which, ut the in miii of the En ~ineer, cannot he tised or auctioned sl all be disposed of as cI ireeted hy the f.i.ngineer with all lifts and upto a lead of 10011
ip
nEt
202.6.
Measurements for Payment
The work of ilisniantling structures shall be paid for ut units indicated I miw hy ok inc iu easiuernents before a nil after. as applicable ot Osinarililig trtck/sinnc masonry!
sonorole (1iliiri rid reinforced) Disinani irrg fte~ and cernci ii Ste concreie pas ririent jut nsrnarrwnt.~sleet siruciiire~ (iv) tE)irrnarrikinii i rnher srmcru ret (v) t)isrnarittirig nlrxrs tonrit rails, kerb.s, guilL rs Mid iitriciig (vi) t.Jiitiiy sen ices tot
cci in
en. in ionrie cii in

irrear ft
Nor
202.7. Rates
The Contract i nit rates for the various i teins of disinanti ing shall paid in hill for carrying out the required operations including hill a ipen sation for all labour, materials, tools, ec~tupnlen safeguards and t, neidentals necessary to complete the work. These will also include cx .avation and back lilling where necessary to the required compac Lion anti for handling, salvaging, piling and disposing of the cli.smantlta:l materials within all lifts and upto a lead of 1000 rn,
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Earthwork, Erosion Control and Drainage
300 Earthwork, Erosion Control and Drainage
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Earthwork, Erosion Control Section 300 and Drainage 301. EXCAVATION FOR ROADWAY AND DRAiNS 301.1. Scope This work shall consist of excavation, removal and satisfactory
disposal of all materials necessary for the construction of roadway, side drains and waterways in accordance with requirements of these Speci~ fications and the lines, grades and cross-sections shown in the drawings or as indicated by the Engineer. It shall include the hauling and stacking of or hauling to sites of embankment and subgrade construction, suitable cut materials as required, as also the disposal of unsuitable cut materials in specified manner, trimming and finishing of the road to specified dimensions or as directed by the Engineer. 301,2. Classification of Excavated Material 301.2.1. Classification All materials involved in excavation shall he classified by the F...~gineerin the following manner:
(a) Soil This shalt comprise topsoil, turf, sand, silt, loam, clay, mud, peat, black cotton soil, soft shale or loose moomna, a mixture of these and similar material which yields to the ordinary application of pick, spade and/or shovel, rake or oth,e.r ordinary digging implement. Removal of gravel or any other nodular material having dimension in any one direction not exceeding 75 mm occurring in such strata shall be deemed to be covered under this category.
(It) Oniinaxy Rock (not reqttiring blast.ing)This shall include:

(i) rock types such as laterites, shales and conglomerates, varieties of limestone and sandstone etc.,, which may be quarried or split with crow bara, also including any rock which in dry slate may be hard, requiring blasting hut which, when wet, becomes soft and manageable by means other than blasting; macadam surfaces such as water bound and bitumen/tar bound; soling of roads, paths etc. and hard core; compact moorum or stabilised soil requiring grafting tool or pick or both and shovel, closely applied; gravel and cobble stone having maximum dirt. ension in any one directionbetween 75 and 300 mm;
(ii)
(iii) lime concrete, stone masonry in lime mortar and brick work in lime/cement mortar below ground level, reinforced cement concrete which may be broken up with crow bars or picks and storw masonry in cement mortar below ground level; and (iv) boulders which do not require. biaating having maximum dimension in any direction of more than 300 mm, found lying loose on the surface or embedded in river bed, soil, talus, slope wash and terrace material of dissimilar origin.
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Sect ion 300 (c) Hard Rock (reqsring blasting) This shall comprise: (i) (ii)
Earthwork, Erosion Control
and Drainage
any rock or cement concrete for the excavation of which the usc of mechanical plant and/or blasting is required; reinforced cement concrete (reinforcement cut through hut not separated from the concrete) below ground level; and
(iii) lxsulders requiring blasting. (il) Hard Rock (blasting prohibited) I-lard rock requiring blasting as describest under (c) but where blasting is prohibited for any reason and eacavation has to be carried out by chiselling, wedging or any other agreed method, (c) Marshy Soil This shall include soils like soft clays and pears eacavated below the original ground level of marshes and swamps and soils excavated from other areas requiring continuous pumpi g or bailing out of water,
301,2.2. Authority for classification The classification of excavation shall he decided by the Engineer and his decision shall be final and binding On the Contractor. Merely the~use of explosives in excavation will not be considered as a reason for higher classification unless blasting is clearly necessary in the opinion of the Engineer. 301.3. Construction Operations 301.31. Seding out After the site has be.e.n cleared as per Clause 201., the. limits of excavation shall he set out hue to lines, curves, slopes, grades and sections as shown on the drawings or a.s directed by the Engineer., The Contractor shall provide all labour, survey instrtiments and materials such as strings, pegs., nails, bamboos, stones, lime,, r.orl.ar, concrete, etc.., required in connection with the setting otit of work,s and the e.,sl.ablishment of bench marks. The Contractor shall be responsible for the maintenance, of bench tnarks and other marks and stakes as long .as in t.he. opinion of the Engineer, they are required for the work. 301,3.2. Stripping and storing topsoil When so directed by the. Enginte., the topsoil existing over the siles of excavation shall be stripped to spe.cified depths constituting Horizon A and stockpile.d at designated locations for re-use in covering embankment slopes, cut slopes, berrns and olher disturbed areas where re-vegetation is desired. Prior to stripping the topsoil, all trees, shrubs etc. shall be removed along with their roots, with approval of the Engineer. 301,3.3. Excavation General All excavations shall he carrie.d out in conformity with the directions laid here.-in~underand in a manner
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50
Section 300
approved by the Engineer, The work shall be so done that the suitable materials available from. excavation are satisfactorily utilized as decided upon beforehand. While planning or executing excavations, the Contractor shall take all adequate precautions against soil erosion, water pollution etc. as per Clause 306, and take appropriate drainage measures to keep the site free of water in accordance with Clause 3li. The excavations shall conform to the lines, grades, side slopes and levels shown on the drawings or as directed by the Engineer. The Contractor shall not excavate outside the limits of excavation. Subject to the pennitted tolerances, any excess depth] width excavated beyond the specified levels/dimensions on the drawings shall be made good at the cost of the Contractor with suitable material of characteristics similar to that removed and compacted to the requirements of Clause 305. All debris and lose material on the slopes of cuttings shall be removed. No backfilling shall be allowed to obtain required slopes excepting that when boulders or soft materials are encOuntered in cut slopes, these shall be excavated to approved depth on instructions of the Engineer and the resulting cavities filled with suitable material and thoroughly compacted in an approved manner.. After excavatior, the sides of excav.ated area shall be trimmed and the area contoured to minimise erosion and ponding, allowing for natural drainage to t4ke. place. If trees were removed, new trees shall be planted, as directed by the Engineer. The cost of planting he deemed to be incidental to the work. new trees shall
301.3.4, Methods, tools and equipment Only such methods, tools and. equipment as approved by the Engineer shall be adopted/used in the work.. If so desired by the Engineer, th..e Contractor shall demonstrate the efficacy of the. type of equipment to be used before the commencement of work. 301.3.5. Rock excavation Rock, when encountered in road excavation, shall be removed upto the formation level or as otherwise indicated on the drawings. Where, however, unstable shales or other un~ suitable materials are encountered at the fonnation level, these shall be excavated to the extent of 500 mm below the formation level or as otherwise specified. In all cases, the excavation operations shall be so carried out that at no point on cut formation the rock protrude.s above the specified levels. Rocks and large boulders which are likely to cause
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51
Section 300
differential settlement and also local drainage problems should he removed to the extent of 500 mm below the formation level in full formation width including drains and cut through the side drains. Where excavation is done to levels lower than those specified, the excess excavation shall be made good as per Clauses 3013 3 and 301.6 to the satisfaction of the Engineer. Slopes in rock cutting shall be finished to uniform lines correspond~ ing to slope lines shown on the drawings or as directed by the Engineer. Notwithstanding the foregoing, all lose pieces of rock on excavaled slope surface which move when pierced by a crowbar shall be removed, to Where blasting is to be resorted to, the same shall he carried out Clause 302 and all precautions indicated therein observed.
Where presplitting is prescribed to he done for the establishment of a specified slope in rock excavation, the same shall be carried oUt to (:latise 303. 3411.3.6. Marsh excavation The excavation of soils from marshes/ swamps shall be carned out as per the programme approved by the Engineer. Excavation of marshes shall begin at one end and prot~eedin one Jirecnun aLEross tIlL entire marsh immediately ahead of backhlling. The method and sequence of excavatin and hackfilling shall he such as to ensure, to the extent practicable, the complete removal or displacement of aM muck from within the lateral limits called for on the drawings or as staked by tlie Eonineer, antI to the botton of the marsh. Ii rm s uppo rt or levels indicated, 301 J,7, Excavation of road shou lders~verge/median for widening of pavement or providing treated shou lder.s:ln works involving widening of es isting pavements or providing treated shoulders, unless ot.herwise spel,Eihed the shoulder/s crgc/mcdian shall he renioved to their full width and to levels shown on drawings or as intlicated by the Engineer. While doing so, care shall he taken to see that no portion of the existing pavement designated br retention is loosened or disttirbed, II the existing pavement gets d isttirhed or loosened, it shall he dis mantletl anrl cut to a regular shape with sides vertical and the. di sttirhed/l oosenetl portion removed completely and relaid as directed by the Engineer, at the cost of the Contractor.
301.18. Excavation for surface/sub-surface drains Where the Contract provides for construction of surface/sub-surface drains to Clause
52
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and Drainage
Section 300
:309, excavation for these shall be carried out in proper sequence with
other works as approved by the Engineer.
301.3.9. Slides If slips, slides, over-breaks or subsidence occur in cuttings during the process of construction, they shall be removed at the cost of the Contractor as ordered by the Engineer. Adequate precautions shall be taken to ensure that during construction, the slopes are not rendered unstable or give rise to recurrent slides after construction. if finished slopes slide into the roadway subsequently, such slides shall he ri~mnovedand oaid for at the Contract rate for the class of excavation involved, provided the. slide.s tire not due to any negligence on the part of the Contractor. The classification of the debris material from the slips, slides etc. shall conform to its condition at the time of removal and payment made accordingly regardless of its cOndition earlier.
301.3,10. Dewatering If water is met with in the excavations due. to springs, seepage, rain., or other causes, it shall he removed by suitable diversions, pumping or bailing out and the excavation ke.pt dry whene.ver so required or directed by the. Engineer. Care shall he taken to ci istEharge the. thai ned water into suitable outlets as not to cause damage to the works, crops or any other property. Due to any negligence on the part of the Contractor, if any such damage. is caused, it shall he the. sole responsibility of the Contractor to re.pair/restore. to the. origtnal condition at his own cost or compensate (Or the damage. 301.3.11 Disposal of excavated materials All the excavated materials shall be the property cf the Employer. The. material obtained from the excavation of roadway, shoulders, verges. drains, cross~ drainage svorks etc.., shall be used for filling up of (i) roatiway emhank~ me.nt, (ii) the. existing pits in the right~of~way (iii) for landscaping and of the road as directed by the Engineer, including levelling and spreadin,g with all lifts and lead upto 10(X) in and no extra payment shall be made for the same.
-
All hard niaterials, such as hard moortim, rubble, etc., not intended for use as above, shall be stacked neatly on ~peeified land as directe.d by the Engineer svith all lifts anti lead upto 1000 m. Unsuitable antI surplus material not intended for use within th.e lead sieciiied above .sh.al.l also, if necessary, he transported with all lifLs anti lead beyond initia.i 1000 m, disposed of or tised as directed by the Engineer.
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.53
Section 300
Earthwork, Erosion
Control and
l)rainagc
301,3,12. Backfllling Backfilling of masonry fconcrete/hume pipe drain excavation shall be done with approved material after concrete/ masonry/hume pipe is fully set and carried out in such a way as not to cause undue thmst on any part of the structure and/or not to cause differential sett.lement. All space between the drain walls and the side of the excavation shall be refilled to the original surface making due, allowance for settlement, in layers generally not exceeding 150 mm compacted thickness to the required density, using suitable compaction equipment such as mechanical tamper, rammer or plate compactor as directed by the Engineer. 301.4, Plying of Construction Traffic Construction traffic shall not use the cut formation and finished subgrade without the prior permission of the Engineer. Any damage arising out of such use shall he made good by the Contractor at his own
expense. 301.5. Preservation of Property
The Contractor shall undertake all reasonable precautions for the protection and preservation of any or all existing roadside trees, drains, sewers or. other sub~surface drains, pipes, conduits and any other structures under or above ground, which may be affected by construction operations and which, in the opinion of the Engineer, shall be continued in use without any change. Safety measures taken by the Contractor in this respect, shall be got approved from the Engineer. However, if any of these objects is damaged by reason of the Contractors negligence, it shall be replaced or restored to the original condition at his expense. if the Contractor fails to do so, within the required time as directed by the Engineer or if, in the opinion of the F ngineer, the actions initiated by thO Contractor to replacefrestore the damaged objects are not satisfactory, the Engineer shall arrange the replacement! restoration directly through any other agency at the risk and cost of the Contractor after issuing, a prior notice to the effect. 301.6. to receive
Preparation of Cut Formation

th( sub-base/base course as directed by the Engineer.
The cut lormation, which serves as a subgrade, shall be prepare.d

Where the material in the suhgracle (that is within 500 mm from the lowest level of the pavement) has a density less than specified in Table 300.2, the same shall he loosened to a depth of 500 mm and e am pacted in layers in accord antEe with the requirenients of CIa use 305
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54
Earthwork, Erosion Control an,d Drainage
Section 300
Any unsuitable material encountered in the subgrade level shall be removed as directed by the Engineer and replaced with suitable material compacted in accordance with Clause 305. in rocky formations, the surface irregularities shall be corrected and the levels brought up to the specified elevation with granular base
niaterial as directed by t.he Engineer, laid and compacted in accordance with the respective Specifications for these materials, The unsuitable material shall be disposed of in accordance with Clause 301 .3.11. After satisfying t.he density requirements, the cut formation shall be prepared to receive the subbase/base course in accordance with Clauses 310 and 311 to receive the sub-base/base course. 391,7. Finishing Operations Finishing operations shall include the work of properly shaping and dressing all excavated surfaces,
When completed, no point on the slopes shall vary from the de.signated slopes by more than 150 mm measured at right angles to the. slope., except where excavation is in rock (hard or soft) where no point shall vary more than 300 mm from the designated slope.. In no case sEhail any portion of the slope encroach on the roadway. The finished cut formation shall satisfy the surface tolerances described in Clause 902. Where directed, th..e topsoil removed earlier and conserved (Clauses :301,3,2 and 3053.3) shall be spread over cut slopes, where feasible, herm.s and other disturbed areas,.. Slopes may be roughened and moistened slightly, pri.or to the application of topsoil, in order to Provide satisfactory bond. The depth of topsoil shall be sufficient to sustain plant growth, the usual thickness being from. 75 mm. to 100 mm.
301,8. Measurements for Payment

Excavation for roadway shall be measured by taking crosssections at suitable intervals in the original position before the work starts and after iLs completion and computing the volumes in cu. m, by the. method of average end areas for each class of material encountered, Where it is not feasible to compute volumes by this method because of erratic location of isolated deposits, the volumes shall he computed by other accepted methods. At the option of the Engineer, the Contractor shalt teave. depth indicators during excavations of such shape and size and in such
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.55
Section 300
Earthwork, Erosion Control and
Drainage
positions as direCted so as to indicate the origina] ground level as accurately as possible. The Contractor shall see that these remain intact till the final measurements are taken. For rock excavation, the overburden shall be removed first so that necessary cross-sections could be taken for measurement. Where cross sectional measurements could not be taken due to irregular configuration or where the rock is admixed with other classes of materials, the volumes shall he computed on the basis of stacks of excavated rubble after making 35 per cent deduction therefrom, When volumes are calculated in this manner for excavated material other than rock, deduction made will be to the extent of 16 per cent of stacked volilimes. Works involved in the preparation of cut formation shall be measured in units indicated below
(i) ii) Loosening and recompacdng the loosened material at subgrade Loosening and removal of unsuitable material and replacing with a suitable material and compacting to required density
...
as. m. as. m.
(iii) Preparing rocky subgrade (iv) Stripping including storing and reapplication of topsoil (v) Disposal of surplus material heyood initial I 000 ns lead
...sq. m.
...
cu. m. cu. m.
...
301.9.
Rates
301,91. The Contract unit rates for the items of roadway and drain excavation shall he payment in full for carrying out the operations required for the individual items including full compensation for
(i) (ii) selling out; transporting the excavated materials and depositing the same on sites of embankment,, spoil banks or stacking as directed within att lifts and lead upto t000 m or as otherwise specified;
(in) trimming bottoms antI slopes of excavation;
(iv) dewatering; ~v) keeping the work free of water as per clause 3tl; and (vi) all labour, materials, tools, equipment, safety measures, testing and incidentats nec~ cssary to complete the work to Specifications.
Provided, however, where presplitting is prescribed to
achieve a
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56
Drainage
Section 300
~pecifled slope in rock excavation, the same shall be paid for vide Clause
3015. 3019.2. The Contract unit rate for loosening and recompacting
the loosened materials at subgrade shall include full compensation for ioosenmg to the specified depth, including breaking clods, spreading in layers, watering where necessary and compacting to the requirements. 301.93. Clauses 301.9.1 and 305.8 shall apply as regards Contract unit. rate for item of removal of unsuitable material and replacement with suitable material respectively. 301.9.4. The Contract unit rate for item of preparing rocky suhgrade as per Clause 301.6 shall be full compensation for providing, laying and compacting granular base material for correcting surface irregularities including all materials, labour and incidentals necessary to complete the work and all leads and lifts. 301.93. The Contract unit rate for the items of stripping and storing topsoil and of reapplication of topsoil shall include full compensation for all the necessary operations including all lifts, hut leads upto 1000 m
301,9.6. The Contract unit rate for disposal of surplus earth from roadway and drain excavation shall be full compensation for all labour, equipment, tools and incidentals necessary on account of the additional haul or transportation involved beyond the initial lead of 1000 m. 302. BLASTING OPERATIONS
302.1. General Blasting shall be carried out in a. manner that completes the excavation to the. lines indicated in drawings, with the least disturbance to adjacent material. It shall be done only with the written permission of the Engineer. All the statutory laws, regulations, rules, etc., pertaining to the. acquisition, transport, storage, handling and use of explosives shall be strictly followed. The Contractor may adopt any method or methods of blasting consistent with the safety and job requirements. Prior to starting any phase of the operation the Contractor shall provide information describing pertinent blasting procedures, dimensions and notes.
The magazine for the storage of explosives shall be built to the.
designs and specifications of the Explosives Department concerned and located at the~approved site. No unauthorized person shall be admitted.
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57
Sec ion .300
Earthwork, Erosion Ccmtrol and Drainage
into the magazine which when not in use shall be kept securely locked, No matches or inflammable material shall be allowed in the magazine. The magazine shall have an effective lighlning conductor The following shall be hung in the lobby of the magazine:
(a) (0) (c)
(to
A copy of the relevant niles regarding safe storage hot.h itt English and in the language with which the workers coneented are familiar. A statement of upto~datestock sn the maga~ inc A certificate showing the lass slate of testing of the lightning conductor.
A notice that smok irtg is strictly proh hued.
All explosives shall be stored in a secure manner in cotnpliance with all laws and ordinances, and all such storage places shall he clearly marked. Where no local laws or ordinances apply, storage shall he provided to the satisfaction of the Engineer anti in general not closer than 3PP in from the road or from any building or camping area or place of human occupancy. In addition to these, the Contractor shall al so observe the following instructions and any itt Iher additional instructions s~h may he given by the En e, ineer and shall be responsible ich for damage to property and tiny aecidetit which may occur to workrtien or the public on account of any operations connected with the storage, itandlitig or use of explosives ard blasting, The Engineer shall frequently check the Contractors compliance with these precautions. 302,2. Materials, Tools and Equipment All the materials, tools and equipment used for blasting operations shall be of approved type. The, Engineer may specify the type of explosives to be allowed in special cases The fuse to be used in wet locations shall he. sufficiently water-resistant as to he unaffected when immersed in water for 30 minutes. The Tate of burning of the fuse shall be ttniibrm and definitely known to permit such a length being cut as will permit sti fficient time to the firer to reach safety before explosion takes place. Ce,tonators shall he capable of giving effective blasting of the explosives. The blasting po~vder,explosives, detonators, fuses, etc., shall be fresh and not damaged due t.o dampness, moisture or any other cause, They shall be inspected before use and damaged articles shall be discarded totally a.i~d removed from the site imrn cr1 iately.
3023.
Personnel
The blasting operation shall remain in the charge of competent and c iperienced supervisor and workmen who are thoroughly acquainted ivi th the details of hartdl ing explosives and blasting Operations,
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58
and Drainage
Section 300
302,4.. Blasting Operations Th..e blasting shall be carried out during fixed hours of the day preferably during the mid-day luncheon hour or at the close of the work as ordered in writing by the Engineer. The hours shall be made known to the people in the vicinity. All the charges shall be. prepared by the man in charge only, The Contractor shall notify each public utility company having structure.s in proximity to the site of the work of his intention to use explosEives. Such notice shall be given sufficiently in advance to enable the companie.s to take such steps as they may deem necessary to protect
their property from injury. In advance of any blasting work within
50 m of any railway track or structures, the Contractor shall notify the. concerned Railway Authority of the location, dale., time. and approximate duration of such blasting operations. Red danger flags shall be displayed prominently in all directions. during, the blasting operations. The flags shall be planted 200 m from the blasting site in all dire,ctions. People, except those who actually light the fuse, shall he prohibited from entering this area, and ill persons including workmen shall he excluded from the flagged area at least 10 minutes be.fore the firing, a warning siren being sounded lot the. purpose, The charge hoic.s shall be drilled to required depths and at suitable places. Blasting should be as light as possible consistent with t.horough breakage of the material necessary for economic loading and hauling. Any method of blasting which leads to overshooting shall be discontinued.
When blasting is done with powder, the fuse cut to the required length shall he inserted into the hole and the. powder dropped in. The powder shall be. gently tamped with copper rods with rounded ends. The explo.sivc. POwder shall then be covered with tamping material which shall be tarnped lightly but firmly. When blasting is done with dynamite and other hig.h explosives, dynamite cartridges shall be prepared by inserting the square cut end of a fuse. mb the de.ton ator and finishing it with nippers at tine opc.tn entl, line. dc.tonatnr gently pushed into the primer leaving 1/3rd of the coppe.r tube expose.d outside. The paper of the cartridge shall then he clc.se.d up anti securely bound with wire or twine. Th..e primer shall be. housr.d. into the explosive.. Boreholes shall be of such size that the cartridge can easily g.n down. The. holes shall be cleared of all debris and
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59
Scetiort 300
esplosmve inserted. The space of about 200 mmn above the charge shall then be gently filled with dry clay, pressed home and the rest of the tamping fOrmed of any convenient material gently packed with a wooden rammer, At a time, not more than 10 such charges will be. prepared and iircd. The man in charge shall blow a siren in a recognised manner for cautioning the people. All the people. shall then he required to move. to safe dIstances. The charges shall be lighied by the man~in-chargeonly, The man-in-charge shall count the number of explosions. He shall satisfy hint selF that all the charges have been exploded before allowing the workmen 1.0 go hack to the work site, Alter blasting operations, the Contractor shall compact the loose rematerial below suhgrade a.nd replace the material removeti below stmbgrade with suitable materiaL
Si LI ttal
302.5.
Misfire
In cast of misfire, the following procedure shall he observedE

.Suiiieietit tune shall he alloaed to account for the delayed blast, The manin ~bsrge shall inspect all the charges and dctenttine the missed c:harge l~ii~II it is rho hlastin
1.; powder charge, it shall he completely flooded with water
ness Fr ~le shall he drilled at about ~i5tl trios from the old hole and fired. This should lrlasr the ,ld charge. Should I I trot hIatt the old charge, the procedure shall ho repeated till the old charge is hlr.tstect
11
i lit 5451 ol ehirges of geltynire, dynamite, etc., the man-ittcharge shall gently rrnrsve the tamping and the primer with the detortator A frssh detonator and u mrr shall then he used to blast the charge. Altsrnattvely, the hole may hre I eared of 10(1 mm of tarrrprng and the drreetisrrr Llten ascertained by p1wittg a strel. itt the hole. Anorlrer hole rrr.rs their he drilled t 50mm away ,snd parallel or it ibis hole shtall then he ettarged and fired when thte to isfired hole shoe Id explede.at the same time. fire man-rn-c barge shall at ortec report to the our r,setor s office artd the Fnrtineer all eases of misfire, the ccrrrse of the sarrrs and ahat steps were taken in ronrreetron therewith.
If a at t sloe has been fOund to he due to defective detonator or ilyrnatlirle, the whole quantity in the box from which defective article was taken must be sent to the authority directed by the Engineer fur inspect ion 10 ascertain whether all the remaining materials in the box are also defective, 302.6. Account
A cLueful and day to day account of the explosive shall he maintained lr~y the Con I racior in an approved register and manner which shall he ripe a to inspect ion by the Engineer at all times.
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60
Section 300
303. PRESPLITTING ROCK EXCAVATION SLOPES 303.1. General

Presplitting is defined as the establishment of a specified excavation slope in rock by the controlled use of explosives and blasting accessories in properly aligned and spaced drill holes. The presplitting technique shall be used for forming rock excavation slopes at locations shown on the plans or as otherwise decided by the Engineer,
303.2. Construction Operations

Prior to starting drilling operations for presplitting, the Contractor sha.I I furnish the Engineer a plan outlining the position of all drill holes, i:iepth of drilli rig, type of explosives to be used, loading pattern and seque rtce of Firing. The drilling and blasting plan is. for record purposes only and will not absolve the Contractor of his responsibility for using proper drilling and blasting procedures. Controlled blasting shall begin with a short test section of a length approved by the Engin.eer The. test sEectiorr shall he presplit, production drilled and blasted and suflTrc. ient mate. naI excavated sviai. reby the Engineer can deier.mn me, if the Contrac tor s methods have produced a.n acceptable slope.
-
All overburden soil and weathered. rock along the top of the r,.~..xeavatinn for a distance of about 5 to 15 rn beyond the. drillirrg limits, or to the iEm.d of the excavation, as decided by Engineer shall be removed belor.e drilling the prespliwng holes, Particular care and attention sEhaII he di recEted to the beginning and end of excavations to ensure complete. removal of all overburden sod and we.athere.d rock and to expose I resEh rock to an elevation equal to the bottom of the adjacent lift of the. lwesplittimtg holes being drilled, S lope. holes for presplitting shall he drilled along the lin.e of the planned slope within the specified tolerances, The drill holes shall be not less than 60 mm nor more. than 75 mm in diameter, Drilling opera.uotts shall be controlled by the use of proper equipment arldl tech muque to ensure. that no hole shall deviate from the plane of the plan neil slope by more. than 300 mm nor shall any hole deviate from being parallel to an adjacent hole by more than two~third of the. planned horizontal spacing between holes. The length
of
presplit holes for any individual lift shall not excee.d
9 ni.
61
<<
Srction 300
Eanhwork, Erosion Control
and Drainage
The spacing of presplit holes shall not exceed 900 mm on centres and shall be adj usted to result in a uniform shear face between holes
-
Auxiliary drill holes along the presplit line, not loaded or stemmed, may be ordered by the Engineer. Except for spacing, auxiliary drill holes shall conform to the provisions for presplit holes. The line of production holes shall be placed inside the presplit lines in such a manner as to avoid damage to the presplit face. If necessary, to reduce shatter and overbreak of the presplit surface, first line of the production holes shall be drilled parallel to the slope line at the top of the cut and at each bench level thereafter, the Any blasting technique, which results in damage surface, shall be immediately discontinued, to the presplit
No portion of any production hole shall be drilled within 2.5 ni of a pmesplit plane except as approved by the Engineer. The bottom of the production holes shall not be lower than the bottotu of the presplit holes, A utaximum offset of 600 mm will he permitted for a construction workiog bench at the bottom of each lift for use in drilling the next IO\5dr presplitting pattern. The dlrilling operations shall be adjusted to corn perrsate for drift of previous levels and for the offset at the start of new levels to maintain the specified slope plane. rhe maximum diameter of explosives used in presplit holes shall not be greater than one-half the diameter of the presplit hole, Only standard cartridge explosives prepared and packaged by explosive otaoufacturing firms shall be used in presplit holes, These shall he fired as roconimcndccl by the manufacturer, Ammonium nitrate composition blasting agents will not be permitted in presplitting operations. Stemming may be required to achieve a satisfactory presplit face. Stemming material shall be dry free-running material all of which passes II mm sieve and 90 per cent of which is retained on 2.80 mm sieve, Stemnmned presplit holes shall be completely filled to the collar, All charges in each presplitting pattern shall be detonated simul tarteously,
303.3. Tolerances The presplit face shall not deviate more than 300 mm from the plane passing through adjacent drill holes, except where the character of the
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62
Section 300
rock is such that, as determined by the Engineer, irregularities are unavoidable, When completed, the average plane of the slopes shall confbrnt to the slopes indicated on the plans and no point on the cumpleted slopes shall vary from the designated slopes by more than 300 mm. These tolerances shall be measured perpendicular to the plane of the slope. En no case shall any portion of the slope encroach on the side drains. As long as equally satisfactory presplit slopes are obtained, then either the. slope face may be presplit before drilling for production blasting or presplitting the slope face and production blasting may he done. at the same time, provided that the presplitting drill holes are fired with zero delay and the production holes are delayed starting ai the row of holes farthest from the slope and progressing in steps to the row of holes nearest the presplit line, which row shall he delayed at least 50 milliseconds, In either case the presplitting holes shall exteod either to the end of the excavation or for a distance of not less than IS m beyond the limn its of the production holes to be detonated,
303.4.
Measurements for Payment
The area of prespli tting to be paid for will be mneasured as sq uare nietres of acceptable presplit slope surface. 303.5. Rates The Contract unit rate for presplitting ~vork shall be payntteot 0 full for carrying out the required operations for obtaining acceptable presplit slope surfaces, The qttantity of rock excavated through the product on/presplit holes shall be paid for as pen Clause 301,9,1.
304. EXCAVATION FOR STRUCTURES 304.1. Scope

Excavatiumn for structures shall consist of the removal of n-iaterial for the constrtic tiun of fotmdations for bridges, c nI verts, retaining walls, headwalls, cutoff walls, pipe culverts and other similar structures, in accordance with the requirements of these Specifications and the lines and dimnensions shown on the drawings or as indicated by the Engineer. The work shall include construction of the necessary cofferdams and cribs and their suhseqtnent remnoval; all necessary sheeting, shoring, bracing, draining and pumping; the removal of all logs, stumps, gnihs and other deleterious niatler and obstructions, necessary for placing the foundations; trimmning bottoms of excavations; hackfilling and clearing up the site
and the disposal of all surplus material.
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61
Section 300
304.2. Classification or Excavation All materials involved in excavation shall be classified in accordance with Clause 301.2. Construction Operations 304,3.1. Setting out A.fter the site has been cleared according to Clause 201, the limits of excavation shall be set out true to lines, curves and slopes to Clause 301.3.1. 304.3.2, Excavation Excavation shall be taken to the width of t,he. lowest step of the footing and the sides shall be left plunib where the nature of soil allows it. Where the nature of soil or the depth of the trench and season of the year do not perat.it vertical sides, the Contractor at his own expense shall put up necessary shoring, strutting and planking or cut slopes to a safer angle or both with due regard to the safety of personnel aqd works and to the satisfaction of
304.3. the Engineer. The depth to which the excavation is to be carried out shall be as shown on the drawings, unless the type of material encountered is such a.s to require changes, in which ease the depth shall be as ordere.d by the Engineer. Propping shall be -undertaken when any foundation or stresse.d zone from an adjoining structure is within a line ol 1 vertica,l to 2. horizontal from the. bottom of the excavation, Where. blasting is to he resorted to, the same shall he carried out in accordance with Clause 302 and all precautions indicated therein ohserved, Where. blastitig is likely to endanger adjoining foundations or other structures, necessary precautions such as controlled blasting, providing rubber mat cover to prevent flying of debris etc, shall he. taken to prevent any damage. 304.3.3. Dewatring and protection Normally, open foundations shall he laid dry. Where water is met with in excavation due to stream flow, seepa.ge, springs, rain or other reasons, the Contractor shall take adequate measures such as hailing, pumping, constructing diversion
channels, drainage channels, bunds, depression of water level by welh point system, cofferdarns and other necessary works to keep the loundation trenches dry when so required and to protect the green concrete/masonry against damage by erosion or sudden rising of ~iaLer level. The methods to be adopted in this regard and other details thereof shall be left to the choice of the Contractor but subject to approval of the Engineer. Approval of the Engineer shall, however, not
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64
dii:
tie or
cii nijr;:tiE.ior
o[
i,hc respt.r fl ,:irhiiriiy For
Lire. reduircEd. t.hflsr shall Lie LEa rr dc ILLnIEd arid (ii rstiiictid MiLl Ii.: inalEle EEL ; is necescEay l:nr facilitatinu, construction tc.i ha carried of the cofh::rrdarn~ shall he suirEh as for thi corOnictieri sni:i irirspr;. toni and el i(i.iLni~riny equ.rpincno. ccc.., nude
it
dcterminedbeLirchrindt th:.u the. laiiriidatio ns ~uEisitoit i.~ friand that the peri:Erihieon too the hmndat.iori iE.oncriEtesliEill hr In case of floycine aater or .uEteslan sprines, the c siuppe.F or redi.iiEiELi as Far as possible Eli the Lint: of any i.iLiridation eneirrs~iriiFoill Fcdrine
iii
iii: iEViIiEEiEE.tir, frri.EEEttide t.h~.E [Eii.ii;::iFiititY 1..FiiE: IEEPF

Tlti~~.niiiEiiiEd
IF
eonerc.rte. No phlaipiliii shall be permitted derin,i:r or for a,nv ju~riod olaF least 24 hon rs thereafc.r., ;s ii. is i,loiic: fire iii ri~~tiittiih st.iniip separated fruni tIte IE:lencr.:t..: a watertlh.lht watt .ir odier simdar rrlcatris.
Ed EEiI]rr rLF(
AL the discretion oF the Contractor, cerrtent i.routmng or other piire%ell nicrthods may he used to prevent or reduce seepEipe L:ind to ][lrotirc i the exiEEalaticlil area. rh.. ContractiErr shall t~.tki:rall precautions in diverting channels Lind in dischareine; the drainei:i wati:~ras FlOt to cause damage to the sr i:rks., crops or arty other property.
.304.3.4. Preparation of toundahon The bouorn of the bEiundatirirl I I hi.:r Fe. i.elled blEith longitudinally art ii transversely or s tepperl L.ts iliri:LctciEi by the hngini:~er. Be..lore looting is laid, the surface shalt be si htly watered amid ramined., in the event ot excavation having been cc per th ~.trihat shown on the draw ings or as otherwise ordcrei:l t by the Engineer, the extra depth shall he made tip with concrete or nr asonry of the fotmn dation at the cost of the Contractor as per Clause 2104. i. Orrhnary lilling shall not he used for the purpose to hring the fortndat inn to level. \\rhctrt rock or other hard strata is encountered, it shall he freed
Ii
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65
Section 3t~.t
Earthwork, Erosion Control and Drainage.
of all soft and loose material., cleaned and cut to a firm surface either level and stepped as directed by the Engineer, All seams shall be cleaned out and filled with cement mortar or grout to the satisfaction of the
Engineer. In the case of excavation in rock, annular space around footing shall be filled with lean concrete (1:3:6 nominal mix) upto the top level
of rock.
If the depth of fill required is more than I .5m above the top of the footing, filling upto 1.5m above top of footing shall be done with lean concrete (1:3:6 nominal mix) followed by boulders grouted with
cement.
When foundation piles are used, the excavation of each pit shall be substantially completed before beginning pile-driving operations therein. After pile driving operations in a given pit are completed, all loose and displaced materials therein shall be removed to the elevation of the bottom of the footings. 304.3.5. Slips and slip-outs : If there are any slips or slip-outs in the excavation, these shall be removed by the Contractor at his own
cost.
3Q4.3.6. Public safety : Near towns, villages and all frequented places, trenches and foundation pits shall be securely fenced, provided with proper caution signs and marked with red lights at night to avoid accidents. Tha Contractor shall take adequate protective measures to see that the excavation operations do not affect or damage adjoining structures. For safety precautions, guidance may be taken from IS : 3764. 304.3.7. Backfilling : Backfilling shall be done with approved material after concrete or masonry is fully set and carried Out in such a way as not to cause undue thrust on any part of the structure. All space between foundation masonry or concrete and the sides of excavation shall be refilled to the original surface in.. layers not exceeding 150 mm compacted thickness. The compaction shall be done with the help of suitable equipment such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as to achieve a density not less than the field density before excavation. 304.3.8. Disposal of surplus excavated materials: Clause 301.3.11 shalL apply. 304.4. Measurements for Payment
-
Excavation for structures shall be measured in cu. m. for each class

66
<<
Section 300
of material encountered, limited to the dimensions shown on the drawings or as directed by the Engineer. Excavation over increased width, cutting of slopes, shoring, shuttering and planking shall be deemed as convenience for the Contractor in executing the work and shall not be measured and paid for separately. Preparation of rock foundation shall be measured iti square metres. Foundation sealing, dewatering, including pumping shall be deemed to be incidental to the work unless separate provision is made for in the ContracL In the latter case, payment shall be on lumpsum basis as provided in the Bill of Quantities. 304.5. Rates 304,5.1. The Contract unit rate for the items of excavation for structures shall be payment in full for carrying out the required operations including full compensation for
(i) (ii) setting out; construction of necessary cofferdams, cribs, sheeting, shoring and bracing and their subsequent removal;
(iii) removal ofalt togs, stumps, grubs and other deleterious matter and obstructions, for placing the foundations including trimming of bottoms of excavations; (iv) fotmdation sealing, dewatering including pimping when no separate provision for it is made in the Contract; (v) backfilling, clearing up the site and disposal of all surplus material within all lifts and leads upto 1000 m or as otherwise specified; and
(vi) alt labour, materials, tools, equipment, safety measures, diversion of traffic and incidentals necessary to complete the work to Specification.
304.5.2. The Contract unit rate for preparation of rock foundation shall be fufl compensation for cutting, trimming and cleaning the foundation surface and filling/sealing of all seams with cement grout or mortar including all materials, labour and incidentals required for completing the work. 304.5.3. The Contract unit rate for transporting material from the excavation for structures shall be full compensation for all labour, equipment, tools and incidentals necessary on account of the additional haul or transportation involved beyond the initial lead of 1000 m. 305. EMBANKMENT CONSTRUCTION 305.1. General 305.1.1. Description : These Specifications shall apply to the construction of embankments including subgrades, earthen shoulders and
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67
Sect ion 300
miscellaneous hack fills with approved material obtained from roadway and drain excavation, borrow pits or other sources. All embarikment.s, suhgrades, earthen shoulders and miscellaneous hackfills shall he constructed in accordance with the requirements of these Specifications and in conformity with the lines, grades, and cross-sections shown on the drawings or as directed by the Engineer. 305.2. 305.21.
Materials and General Requirements

Physical requirements:
305,21.!. The materials used in emhankments, subgrades, earthen ;houlders and miscellaneous backfills shall he soil, moorum, gravel, a nttxture of these or any other material approved by the Engineer. Such materials shall be free of logs, stumps, roots, rubbish or any other Lngredient likely to deteriorate or affect the stability of the embankment! subg rade.
The following types of material shall be considered unsuitable for

embankment:
(a) (h) Cc Cd Materials from swamps, marshes and bogs; Peat, log, stump and pedshable material; any soil that Oti or Pt in accordance with IS 1498; Materials susceptible to spontaneous combustion; Materials in a frozen conditioss; Clay having liquid limit eacceding 70 and plasticity index exceeding 45 and (11 Materials wills salts resulting in leaching in thc embankment. classifies as 01., 01,
305.2.1.2, Expansive clay exhibiting marked swell and shrinkage properties (free swelling index exceeding 50 per cent when tested as per IS: 2720 Part 40) shall not be used as a fill material. Where an expansive clay with acceptable free swelling index value is used as a till material, suhgrade and top 5(X) mm portion of the embankment just below subgrade shall be non-expansive in nature.
-
305.2.1.3. Any fill material with a soluble sulphate content exceeding 1.9 grams of sulphate (expressed as SOS) per litre when tested in accordance with 55 : 1377 Test 10, but using a 2:1 water-soil ratio shall not be deposited within 500 mm or other distance described in the Contract, of concrete, cement bound materials or other cementitious
materials forming part of the Permanent Works.
Materials with a total sulphate content (expressed as SO3) exceeding 0.5 per cent by mass, when tested in accordance with BS : 1377 Test
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68
]~5~
Fxosion Control and Drainage
Section 3(X)
itt
shall not be deposited within 500 mm, or other distances described the~Contract, of metallic items forming part of the Permanent Works,
305,2.1,4. The size of the coarse material in the mixture of earth

ill c~ nan ft ttol exceed 75 mm when he int; placed in the embank tnert id
and. 50 rnni when placed in the suhgrade. However, the Engineer may hi discretion Permit the use of maieriai coarser than this also if he :Eltts [ted that the same will not present any difficulty as regards the a:.: EE tit Itt of fill material and its compactton to the requirements of : ~pecifi,caiions, the maximum particle siie shall not he more than c ~ ii nil I I he compacted layer thickness.
c
~i
305. 2,1.5. OrcI manly, ortly the materials sEatisfying the density ttten U; g iv ert mn Table 3(X)i shall be employed for the construct]on te e nit bank men t and the subgrade.
id liL 300 I. IE)ENSt1Y REQI,IRESIFNTS OF KMBASKME%T ANt) SUBGRADE MATERIALS
si[
SYsirk
Maxinsum I aborsstory dry ssntt weight wEt eti tested as per IS: 2T20 (Part S~ Net tess th:sts 15.2 kNCcti m,
.i]:,]K.srH nts tip to 3 metres flit si.ibjec.tirit to Itoso li it g.

ii..
is
e,ceidirsr, srntsanksiettts lit s tihtect to eli irmndatiort
Net less than 16.0 kN/cti, en.
ii
md eari.hcn lie t.i/ier5e (ls,sckfil
Not tess tts3n t7.5 kS/eu. en.
(1
0 it t:.iltle is net applicable for lightweight fill sssateciat e.g cinder, ft~ash [he Ertc sneer etemy relax these rel:Iutrclments at his disc retton taking into account its exists Lilsi lit 5 stE materials for cssitsrnsctton sand other relevant itsce~srs. I i
1.115 ILtOLt
is he used in tat:mgraste slsststld also satisfy wetg,ht apptt cable as ~ Tatsle 300Z,
design dEeR
at
diii
.305,2,2 General requirements 395,23,1, The tnaterials for embankment shall he obtained froni apratieliEl source.; vs ith preference given to materials becoming available it nearby road way excavation or any other excavation under the satne It ir;Etet.
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69
Section 300
The work shall be so planned and executed that the best available materials are saved for the subgrade and the embankment portion just below the subgrade. 305.2,2.2. Borrow materials Where the materials are to be obtained from designated borrow areas, the location, size and shape of these areas shall be as indicated by the Engineer and the same shall not be opened without his written permission. Where specific borrow areas are not designated by the Employer/the Engineer, arrangement for locating the source of supply of material for embankment and subgrade as well as compliance to environmental requirements in respect of excavation and borrow areas as stipulated, from time to time by the Ministry of Environment and Forests, Government of India and the local bodies, as applicable, shall be the sole responsibility of the Contractor. Borrowpits along the road shall be discouraged. If permitted by the Engineer, these shall not be dug continuously. Ridges of not less than 8 m width should be left at intervals not exceeding 300 m. Small drains shall be cut through the ridges to facilitate drainage. The depth of the pits shall be so regulated that their bottom does not cut an imaginary line having a slope of 1 vertical to 4 horizontal projected from the edge of the final section of the bank, the maximum depth in any case being limited to 1.5 m. Also, no pit shall be dug within the offset width from the toe of the embankment required as per the consideration of stability with a minimum width of 10 m. Haulage of material to embankments or other areas of fill shall proceed only when sufficient spreading and compaction plant is operating at the place of deposition. No excavated acceptable material other than surplus to requirements of the Contract shall be removed from the site. Should the Contractor be permitted to remove acceptable material from the site to suit his operational procedure, then he shall make good any consequent deficit of material arising therefrom. Where the excavation reveals a combination of acceptable and unacceptable materials, the Contractor shall, unless otherwise agreed by the Engineer, carry out the excavation in such a manner that the acceptable materials are excavated separately for use in the permanent works without contamination by the unacccptable materials. The acceptable materials shall be stockpiled separately. The Contractor shall ensure that he does not adversely affect the
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70
Earthwork, E~sionControl and l)rainage
Section 300
stability of excavation or fills by the methods of stockpiling materials, use of plants or siting of temporary buildings or structures. The Contractor shall obtain representative samples from each of the identified borrow areas and have these tested at the site laboratory following a testing programme approved by the Engineer. It shall be ensured that the subgrade material when compacted to the density requirements as in Table 300-2 shall yield the design CBR value of the subgrade.
TABLE 300-2. COMPACTION REQUIREMENTS FOR EMBANKMENT AND SUIGRADE
Type of work! material
R~iativecompaction as percentage
of max. laboratory dry density as per IS: 2720 (Part 8).
1, 2. 3.
Subgrade and earthen shoulders Embankment Ex pansive Clays a) Subgrade and 500 mm portion just below the subgrade b) Remaining portion of embankment
Not less than 97 Not less than 95 Not allowed Not less than 90
The Contractor shall at least 7 working days before commencement of compaction submit the following to the Engineer for approval:
(i) The values of maximum thy density and optimum moisture content obtained in accordance with IS: 2720 (Part 7) or (Part 8), as the case may be, appropriate for each of the fill materials he intends to~use A graph of density plotted against moisture content from which each of the values in (I) above of maximum dry density and optimum moisture content were determined.
(ii)
(iii)
The Dry density-moisture content .CBR relationships for light, intermediate and heavy compactive efforts (light corresponding to IS: 2720 (Part 7), heavy corresponding to IS: 2720 (Part 8) and intermediate in-between the two) for each of the fill materials he intends to use in the subgrade.
Once the above information has been approved by the Engineer, it shall form the basis for compaction. 305.3. Construction Operations 305.3.1. Setting out : After the site has been cleared to Clause 201, the work shall be set out to Clause 301.3.1. The limits of embankment/subgrade shall be marked by fixing batter pegs on both sides at regular intervals as guides before commencing the earthwork. The embankmenl/subgrade shall be built sufficiently wider than the
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71
Sec kit 300
Earthwork, Erqsion Control and Drainage
ilesign dimensnan so that surplus material may be trimmed, ensuring chat the remaining material is to the desired density and in position speci fled and conforms to the specified side slopes. 305.3,2. Dewatering lithe foundation of the embankment is in
an urea with stagnant water and in the op in ion of the i...ngineer it

is Feasible to remove it, the same shall he removed by bailing out or
p1: m pin oi~ di reetci I by the En gineer and the area of the embankment II nil at ion hull be k:ept dry. Care shall be taken to d ~scharge the
ci
ic.attr so niL 10 cause daniac 10 the works, crops or any property. [)i ie 0 any negligence on the part of the Contractor, nucEh iI1ifl1aL~E LEalised, it shall be the sole responsih~Iityol the 1 IC re]pair/Iestore U to e.rkEEinal condition or compensate LiL1flW~c ii, his own COSt.
?~
LIIi,
LEmi:mnkrnent
B5 10
be eIE)nsL.rueted
under
water, Clause
.0115 ,.:t .3.

Sir ~ pmg and storing topsoil
~.,I IELHe
In localities where 010..I. eIl]LIEllkalcIlnent materials are net conducive to plant growth. the bng:ne.ei, chc Lopsoil from all areas of all ...eeas to be covered by ernhankntent leundaLion ..r]:lcI.Eiiielt depths not exr:Eecd~ng i50 mm and .stored
I
III
[ii In
..;irIl{P 15~...I
IrL,
csr.Eeecllllll 2 iti for covering enthankrnent IErther I:E1i1ltullEncLl ~lie.1Et1r; ~h~rrct re~vef1et.ittieIn iS be c.nn,Erce.ssarlis LralfilEEkc.d either bIEIIL1rL1 hen iii, i stol::Ekpile. StoehpillEls shall not he suicharged or eIEl multiple hanr.ilinft,L.!, shall be kept to a minimum. .1~115.3.4. Cr.im~wetingi~rourirlso pporting embankment/subgradeE .~l,.D,..,; nEce~sEtr. thcr eriginal grourul :;hall be levelled tiEl Facilitate hr~~~i of cmhanlanent sLE1uEiIiI::ld, tnned with waler IdyLl .irr~lthen LEI:inipacted by rollIng ~ a~.e ~:ti:hieve t :ninirnum dry densitl, spvcn ut Table 1001..
~LlhiIt IIitt
..iIt
.~1...r..:sp1ler; 1
~,lI:r(rL:~. and
l]llr~,,E,.o:r,:1, ~ltere (he dilferenee between the suhc;rade level (top of the .~vibrradeOil which pi.tvement rests t and ground level is less, than U.S round dc.ie.s not have 97 per cent relative compaction It 1.~ic pr..~cI ri ih Ar, level 0.5as given in Table 30O~2,the wateretEl rlEi,i li.iosened LJpLIE1 it density rn below the subgrade level, ground all ii LEcU It piaEted mu I ayers in aciEEordance witlt Clauses 305,3.5 and 3053.6 I El riot less than 97 per cent of dry dens,ity as given in Talle 3002.
A lucre. so directed by the Engineer, any unsuitable material occurring 7,
<<
h.Lrthl~ IITk
,
E.,r1lSik,TI I:EOil trot and
l)rainage
Secliorl
.itx:
,in the ent haru k nue n t foundation shall he removed and replaced by approve il irtaterials lairl in layers to the required degree of compaction. ntban k.rtie n t or sEubgrade work shall not proceed until the fouttdttt~ tons fur sin bank men lJsuhg rrtde have he.eit inspected by tltc Engineer er Lau.i sl:LIIE liEtry i:nttd itiOn and approved. undati on tre attnent specified for crnhankments especially high reittny on suspect foundations as revealed by horchole sha llhe LEarned out iru a rrtanne.r and to the depth as desinsd by the entElund t:tn ~, hich ait emhankmnent is to he huilt at cr1 IfI~.. .Erts.Fte.I tel types a.) to (I.) in Clause 3052.1, at least 500 inasi be rerrioved and replaced by aceclELthlc ~atEbrinkntentconstruction comnlencrt,s,
Fri
~pr eri,r.ling material
itt
layers and bringing to apprn.
Hi
Eli..
i.
1iritittr moisture content .h,,.: enil.tattkment tori subgrade material rhail be spread teirierat thicLness nut ~.Etxceeding 200 rout cnittpa~.Er...d c ihe .Eotire trtrlth tO i::attl:tattkntent hy mecltaruurEal incas.,;, smiler ,,trti eantpacted as per Clause 305J.fa The have lty..lrauiic control suitable. ion sattt~,Escasto achieve the speed le t.~l:.:tpc i.e er~~. Thahl itctt be placed until the Layer
.j~~q,t,..tL.~, Ftu... hsLtt Lhrlrtugitl5 compacted to dir: s e .5 ..ttI tI ttt L,.Fie 1001 curl cot approved by the Engineer. built
ted
Er
tsr
ii . i~I
.hail
lttE litttsl,ed p.rallel
10
the final cruss~st:.,EELirt!t
Ku,
Ito to tEontrttcnce.tneot of compaction; if fr:aud tsr iL .0 cc rr:H l,,ttets, the satttiEr .rltall he made good. Wltere water is Os .,trlLlrEri in sttch rEr.lrtstrutEtLons, water shall he. sprinkled t,tti.:er f;ttcd .tit.h sprinkler capable of applying F, :n lv .rLtlt a sun crollahie rate of flow to variable widths of sunia:e an, fleer.:Iin,e,. The water shall he added unifbnnly arid : ml:, eti use, I hy hiading, disc inc or harrowing until a uotfonn ,:..IJttE s.c eut d.tlE,tained tltrottghottt. the depth of the la,,er.
H .
.51. \ir.ti.t.tI.Jt:L. crtttl,etE,i, of the rttal.eriai shall he checked Ert
titt Ptdttvrl;.I I r.Iehi~eted tO tlte roatElbed is too wet, it shall he t,,LnietEl, tflt antI itire,t tire to the en it, till the moisture content is acceptable
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I [aLEtrt:trt. .Sltneiri eirt:Eutrtslances tuise, where. owing to wet weather, hIts notrtt,rtt LEontertt eEtnno~be reduced to the required am.iuot by the i;tOc.:riurC~ t..ttittpctet ittnw tEnEk shall he suspended. 73
Section 300
Moisture content of each layer of soil shall be checked in accordance with IS: 2720 (Part 2), and unless otherwise mentioned, shall be so adjusted, making due allowance for evaporation losses, that at the time of compaction it is in the range of 1 per cent above to 2 per cent below the optimum moisture content determined in accordance with IS :2720 (Part 7) or IS:2720 (Part 8) as the case may be. Expansive clays shall, however, be compacted at moisture content corresponding to the specified dry density, but on the wet side of the optimum moisture content obtained from the laboratory compaction curve. After adding the required amount of water, the soil shall be processed by means of graders, harrows, rotary mixers or as otherwise approved by the Engineer until the layer is uniformly wet. Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when being placed in the embankment and a maximum size of 50 mm when being placed in the subgrade. 305.3.5.3. Embankment and other areas of fill shall, unless otherwise required in the Contract or permitted by the Engineer, be constructed evenly over their full width and their fullest possible extent and the Contractor shall control and direct construction plant and other vehicular traffic uniformly over them. Damage by construction plant and other vehicular traffic shall be made good by the Contractor with material having the same characteristics and strength as the material had before it was damaged. Embankments and other areas of unsupported fills shall not be constructed with steeper side slopes, or to greater widths than those shown in the Contract, except to permit adequate compaction at the edges before trimming back, or to obtain the final profile following any settlement of the fill and the underlying material. Whenever fill is to be deposited against the face of a natural slope, or sloping earthworks face including embankments, cuttings, other fills and excavations steeper than I vertical on 4 horizontal, such faces shall be benched as per Clause 305.4.1 immediately before placing the subsequent fill. All permaneni faces of side slopes of embankments and other areas of fill formed shall, subsequent to any trimming operations, be reworked and sealed to the satisfaction of the Engineer by tracking a tracked vehicle, considered suitable by the Engineer, on the slope or any other method approved by the Engineer.
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74
Earthwork,
Erosion Control and Drainage
Section 300
305.3.6. Compaction : Only the compaction equipment approved by the Engineer shall be employed to compact the different material types encountered during construction. Smooth wheeled, vibratory, pneumatic tyred, sheepsfoot or pad foot rollers, etc. of suitable size and capacity as approved by the Engineer shall t~used for the different types and grades of materials required to be compacted either individually or in suitable combinations. The compaction shall be done with the help of vibratory roller of 80 to 100 kN static weight with plain or pad foot drum or heavy pneumatic tyred roller of adequate capacity capable of achieving required compaction. The Contractor shall demonstrate the efficacy of the equipment he intends to use by carrying out compaction trials. The procedure to be adopted for these site trials shall first be submitted to the Engineer for approval. Earthmoving plant shall not be accepted as compaction equipment nor shall the use of a lighter category of plant to provide any preliminary compaction to assist the use of heavier plant be taken into account. Each layer of the material shall be thoroughly compacted to the densities specified in Table 300-2. Subsequent layers shall be placed only after the finished layer has been tested according to Clause 903.2.2 and accepted by the Engineer, The Engineer may permit measurement of field dry density bya nuclear moisture/density gauge used in accordance with agreed procedure and the gauge is calibrated to provide results identical to that obtained from tests in accordance with IS: 2720 (Part 28). A record of the same shall be maintained by the Contractor. When density measurements reveal any soft areas in the embank~ mentjsubgrade/earthen shoulders, further compaction shall be carried out as directed by the Engineer. If inspite of that the specified compaction is not achieved, the material in the soft areas shall be removed and replaced by approved material, compacted to the density requirements and satisfaction of the Engineer. 305.3.7. Drainage : The surface of the embankrnent/subgrade at all times during construction shall be maintained at such a cross fall (not flatter than that required for effective drainage of an earthen surface) as will shed water and prevent ponding. 305.3,8. Repairing of damages caused by rain/spillage of water: The soil in the affected portion shall be removed in such areas as
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75
Section 300
Drainage
directed by the Engineer before next layer is laid and refilled in layers and compacted using appropriate mechanical means such as small vibratory roller, plate compactor or power rammer to achieve the required density in accordance with Clause 305.16. If the cut is not sufficiently wide for use of required mechanical means for compaction, the same shall be widened suitably to permit their use for proper compaction. Tests shall be carried out as directed by the Engineer to ascertain the density requirements of the repaired area. The work of repairing the damages including widening of the cut, if any, shall be earned out by the Contractor at his own cost, including the arranging of machinery/equipment for the purpose. 305.3,9. Finishing operations Finishing operations shall include
the work of shaping and dressing the shoulders/verge/roadbed and side slopes to conform to the alignment, levels, cross-sections and dimensions shown on the drawings or as directed by the Engineer \ubject to the surface tolerance described in Clause 902. Both the upper and lower ends of the side slopes shall be rounded off to
4tnprove appearance and tb merge the embankment with the adjacent

terra in.
The topsoil, removed and conserved earlier (Clause 301.3.2 and ) shall be spread over the fill slopes as per directions of the Engineer to facilitate the growth of vegetation. Slopes shall be roughened and niotstened slightly prior to the application of the topsoil in order La provide satisfactory bond. The depth of the topsoil shall be sufficient a sustain plant growth, the usual thickness being from 75 mm to 150 unrn Where directed, the slopes shall be turfed with sods in accordance
i~iih Clause 307. if seeding and mulching of slopes is prescribed, this shall he done to the requirement of Clause 308. When earthwork operations have been substantially completed, the road area shall be cleared of all debris, and ugly scars in the construction area responsible for objectionable appearance eliminated.
under Special Conditions 305.4] Earthwork for widening existing road embankmenu When art existing embankment and/or subgrade is to be widened and its slopes are steeper than 1 vertical on 4 horizontal, continuous horizontal benches, each at least 300 mm wide, shall be cut into the
305.4. Construction of Embankment and Subgrade
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76
Section 300
old slope for easuring adequate bond with the fresh embankment/subgrade material to be added. The material obtained from cutting of benches could be utilized in the widening of the embankmeni/subgrade. However, when the existing slope against which the fresh material is to be placed is flatter than 1~vertical on 4 horizontal,the slope surface may only be ploughed or scarified instead of resorting to benching. Where the width of the widened portions is insufficient to permit the use of conventional rollers, compaction shall be carried out with the help of small vibratory rollers/plate compactor~powerrammers or arty other appropriate equipment approved by the Engineer. End dumping of material from trucks for widening operations shall be avoided except in difficult circumstances when the extra width is too narrow to permit the movement of any other types of hauling equipment. 305.4.2. Earthwork for embankment and subgrade to be placed against sloping ground Where an embankment/subgrade is to be placed against sloping ground, the latter shalt be appropriately benched or ploughed/scarified as required in Clause 305.4,1 before placing the embankrnent/subgrade material. Extra earthwork involved in benching or dtie to ploughing/scarifying etc. shall be considered incidental to the work. For wet conditions, benches with slightly inward fall and subsoil drains at the lowest point shall be provided as per the drawings, before the till is placed against sloping ground. Where the Contract requires construction of transverse subsurface drain at the cut~llllinterface, work on the same shall be carried out to Claose 309 in proper sequence with the embankment and suhgrade work as approved by the Engineer. 305.4.3. Earthwork over existing road surface Where the embankment is to be placed over an existing road surface, the work shall he earned out as indicated below
(ii If the existing road surface is of granular or bituminous type and lies within 1 in of the new subgradc level, the same shatl be scarified to a stepth of 50 mm or more if specified, so as to provide ample bond between the old and new material ensuring that at least SOt) mm portion below the top of new suhgracle level is compactesl to the desired density. If the existing road surface is of cement concrete type and lies within I m of the new subgrade level the same shall be removed completely. level is snore than tm, the existing surface shall be petmitted to stay in place without any modification.
(ii)
(iii) If she level difference between the existing road surface and the new formation
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77
Section 3(X)
305.4.4. Embankment and subgrade around structures To avoid interference with the construction of abutments, wing walls or return walls of culvert/bridge structures, the Contractor shall, at points to be determined by the Engineer suspend work on embankment forming approaches to such structures, until such time as the construction of the latter is sufficiently advanced to permit the completion of approaches without the risk of damage to the structure.
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Unless directed otherwise, the filling around culverts, bridges and other structures upto a distance of twice the height of the road from the back of the abutment shall be carried out independent of the work on the main embankment. The fill material shall not be placed against any abutment or wing wall, unless permission has been given by the Engineer but in any case not until the concrete or masonry has been in position for 14 days. The embankment and subgrade shall be brought up simultaneously in equal layers on each side of the structure to avoid displacement and unequal pressure. The sequence of work in this regard shall be got approved from the Engineer. The material used for backfill shall not be an organic soil or highly plastic clay having plaiticity index and liquid limit more than 20 and 40 respectively when tested according to 15:2720 (Part 5). Filling behind abutments and wing walls for all structures shall conform to the general guidelines given in Appendix 6 of IRC:78 (Standard Specifications and Code of Practice for Road Bridges-Section VII) in respect of the type of material, the extent of backfill, its laying and compaction etc. Thc fill tnaterial shall be deposited in horizontal layers in loose thickness and compacted thoroughly to the requirements of Table 300-2. Where the provision of any filter medium is specified behind the abutment, the same shall be laid in layers simultaneously with the laying of fill material. The material used for filter shall conform to the requirements for filter medium spelt out in Clause 2502/309.3.2 (B) unless otherwise specified in the Contract. Where it may be impracticable to use conventional rollers, the compaction shall be carried out by appropriate mechanical means such as small vibratory roller, plate compactor or power rammer. Care shall be taken to see that the compaction equipment does not hit or come too close to any structural member so as to cause any damage to them or excessive pressure against the structure. 305.4.5. Construction of embankment over ground incapable of supporting construction equipment Where embankment is to 78
Drainage
Section 300
be constructed across ground which will not support the weight of repeated heavy loads of construction equipment, the first layer of the fill may be constructed by placing successive loads of material in a uniformly distributed layer of a minimum thickness required to support the construction equipment as permitted by the Engineer. The Contractor, if so desired by him, may also use suitable geosynthetic material to increase the bearing capacity of the foundation. This exception to normal procedure will not be permitted where, in the opinion of the Engineer, the embankments could be constructed in the approved manner over such ground by the use-cf lighter or modified equipment after proper ditching and drainage have been provided. Where this exception is permitted, the selection of the material and the construction procedure to obtain an acceptable layer shall be the responsibility of the Contractor. The cost of providing suitable traffic conditions for construction equipment over any area of the Contract will be the responsibility of the Contractor and no extra payment will be made to him. The remainder of the embankment shall be constructed as specified in Clause 305.3. 305.4.6. Embankment construction under water : Where filling or backfilling is to be placed under water, only acceptable granular material or rock shall be used unless otherwise approved by the Engineer. Acceptable granular material shall consist of graded, hard durable particles with maximum particle size not exceeding 75 mm. The material should be non-plastic having uniformity coefficient of not less than 10. The material placed in open water shall be deposited by end tipping without compaction. 305.4,7. Earthwork for high embankment : In the case of high embankments, the Contractor shall normally use the material from the specified borrow area. In case he desires to use different material for his own convenience, he shall have to carry out neces~ary soil investigations and redesign the high embankment at his own cost. The Contractor shall then furnish the soil test data arid design of high embankment for approval of thb Engineer, who reserves the right to accept or reject it. If necessary, stage construction of fills and any controlled rates of filling shall be carried out in accordance with the Contract including installation of instruments and its monitoring. Where required, the Contractor shall surcharge embankments or other areas of fill with approved material for the periods specified in the Contract. If settlement of surcharged fill results in any surcharging
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79
Sec.t ion 300
Ear hwnrk,
ntaterial, which is unacceptable for use in the fill being surcharged, lying below formation level, the ContracEtor shall remove the unacceptable material and dispose it as per direction of the Engineer. I-Ic shall then bring the resultant level up to formation level with acceptable material, \Vhere settlement period is specified the required sLttIeFrlit.nt period before excavating for abutment, wingwall, retaining wall, footings, etc., or driving foundation piles. The duration of the required settlement period at each location shall be as provided for in the Contract or as directed by the Engineer.
iii the Contract, tI-c embankment shall remain in place for
305,4.8. Settlement period
305.5. Plying of Traffic Consiructien and other vehicular traffic shall not use the prepared surLice of the embankment and/or subgrade without the prior permission of the Engineer. Any damage arising out of such use shall, however, he made good by the Contractor at his own expense as directed by the
Engineer.
34)5,6. Surface Finish and Quality Control of Work The surface finish of comaruction of subgrade shall conform to the u reiuents of Clause 902 Control on the quality of materials and weeks shall be exercised in accordance with Clau~e903 305.7, Subgrade Strength 305.7.1. It shall be ensured prior to actual execution that the borrow are:i material to be used in the subgrade satisfies the requirements of design CBR. 305.7.2. Suhgrade shall be compacted and finished to the design strength consistent with other physical requirements. The acwal laboratory CI3R values of constructed subgrade shall he determined on undisturbeci samples cut out from the compacted subgrade in CBR mould fitted with cutting shoe or on remoulded samples, compacted to the field density at the field moisture content. 3058. Measurements for Payment Earth emhanknienllsubgrade construction shall be measured separately by taking cross sections at intervals in the original position before the work starts and after its completion and computing the volumes of earthwork in cubic metres by the method of average end areas.
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80
Section 300
The measurement of fill material from borrow areas shall be the difference between the net quantities of compacted fill and the net quantities of suitable material brought from roadway and drainage excavation. For this purpose, it shall be assumed that one cu,m. of suitable material brought to site from road and drainage excavation forms one cu.m. of cbmpacted fill and all buiking or shrinkage shall be ignored. Construction of embankment under water shall be measured in Cu,m. Construction of high embankment with specified material and in specified manner shall be measured in cu.m. Stripping including storing and reapplication of topsoil shall be measured in cu.m. Work involving Loosening and recompacting of ground supporting embankment/subgrade shall be measured in cu. m. Removal of unsuitable material at embankmentisubgrade foundation and replacement with suitable material shall be measured in cu.m. Scarifying existing granular/bituminous road surface shall be measured in square metres. Dismantling and removal of existing cement concrete pavement shall be measured vide Clause 202.6, Filter medium and backfill material behind abutments, wing walls and other retaining structures shall be measured as finished work in position in cu.m. 305.9. Rates 305.9.1. The Contract unit rates for the items of embankment ~nd subgrade construction shall be payment in full for carrying out the required operations including full compensation for
(1) (ii) Cost of arrangement of land as a source of supply of material of required quantity for construction unless provided otherwise in the Contract; Setting
Out;
(iii) Compacting ground supporting embankment/subgrade except where removal and replacement of unsuitable material or loosening and recompacling is involved; (iv) Scarifying or cutting continuous horizontal benches 300mm wide on side slopes of existing embankment and subgrade as applicable; (v) Cost of watering or drying of material in borrow . areas andlor embankment and subgTade during construction as required;
81
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Section 300
(vi) Spreading in layers, bringing to appropriate moisture content and compacting to Specification requirements; (vii) Shaping and dressing top and slopes of the embankment and subgrade including rounding of corners; (viii) Restricted working at sites o.f structures (ix) Working on narrow width of embankment and subgrade; (x) Excavation in all$oils from borrow pits/designated borrow areas including clearing and grubbing and transporting the material to embankment and subgrade sire with all lifts and leads unless otherwise provided for in the Contract;
(xi) All labour, materials, tools, equipnent and incidentals necessary to complete the work to the Specifications; (xii) Dewatering; and (xiii) Keeping the embankment/completed formation free of water as per Clause 311.
305.9.2. In case the Contract unit rate specified is not inclusive of all leads, the unit rate for transporting material beyond the initial lead, as specified in the Contract for construction of embankment and subgrade shall be inclusive of full compensation for all labour, equipment, tools and incidentals necessary on account of the additional haul or transpertation involved beyond the specified initial lead. 305.9.3. Clause 301.9.5 shall apply as regards Contract unit rates for items of stripping and storing top soil and of reapplication of topsoil. 305.9.4. Clause 301.9.2 shall apply as regards Contract unit rate for the item of loosening and recompacting the embankmenl/subgrade
foundation.
305.9.5. Clauses 301.9.1 and 305.8 shall apply as regards Contract rates for items of removal of unsuitable material and replacement with suitable material respectively. 305.9.6. The Contract unit rate for sarifying existing granular/bituminous road surface shall be payment in full for carrying out the required operations including full compensation for all labour, materials, tools, equipment and incidentals necessary to complete the work. This will also comprise of handling, salvaging, stacking and disposing of the dismantled materials within all lifts and upto a lead of 1000 m or as otherwise specified. 305.9.7. Clause 202.7 shall apply as regards Contract unit rate for dismantling and removal of existing cement concrete pavement. 305.9.8. The Contract unit rate for providing and laying filter material behind abutments shall be payment in full for carrying out
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82
Earthwork, Erosion Control nd Drainagc Section. 300 the required operations including all materials, labour, tools, equipment and incidentals to complete the work to Specifications.
305.9.9. Clause 305A..6 shall apply as regards Contract unit rate for construction of embankment under water. 305.9.10. Clause 305.4.7 shall apply as regards Contract unit rate for construction of high embankment. It shall include cost of instrumentation, its monitoring and settlement period, where specified in the Contract or directed by the Engineer. 306. SOIL EROSION AND SEDIMENTATION CONTROL 3061. Description This work shall consist of measures as shown on plans or as directed by the Engineer to conirol soil erosion, sedimentation and water pollution, through use of berms, dikes, sediment basins, fibre mats, mulches, grasses, slope drains, and other devices. 306.2. Materials All materials shall meet commercial grade standards and shall be approved by the Engineer before being used in the work. 3063. Construction Operations Prior to the start of the relevant construction, the Contractor shall submit to the Engineer for approval his schedules for carrying out temporary and permanent emsion/sedimentation control works as are applicable for the items of clearing and grubbing, roadway and drainage excavation, embankipent/subgrade constructio~i, ridges and other strucb tures across water courses, pavement courses and shoulders. He shall also submit for approval his proposed method of erosion/sedimentation control on service road and borrowpits and his plan for disposal of waste materials. Work shall not be started until the erosion/sedimentation control schedules and methods of operations for the applicable construction have been approved by the Engineer. The surface area of erodible earth material exposed by clearing and grubbing, excavation, borrow and fill operations shall be limited to the extent practicable. The Contractor may be directed to provide immediate permanent or temporary erosion and sedimentation control measures to prevent soil erosion and sedimentation that will adversely affect construction operations, damage adjacent propeEties, or cause contamination of nearby streamS or ether water cotu~es, lakes, reservoirs etc. Such work may involve the construction of temporary berms, dikes,
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83
Section 300
sediment basins, slope drains and use of temporary mulches, fabrics, mats, seeding, or other control devices or methods as necessary to control erosion and sedimentation. Cut and fill slopes shall be seeded and turfed as required on the plans. The Contractor shall be required to incorporate all permanent erosion and sedimentation control features into the project at the earliest practicable time as outlined in his accepted schedule to minimize the need for temporary erosion and sedimentation control measures. Temporary erosion/sedimentation and pollution control measures will be used to control the phenomenon of erosion,sedimentation and pollution that may develop during normal construction practices, but may neither be foreseen during design stage nor associated with permanent control features on the Project. Where erosion or sedimentation is likely to be a problem, clearing and grubbing operations should be so scheduled and performed that grading operations and permanent erosion or sedimentation control features can follow immediately thereafter if the project conditions permit; otherwise temporary erosion or sedimentation control measures may be required between successive construction stages. Under no conditions shall a large surface area of erodible earth material be exposed at one time by clearing and grubbing or excavation without prior approval of the Engineer. The Engineer may limit the area of excavation, borrow and embankment operations in progress, commensurate with the Contractors capability and progress in keeping the finish grading, mulching, seeding and other such permanent erosion, sedimentation and pollution control measures, in accordance with the accepted schedule, Should seasonal limitations make such coordination unrealistic; temporary erosion/sedimentation control measures shall be taken immediately to the extent feasible and justifkd. in the event temporary erosion, sedimentation and pollution control measures become necessary due to the Contractors negligence, carelessness or failure to install permanent controls as a part of ~thework as scheduled or ordered by the Engineer, these shall be carried out at the Contractors own expense. Temporary erosion, sedimentation and pollution control work required, which is not attributed to the Contractors negligence, carelessness or failure to install permanent controls, will be performed as ordered by the Engineer. 84
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Earthwork,
Section 300
Temporary erosion, sedimentation and pollution control may include construction work outside the right-of-way where such work is necessary as a result of road construction such as borrow pit operations, service roads and equipment storage sites. The temporary erosion,sedimentation and pollution control features installed by the Contractor shall be acceptably maintained by him till these are needed, unless otherwise agreed by the Engineer. 306.4. Measurements for Payment The soil erosion, sedimentation and pollution control works will be measured in terms of units specified in the Bill of Quantities for the respective items.
306.5. Rates The Contract unit rate for different items of soil erosion, sedimentation and pollution control works shall be payment in full for carrying out all required operations including full compensation for all laboui, tools, equipment and incidentals to complete the works to the Specifications. 307. TURFING WITH SODS 307.1. Scope This work shall consist of furnishing and laying of the live sod of perennial turf forming grass on embankment slopes, verges (earthen shoulders) or other locatiOns shown on the drawings or as directed by the Engineer. Unless otherwise specifled, the work shall be taken up as soon as possible following construction of the embankment, provided the season is favourable for establishment of the sod. 307.2. Materials The sod shall consist of dense, well-rooted growth of permanent and desirable grasses, indigenous to the locality where it is to be used, and shall be practically free from weeds or other undesirable matter. At the time the sod is cut, the grass on the sod shall have a length of approximately 50 mm and the sod shall have been freed of debris. Thickness of the sod shall be as uniform as possible, with some 5080 mm or so of soil covering the grass roots depending on the nature of the sod, so that practically all the dense root system of the grasses is retained in the sod strip. The sods shall be cut in rectangular strips of uniform width, not less than about 250 mm x 300 mm in size but not so large that it is inconvenient to handle and transport these
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85
Section 3(X)
without damage. During wet weather, the sod shall be allowed to dry sufficiently to prevent rearing during handling and during dry weather shall be watered before lifting to ensure its vitality and prevent the droppmg of the soil in handling. 307.3, Construction Operations 307.3,1. Preparation of the earth bed : The area to be sodded shall have been previously constructed to the required slope and cross section. Soil on the area shall be loosened, freed of all stones larger than 50 mm size, sticks, stumps and any undesirable foreign matter, and brought to a reasonably fine granular texture to a depth of not less than 25 mm for receiving the sod. Where required, topsoil shall be spread over the slopes. Prior to placing the topsoil, the slopes shalt be scarified to a depth which, after settlement, will provide the required nominal depth shown on the plans. Spreading shall not be done when the ground is excessively wet. Following soil preparation and top soiLing, where required, fertilizer and ground limestone when specified shalt be spread uniformly at the rate indicated on the plans. After spreading, the materials are incorporated in the soil by discing or other means to the depths shown on the plans. 307.3.2. Placing the sods : The prepared sod bed shall be moistened to the loosened depth, if not already sufficiently moist, and the sod shall be placed thereon within approximately 24 hours after the same had been cut. Each sod strip shall be laid edge to edge and such that the joints caused by abutting ends are staggered. Every strip, after it is snugly placed against the strips already in position, shall be lightly tamped with suitable wooden or metal tampers so as to eliminate air pockets and to press it into the underlying soil. On side slopes steeper than 2 (horizontal) to I (vertical), the laying of sods shall be started from bottom upwards. At points where water may flow over a sodded area, the upper edges of the sod strips shall, be turned into the soil below the adjacent area and a layer of earth placed over this followed by its thorough compaction. 307.33. Staking the sods: Where the side slope is 2 (horizontal) to 1 (vertical) or steeper and the distance along the slope is more than 2 m, the sods shall be staked with pegs or~ nails spaced approximately 500 to 1000 mm along the longitudinal axis of the sod strips, Stakes shall be driven approximately plumb through the sods to be almost flush with them.
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86
Earthwork, Erosion Control andOrainage
Section 300
307.3.4. Top dressing: After the sods have been laid in position, the surface shall be cleaned of loose sod, excess soil and other foreign material. Thereafter, a thin layer of topsoil shall be scattered over the surface of top dressing and the area thoroughly moistened by sprinkling with water. 307.3.5. Wateri~igand maintenance : The sods shall be watered by the Contractor for a period of at least four weeks after laying. Watering shall be so done as to avoid erosion and prevent damage to sodded areas by wheels of water tanks. The Contractor shall erect necessary warning signs and barriers, repair or replace sodded areas failing to show uniform growth of grass or damaged by his operations and shall otherwise maintain the sod at his cost until final acceptance. 307.4. Measurements for Payment Turfing with sods shall be measured as finished work in square metres. 307.5. Rate The Contract unit rate for turfing with sods shall mean payment in full for carrying out all the required operations explained above including compensation for
(i) (ii) furnishing all the materials to be incorporated in the Works with all leads and lifts; and all labour, tools, equipments and incidentals to complete the work in accordance with these Specificaons.
The Contract unit rate for application of topsoil shall be Clause 301.9.5. 308. SEEDING AND MULCHING 308.1. Scope
as per
This shall consist of preparing slopes, placing topsoil, furnishing alL seeds, commercial or organic fertilizers and mulching materials, providing jute netting and placing and incorporating the same on embankment slopes or other locations designated by the Engineer or shown in the Contract documents. 308.2. Materials
A. Seeds: The seeds shall be of approved quality and type suitable for the soil on which these are to be applied, and shall have acceptable purity and germination to requirements set down by the Engineer. 87
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Section 300
Fertilizer shall consist of standard commercial materials and conform to the grade specified. Organic manure shall be fully puirefied organic maser such as cow dung. Mulching materials shall consist of straw, hay, wood shavings or sawdust, and shall be delivered dry. They shall be reasonably free of weed seed and such foreign materials as may detract from their effectiveness as a mulch or be injurious so the plant growth. B. Topsoil: Topsoil shall not be obtained from an area known to have noxious weeds growing in it. If treated with herbicides or sterilents, it shall be got tested by appropriate ~gricultural uthority to determine the residual in the soil. Topsoil a shall not contain less than 2 per cent and more than 12 per cent organic matLer. BltumLrtous Emulsion: A suitable grade of bituminous cutback or emulsion used as a tie down for mulch shall be as described in the Contract doarment or as desired by the Engineer. Emulsified bitumen shall not contain any solvent or diluting agent toxic to plant life. Netting: Jute netting shall be undyed jute yam woven into a uniform open weave with approximate 2.5 cm square openings. Geonetting shall he made of uniformly extruded rectangular mesh having mesh opening of 2 cm x 2 cm. The colour may be black or green. It shall weigh not less than 3.8 kg per 1000 sq. m.
C.
D.
308.3. Seeding Operations 308.3.1. Seed-bed preparation : The area to be seeded shall be brought to the required slope and cross-section by filling, reshaping eroded areas and refinishing slopes, medians etc. Topsoil shall be evenLy spread over the specified areas to the depth shown on the plans, unless otherwise approved by the Engineer. The seed-bed preparation shall consist of eliminating all live plants by suitable means using agricultural implements. All stones 150 mm in smallest dimension and larger shall be removed. The soil shall be excavated on the contour to a depth of 100 mm. All clods larger than 25 mm in diameter shall be crushed and packed. Where necessary, water shall then be applied. All topsoil shall be compacted unless otherwise specified or approved by the Engineer. Compaction shall be by slope compactor, cleated tractor or similar equipment approved by the Engineer. Equipment shall be so designed and constructed as to produce a uniform rough textured surface ready for seeding and mulching and which will bond the topsoil to the underlying material. The entire area shall be covered by a minimum of 4 passes or 2 round trips of the roller or approved equipment. 308.3,2. Fertilizer application : Fertilizer to the required quantities shall be spread and thoroughly incorporated into the soil surface as a part of the seed-bed preparation.
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308.3.3. Planting of seeds : All seeds shall be planted uniformly at the approved rate. Immediately after sowing, the area shall be raked, dragged or otherwise treated so as to cover the seeds to a depth of 6 mm. The operation of seed sowing shall not be performed when the ground is muddy or when the soil or weather conditions would otherwise prevent proper soil preparation and subsequent operations. 308.3.4. Soil moisture and watering requirements: Soil-moisture shall exist throughout the zone from 25 mm to at least 125 mm below the surface at the time of planting. Watering of the seeded areas shall be carried out as determined by the Engineer. 308.4. Mulching, Applying Bituminous Emulsion and Jute Netting! Geonetting Within 24 hours of seeding, mulching material mixed with organic manure shall be placed so as to form a continuous, unbroken cover of approximate uniform thickness of 25 mm using an acceptable mechanical blower. Mulching material shall be held in place and made resistant to being -blown away by suitable means approved by the Engineer. When called for in the Contract documents, mulch material shall be anchored in place with bituminous emulsion applied at the rate of 2300 litres per hectare. Any mulch disturbed or displaced following application shall be removed, reseeded and remulched as specified. Jute netting/Geonetting shall be unrolled and placed parallel to the flow of water immediately following the bringing, tafinished grade, the area specified on the plans or the placing of seed and fertilizer. Where more than one strip is required to cover the given areas, they shall overlap a minimum of 100 mm. Jute netting/ Geonetting shall be held in place by approved wire staples, pins, spikes or wooden stakes driven vertically into the soil. 308.5. Maintenance The Contractor shall maintain all seeded and mulched areas until final acceptance. Maintenance shall inciud~ protection of traffic by approved warning signs or barricades ax~d repairing any areas damaged following the seeding and mulching operations. If mulched areas become damaged, the area shall be reshaped and then seeded and mulched again as originally spe~ified.
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Section
300
308.6. Measurements for payment Seeding and mulching shall be measured as finished work in square metxes. 308.7. Rate The Contract unit rate for seeding and mulching shall be payment in full for carrying out all the required operations including full compensation for all materials, labour, tools and incidentals. 309. SURFACE/SUB-SURFACE DRAINS 309.1. Scope This work shall consist of constructing surface and/or sub-surface drains in accordance with the requirements of these Specifications and to the lines, grades, dimensions and other particulars shown on the drawings or as directed by the Engineer. Schedule of work shall be so arranged that the drains are completed in proper sequence with road works to ensure that no excavation of the completed road works is necessary subsequently or any damage is caused to these works due to lack of drainage. 309.2. Surface Drains Surface drains shall be excavated to the specified lines, grades, levels and dimensions to the requirements of Clause 301. The excavated material shall be removed from the area adjoining the drains and if found suitable, utilised in embankment/subgrade construction. All unsuitable material shall be disposed of as directed. The excavated bed and sides of the drains shall be dressed to bring these in close conformity with the specified dimensions, levels and slopes. Where so indicated, drains shall be lined or turfed with suitable materials in accordance with details shown on the drawings. All works on drain construction shall be planned and executed in proper sequence with other works as approved by the Engineer, with a view to ensuring adequate drainage for the area and minimising erosion/ sedimentation. 3093. Sub-surface Dralns 309.3.1. Scope : Sub-surface drains shall be of close-jointed perforated pipes, open-jointed unperforated pipes, surrounded by granular material laid in a trench or aggregate drains to drain the pavement courses. Sub-surface drains designed using Geosynthetics and approved by the Engineer can also be used.
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Section 300
309.3.2. Materials
A. PIpe Perforated pipes br the drains may be ofmetatlasbestos cement/ cement concretelPVC, and unperforated pipes of vitrified claylccment concrete/ asbestos cement. The type, size and grade of the pipe to be used shall be as specified in the Contract. In an case, however, shall the internal diameter of the pipe be less than 100 mm. Holes for perforated pipes shall be on one half of the circumference only and conform to the spacing indicated on the drawings. Size of the holes shall not ordinarily be greater than half of ~ size of the material surrounding the pipe, subject to being minimum 3 mm and maximum 6 mm. l)~~ stands for the size of the sieve that allows 85 per cent of the material to pass through it. Backfill materIal Backfill material shall consist of sound, tough, hard, durable
R,
particles of free draining sand-gravel material or crushed stone and shall be free of organic material, clay balls or other deleterious matter Unless the Contract specifies any particular gradings for the backfill material or requires these to be designed on inverted filter criteria for filtration and permeability to the approval
of the Engineer, the backfill material shall be provided on the following lines: (i) Where the soil met with in the trench is of fine grained type (e.g.. silt,clay or a mixture *hereot),the backfill material shall conform to Class I grading set out in-Table 300-3. Where the soil met with in the trench is of coarse silt to medium sand or sandy type, the backfill material shall correspond to Class 11 grading of Table 300-3.
(ii)
(iii) Where soil met with in the trench is gravelly sand, the backfill material shall correspond to Class III grading of Table 300-3.
Thickness of backfill material arouna the pipe shall be as shown on the drawings subject to being at least 150 mm airound in all cases. Geosynthetics for use with subsurface drain shall conform to the requirements as per Section 700.
Table 300-3. GRADING REQUIREMENTS FOR FILTER MATERIAL Par cent passIng by weIght SIeve DesignatIon Class I

Class H
.
Class III
53mm 45 mm
26.5mm 22,4 mm 11.2 mm 5.6 mm 2.8 mm 1,4 mm 710 micron 355 micron l80micron 90 micron
100
97.100
100
95-100
58-100
20-60 4-32
100
92-100 83-100
48-100 28-54 20-35
59-96 35-80
14-40 3-15
0-10 0-5

6-18
2-9
0-5
0-4
0-3
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309.3.3. Trench excavation: Trench for sub-surface drain shall be excavated to the specified lines, grades and dimensions shown in the drawings provided that width of trench at pipe level shall not be less than 450 mm. The excavation shall begin at the outlet end of the drain and proceed towards the upper end. Where unsuitable material is met with at the trench bed, the same shall be removed to such depth as directed by the Engineer and backfilied with approved material which shall be thoroughly compacted to the specified degree. 309.3.4. Laying of pipe and backiilling Laying of pipe in the trench shall be started at the outlet end and proceed towards the upper end, true to the lines and grades specified. Unless otherwise provided, longitudinal gradient of the pipe shall not be less than 1 in 100. Before placing the pipe, backfill material of the required grading(s) shall be laid for full width of the trench bed ana compacted to a minimum thickness of 150 mm or as shown on the drawings. The pipe shall then be embedded flrmly on the bed. Perforated pipes, unless otherwise specified, shall be placed with their perforations down to minimise clogging. The pipe Sections shall be joined securely with appropriate coupling fittings or bands. Non-perforated pipes shall be laid with joints as close as possible with the open joints wrapped with suitable pervious material (like double layer of hessian, suitable Geosynthetics or some other material ~f not less than 150 mm width) to permit entry of water but prevent fines entering the pipes. In the case of non-perforated pipes with bell end, the bell shall face upgrade. Upgrade end sections of the pipe installation shall be tightly closed by means of concrete plugs or plugs fabricated from the same material as the pipe and securely held in place to prevent entry of soil materials. After the pipe installation has been completed and approved, backfill material of the required grading(s) (see Clause 309.3.2B) shall be placed over the pipe to the required level in horizontal layers not exceding 150 mm in thickness and thoroughly compacted. The minimum thickness of material above the top of the pipe shall be 300 mm. Unless otherwise provided, sub-surface drains not located below the road pavement shall be sealed at the top by means of 150 mm thick layer of compacted clay so as to prevent percolation of surface water.
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309.3.5. Use of geosynthetic in bying of pipe and backfilling After excavating the trench for subsurface drain, the filter fabric shall be placed, the pipe installed and the trench backfilled with permeable material according to dimensions and details shown on the plans. Surfaces to receive filter fabric prior to placing shall be free of loose or extraneous material and sharp objects that may damage the filter fabric ~during installation. Adjacent rolls of the fabric shall be overlapped a minimum of 450 mm. The preceding roll shall overlap the following roll in the direction the material is being spread. Damage to the fabric resulting from Contractors vehicles, equipment or operations shall be replaced or repaired by the Contractor at his expense. 309.3.6. Drain outlet The outlet for a sub-drain shall not be under water or plugged with debris but should be a free outlet discharging into a stream, culvert or open ditch. The bottom of the pipe shall be kept above high water in the ditch and the end protected with a grate or screen. For a length of 500 mm from the outlet end, the trench for pipe shall not be provided with granular material but backfilled with excavated soil and thoroughly compacted so as to stop water directly percolating from the backfill material around the pipe. The pipe in this section shall not have any perforations. 309.3.7. Aggregate drains : Aggregate drains shall be placed within the verge/shoulders after completion of the pavement. Depth, thickness and spacing of the aggregate drains shall be as shown on the plan. Trenches for aggregate drains shall be excavated to a minimum width of 300 mm and to the depth shown on the plans or ordered by the Engineer. The bottom of the trench shall be sloped to drain and shall be free from loose particles of soil. The trench shall be excavated so as to expose clearly the granular pavement courses to be drained. Aggregate for the drains shall ~e durable gravel, stone or slag and shall be free from vegetable matter and other deleterious substances. The grading requirements are given at Table 300-4. Type B grading may be used only where the drain is designed to intercept surface water [lowingto the pipe and is likely to get slowly blocked. Type A grading allows a much wider range.
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Section 300
Sieve Size
Earthwork, Erosion Control an4 Drainage Per cent passing by weight TypeA TypeB
100
TABLE 300.4. GRADING REQUIREMENTS FOR AGGREGATE DRAINS
63mm 37.5 mm
19mm
100
9.5 rum 3.35 mm 600 micron 150 micron 75 micron
45-100 25-80 8-45 0-10 0-5
85-100 0-20 0-5

309.4. Measurements for Payment Measurement for surface and sub-surface drains shall be per running metre length of the drain. Disposal of surplus material beyond 1000 m shall be measured in cu. m. 309.5. Rates The Contract unit rates for surface and subsurface drains shall be payment in full for all items such as excavation, dressing the sides and bottom; providing lining, turfing, pitching, masonry, concrete and plastering; providing, laying and jointing pipes; providing, laying and compacting backfill and bed of granular material; providing, fixing and painting of cover etc. including full compensation for all materials, labour, tools, equipment and other incidentals to complete the work as shown on drawings with all leads and lifts except for removal of unsuitable material for which the lead shall be 1000 m. Provision of inlets, gratings, sumps, outlet pipes, bedding, disbursers etc. wherever required shall be incidental to construction of drain. The Contract unit rate for disposal of surplus and unsuitable material beyond the initial 1000 m lead shall be in accordance with Clause 304.5.3. 310. PREPARATION AND SURFACE TREATMENT OF FORMATION Preparation and surface treatment of the formation, that is top of the subgrade, shall be carried out only after completion of any specified subgrade drainage and unless otherwise agreed by the Engineer, immediately prior to laying the sub-base or the road base where no sub-base is required. The sequence of operations shall be as follows:
(a) All surfaces below carriageway, laybyes, footways and hard shoulders shall, after reinstatement of any soft areas to the required Specifications be well cleaned and freed of mud and slurry.
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(b) The surface shall be compacted by 4 passes of a smooth wheeled roller of 80 to 100 kN weight after spraying requisite amount of waler, if required, before the commencement of rolling.
(c) (d) The formation shall, wherever necessary, be regulated and trimmed to the requirements of Clause 505.3.9 with motor grader. The trimmed formation shall be rolled by one pass of smooth wheeled roller of 80 to 100 kN weight after spraying requisite amount of water, if required, before the commencement of rolling.
Where the completed formation is not immediately covered with subbase or road base material, its moisture content shall be maintained to prevent cracking in the formation by suitable measures as approved by the Engineer. The entire work of surface treatment of formation shall be deemed as incidental to the work of sub-base/base course to be provided on the subgrade and as such no extra payment shall be made for the same. 311. WORKS TO BE KEPT FREE OF WATER 311.1. The Contractor shall arrange for the rapid dispersal of water collected/accumulated on the earthwork or completed formation during construction or on the existing roadway or which enters the earthwork or any other item of work from any source, and where practicable, the water shall be discharged into the permanent outfall of the drainage system. The arrangements shall be made in respect of all earthwork including excavation for pipe trenches, foundations or cuttings. 311.2. The~ Contractor shall provide, where necessary, temporary water courses, ditches, drains, pumping or other means for maintaining the earthwork free from water. Such provisions shall include carrying out the work of forming the cut sections and embankments in such manner that their surfaces have at all times a sufficient minimum crossfall and, where practicable, a sufficient longitudinal gradient to enable them to shed water ,and prevent ponding. The works involved in keeping the earthwork or any other item of works free of water shall be deemed as incidental to the respective item of work and as such no separate payment shall be made for the s~me. 312. WATER COURSES AT CULTERTS 312.1, Excavation carried out in the diversion, enlargement, deepening or straightening water courses at culverts, where necessary, shall include the operations such as clearing, grubbing, removal of vegetation, trimming of slopes, grading of beds, disposal of excavated
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Earthwork, ErosionControl and Drainage
materials, pumping, timbering etc. necessary for dealing with the flow of water. 3 12.2. The beds and sloping sides of water courses shall, where shown on the Drawings, be protected against the action of water by rubble paving to form a flat or curved surface as indicated. The protection shall consist of large smooth faced stones or of blocks of precast concrete. Stones for rubble paving shall be roughly dressed square. No stone shall be less than 255 mm in depth nor less than 0.02 cu. m. in volume and no rounded boulders shall be used. After completion of construction of culverts, temporary diversion of watercourse, if any, shall be closed and water course restored for flow through the culvert as per the direction of the Engineer. 312.3. Measurements for Payment The work for water courses at culverts as stated above shall be measured in terms of units specified in the Bill of Quantities for respective items. The temporary diversion of channel to facilitate construction of culverts, its closure and restoration to original water course shall be considered incidental to the work of construction of clverts and no extra payment shall be made for the same. 312.4. Rates The Contract unit rates for di:fferent items for water courses at culverts shall be payment in full for carrying out all j~equired operations including full compensation for all cost of materials, laboUr, tools, equipment and other incidentals to complete the work to the Specification, 313. CONSTRUCTION OF ROCKFILL EMBANKMENT 313.1, Scope In normal circumstances, the embankment should not be constructed with rockfill material. However, where specifically permitted by the Engineer because of imperative economic or technical reasons, construction of rockfill embankments shall be in accordance with th~ lines, grades and cross-sections as shown in drawings or as directed by the Engineer. Rockfill shall not be used at least for a depth of 500 mm below the formation level. There sho~ild a minimum of 500 mm thick earthen be cushion over the rocklill. 313.2. Material The size of rock pieces used in rockfihl embankments shall be such that they can be deposited in layers so as to suit the conditions
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Section 300
evaluated in the field compaction trials or as directed by the Engineer. The rockfill shall consist of hard, durable and inert~aterial,preferably maximum size not exceeding 300 mm and per cent finer than 125 mm not exceeding 10 per cent. Argillaceous rocks (clay, shales etc.), unburnt colliery stock and chalk shall not be used in rockfill. The rock fragments and blinding material required for filling the voids shall also satisfy the above requirements. 313.3. Spreading and Compaction The material shall be tipped, spread and levelled in layers extending to the full width of embankment by a suitable dozer. Fragments of rock shall then be spread on the top of layer to the required extent and layer compacted by minimum of 5 passes of vibratory roller having Static weight 8-10 tonnes. The compacted thickness of each layer shall not exceed 500 mm. After compaction of each layer, the surface voids shall be filled with broken fragments. Next layer, where required, shall be placed in the same manner, above the earlier compacted layer. The top layer of rockfill, on which normal earth fill will rest shall be thoroughly blinded with suitable granular material to seal its surface. 313.4. Measurements for Payment Measurement shall be made by taking cross-sections at intervals in the original position before the work starts and after its completion and computing the volume in cu. m. by the method of average end areas. 313.5. Rate The Contract unit rate shall be paid in full for carrying out all the above operations including cost of rockfill, broken fragments and blinding material and shall provide full compensation for all items as per Clause 305.9.1 and 305.9.2.
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Sub-Bases, Bases (Non-Bituminous) and

Shoulders
400 Sub-Bases, Bases (NonBituminous) and Shoulders
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Section 400
401. GRANULAR SUB-BASE
401.1. Scope
This work shall consist of laying and compacting well-graded material on prepared subgrade in accordance with the requirements of these Specifications. The material shall be Laid in one or more layers as sub-base or lower sub-base and upper sub-base (termed as sub-base hereinafter) as necessary according to lines, grades and cross-sections shown on the drawings or as directed by the Engineer. 401.2. Materials 401.2.1. The material to be used for the work shall be natural sand, moorum, gravel, crushed stone, or combination thereof depending upon the grading required. Materials like crushed slag, crushed concrete, brick metal and kankar may be allowed only with the specific approval of the Engineer. The material shall be free from organic or other deleterious constituents and conform to one of the three gradings given in Table 400-1. While the gradings in Table 400-1 are in respect of close-graded granular sub-base materials, one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, the corresponding gradings for the coarsegraded materials for each of the three maximum particle sizes are given at Table 400-2. The grading to be adopted for a project shall be as specified in the Contract. 401.2,2. Physical requirements: The material shall have a 10 per cent fines value of 50 kN or more (for sample in soaked condition) when tested in compliance with BS:812 (Part Ill). The water absorption value of the coarse aggregate shall be determined as per IS 2386 (Part 3); if this value is greater than 2 per cent, the soundness test shall be carried Out on the material delivered to site as per IS : 383. For Grading II and Ill materials, the CBR shall be determined at the density and moisture content likely to be developed in equilibrium conditions which shall be taken as being the density relating to a uniform air voids content of 5 per cent.
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Section 400
Sub-Bases, Bases (Non-Bituminous) and Shoulders SUB-BASE MATERIALS
TABLE 400-1. GRADING FOR CLOSE-GRADED GRANULAR
IS Sieve
Designation 75.0mm 53.0 mm 26.5 mm 9.50 mm
Per cent by weight passing the IS sieve Grading I 100 80-100 55-90
35-65 25-55 20-40 10-25 3-10 30 MATERIALS
Grading H
G rading HI

100 70-100
50-80 40-65 30-50
100
65-95 50-80 40-65 20-35 3-10 20
4.75 mm
2.36 mm 0.425 mm 0.015 mm CBR Value (Minimum)
15-25
3-10 25
TABLE 400-2. GRADING FOR COARSE GRADED GRANULAR SUB-BASE

IS Sieve Designation Per cent by weight passing the IS Sieve Grading I Grading II
Gm ding III
75.0 mm
53.0 mm 26.5 mm 9.50 mm 4,75 mm 2.36 mm 0.425 mm 0.075 mm CBR Value (Minimum) Nate
100
55-75 10-30
100 50-80
15-35
100
25-45
<10 30
<10 25
<10 20
The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS 2720 (Pail 5) shafi have liquid limit and plasticity index not more than 25 and 6 per cent respectively.
401.3. Strength of sub-base It shall be ensured prior to actual execution that the material to be used in the sub-base satisfies the requirements of CBR and other physical requirements when compacted and finished. When directed by the Engineer, this shall be verified by performing CBR tests in the laboratory as required on specimens remoulded at field dry density and moisture content and any other tests for the quality of materials, as may be necessary. 401.4. Construction Operations 401.4.1. Preparation of subgrade Immediately prior to the laying of sub-base, the subgrade already finished to Clause 301 or 305 as applicable shall be prepared by removing all vegetation and other
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extraneous matter, lightly sprinkled with water if necessary and rolled

with two passes of 80 -100 kN smooth wheeled roller. 401.4.2, Spreading and compacting The sub-base material of grading specified in the Contract shall be spread on the prepared subgrade with the help of a motor grader of adequate capacity, its blade having
hydraulic controls suitable for initial adjustment and for maintaining the required slope and grade during the operation or other means as approved by the Engineer.
When the sub-base material consists of combination of materials mentioned in Clause 401.2.1, mixing shall be done mechanically by the mixin-place method. Manual mixing shall be permitted only where the width of laying is not adequate for mechanical operations, as in small-sized jobs. The equipment used for mix-in-place construction shall be a rotavator or similar approved equipment capable of mixing the material to the desired degree. If so desired by the Engineer, trial runs with the equipment shall be carried out to establish its suitability for the work.
Moisture content of the loose material shall be checked in accordance with IS:2720 (Part 2) and suitably adjusted by sprinkling additional water from a truck mounted or trailer mounted water tank and suitable for applying water uniformly and at controlled quantities to variable widths of surMce or other means approved by the Engineer so that, at the time of compaction, it is from I per cent above to 2 per cent below the optimtim moisture content corresponding to 15:2720 (Part 8). While adding water, due allowance shall be made for evaporation losses. After
water has been added, the material shall be processed by mechanical
or other approved means like disc harrows, rotavators until the layer is uniformly wet. Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For a compacted single layer upto 225 mm the compaction shall be done with the help of a vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad footdrum or heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum tyre pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required compaction. Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for porthns having unidirectional crossfall and super-.
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elevation and shall commence at the edges and progress towards the centre for portions having crossfall on both sides. Each pass of the roller shall uniformly overlap not less than onethird of the track made in the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and any high spots or depressions, which became apparent, corrected by removing or adding fresh material. The speed of the roller shall not exceed 5 km per hour. Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry density for the material determined as per IS:2720 (Part 8). The surface of any layer of material on completion of compaction shall be well closed, free from movement under compaction equipment and from compaction planes, ridges, cracks or loose material. All loose, segregated or otherwise defective areas shall he made good to the full thickness of layer and re-compacted. 401.5. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the~Engineer in accordance with Section 900. 401.6. Arrangements for Traffic During the period of construction, arrangement of traffic shall be maintained in accordance with Clause 112. 401.7. Measurements for Payment Granular sub-base shall be measured as finished work in position in cubic metres. The protection of edges of granular sub-base extended over the full formation as shown in the drawing shall be considered incidental to the work of providing granular sub-base and as such no extra payment shall be made for the same. 401.8. Rate The Contract unit rate for granular sub-base shall be payment in full for carrying out the required operations including full compensation for
(i) making arrangements for traffic to Clause 112 except for initial treatment to verges, shoulders and construction of diversions;
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Section 400
furnishing all materials to be incorporated in the work including all royalties, fees, rents where necessary and all leads and lifts; fications;
(iii) all labour, tools, equipment and incidentals to complete the work to the Speci.
(iv) carrying out (v) the work in part widths
of road where directed; and
carrying out the required tests for quality control.
402. LIME TREATED SOIL FOR IMPROVED SUB-GRADFJSUB-BASE 402.1. Scope This work shall consist of laying and compacting an improved subgrade/lower sub-base of soil treated with lime on prepared sub-grade in accordance with the requirements of these Specifications and in conformity with the lines, grades and cross-sections shown on the drawings or as directed by the Engineer. Lime treatment is generally effective for soils which contain a relatively high percentage of clay and silty clay. 402.2. Materials 402.2.1. Soil : Except when otherwise specified, the soil used for stabilisation shall be the local clayey soil having a plasticity index greater than 8. 402.2.2. Lime Lime for lime-soil stabilisation work shall be commercial dry lime slaked at site or pre-slaked lime delivered to the site in suitable packing. Unless otherwise permitted by the Engineer, the lime shall have purity of not less than 70 per cent by weight of Quicklime (CaO) when tested in accordance with IS :1514, Lime shall be properly stored to avoid prolonged exposure to the atmosphere and consequent carbonation which would reduce its binding properties. 402.2.3. Quantity of lime in stabilised mix Quantity of lime to be added as percentage by weight of the dry soil shall be as specified in the Contract, The quantity of lime used shall be related to its calcium oxide content which shall be speified. Where the lime of different calcium oxide content is to be used, its quantity shall be suitably adjusted to the approval of the Engineer so that equivalent calcium oxide is incorporated in the wotk, The mix design shall be done to arrive at the appropriate quantity of lime to be added, having due regard to the purity of lime, the type of soil, the moisture-density relationship, and the design CBRiUnconflned Compressive Strength (UCS) value specified in the Contract. The laboratory CBR/UCS value shall be at least 1.5 times thc minimum field value of CBR/UCS stipulated in the Contract. 105
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402.2.4. Water : The water to be used for lime stabilisation shall be clean and free from injurious substances. Potable water shall be preferred. 402.3. Construction Operations 402.3.1. Weather limitations : Lime-soil stahilisation shall not be done when the air temperature in the shade is less than 100 C. 402.3.2. Degree of pulverisation: For lime stabilisation, the soil before addition of stabiliser, shall be pulverised using agricultural implements like disc harrows and rotavators to the extent that it passes the requirements set out in Table 400-3 when tested in accordance with the method described in Appendix 3.
TABLE 400-3. IS Sieve designation SOIL PULVERISATION REQUIREMENTS FOR LIME STABILISATION Minimum per cent by weight passing the IS Sieve
26.5 mm
5.6 mm
100
80
40233. Equipment for construction: Stabilised soil sub-bases shall be constructed by mix-in-place method of construction or as otherwise approved by the Engineer. Manual mixing shall be permitted only where the width of laying is not adequate for mechanical operations, as in small-sized jobs. The equipment used for mix-in-place construction shall be a rotavator or similar approved equipment capable of pulverising and mixing the soil with additive and water to specified degree to the full thickness of the layer being processed, and of achieving the desired degree of mixing and uniformity of the stabilised material. If so desired by the Engineer, trial runs with the equipment shall be carried out to establish its suitability for work. The thickness of any layer to be stabilised shall be not less than 100 mm when compacted. The maximum thickness shall be 200 mm, provided the plant used is accepted by the Engineer. 402.3.4. Mix-in-place method of construction:. Before deploying the equipment, the soil after it is made free of undesirable vegetation or other deleterious matter shall be spread uniformly on the prepared subgrade in a quantity sufficient to achieve the desired compacted thickness of the stabilised layer. Where single-pass equipment is to be employed, the soil shall be lightly rolled at the discretion of the Engineer.
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Section 400
The equipment used shall either be of single-pass or multiple pass type. The mixers shall be equipped with an appropriate device for controlling the depth of processing and the mixing blades shall be maintained or reset periodically so that the correct depth of mixing is obtained at all times. With single-pass equipment the forward speed of the machine shall be so selected in relation to the rotor speed that the required degree of mixing, pulverisation and depth of processing is obtained. In multiplepass processing, the prepared subgrade shall be pulverised to the required depth with successive passes of the equipment and the moisture content adjusted to be within prescribed limits mentioned hereinafter. The blending or stabilising material shall then be spread uniformly and mixing continued with successive passes until the required depth and uniformity of processing have been obtained. The mixing equipment shall be so set that it cuts slightly into the edge of the adjoining lane processed previously so as to ensure that all the material forming a layer has been properly processed for the full width. 402.3.5. Construction with manual means: Where manual mixing is permitted, the soil from borrow areas shall first be freed of all vegetation and other deleterious matter and placed on the prepared subgrade. The soil shall then be pulverised by means of crow-bars, pick axes or other means approved by the Engineer. Water in requisite quantities may be sprinkled on the soil for aiding pulverisation. On the pulverised soil, the blending material(s) in requisite quantities shall be spread uniformly and mixed thoroughly by working with spades or other similar implements till the whole mass is uniform. After adjusting the moisture content to be within the limits mentioned later, the mixed material shall be levelled up to the required thickness so that it is ready to be rolled. 402.3.6. Addition of lime: Lime may be mixed with the prepared material either in slurry form or dry state at the option of the Contractor with the approval of the Engineer. Dry lime shall be prevented from blowing by adding water to the limc or other suitable means selected by the Contractor, with the approval of the Engineer. The tops of windrowed material may be flattened or slightly trenched to receive the lime. The distance to which lime may be spread upon
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the prepared material ahead of the mixing operation shall be determined by the Engineer. No traffic other than the mixing equipment shall be allowed to pass over the spread lime until after completion of mixing. Mixing or remixing operations, regardless of equipment used, shall continue until the material is free of any white streaks or pockets of lime and the mixture is uniform, Non-uniformity of colour reaction, when the treated material is tested with the standard phcnolphthalein alcohol indicator, will be considered e~idenceof inadequate mixing, 402.3.7. Moisture content for compaction: The moisture content at compaction checked vide IS :2720 (Part 2) shall neither be less than the optimum moisture content corresponding to IS: 2720 (Part 8) nor more than 2 per cent above it. 402.3.8. RoIling: Immediately after spreading, grading and levelling of the mixed material, compaction shall be carried Out with approved equipment preceded by a few passes of lighter rollers if necessary. Rolling shall commence at edges and progress towards the centre, except at superelevated portions where it shall commence at the inner edge and progress towards outer edge. During rolling the surface shall be frequently checked for grade and crossfall (camber) and any irregularities corrected by loosening the material and rebioving/ adding fresh material. Compaction shall continue until the density achieved is at least 98 per cent of the maximum dry density for the material determined in accordance with IS: 2720 (Part 8). Care shall be taken to see that the compaction of lime stabilised material is completed within three hours of its mixing or such shorter period as may be found necessary in dry weather. During rolling it shall be ensured that roller does not bear directly on hardened or partially hardened treated material previously laid other than what may be necessary for achieving the specified compaction at the joint. The final surface shall be well closed, free from movement under compaction planes, ridges, cracks or loose material. All loose or segregated or otherwise defective areas shall be made good to the full thickness of the layer and recompacted. 402.3.9. Curing: The sub-base course shall be suitably cured for a minimum period of 7 days after which subsequent pavement courses shall he laid to prevent the surface from drying out and becoming
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friable. No traffic of any kind shall ply over the completed sub-base unless pepnitted by the Engineer. 402.4. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 402.5. Strength When lime is used for improving the subgrade, the soil-lime mix shall be tested for its CBR value. When lime stabilised soil is used in a sub-base, it shall be tested for unconfined compressive strength (UCS) at 7 days. In case of variation from the design CBR/UCS, in situ value being lower, the pavement design shall be reviewed based on the actua.l CBR/UCS values. The extra pavement thickness needed on account of lower CBR/UCS value shall be constructed by the Contractor at his own cost. 402.6. Arrangements of Traffic During the period of construction, arrangement of traffic shall be maintained in accordance with Clause 112. 402.7, Measurements for Payment Stabilised soil sub-base shall be measured as finished work in position in cubic metres. 402.8. Rates The Contract unit rate for lime stabilised soil sub-base shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v). 403. CEMENT TREATED SOIL SUB-BASE/BASE 403.1. Scope This work shall consist of laying and compacting a sub-base/base course of soil treated with cement on prepared subgrade/sub-base, in accordance with the requirements of these Specifications and in conformity with the lines, grades and cross-sections shown on the drawings or as directed by the Engineer.
403.2. Materials
403.2.1. Material to be stabilised: The material used for cement
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Section 400
treatment shall be soil including sand and gravel, laterite, ,kankar, brick aggregate, crushed rock or slag or any combination of these. For use in a sub-base course, the material shall have a grading shown in Table 400-4; it shall have a uniformity coefficient not less than 5, capable of producing a well closed surface finish, For use in a base course, the material shall be sufficiently well graded to ensure a well-closed surface finish and have a grading within the range given in Table 400-4. If the material passing 425 micron sieve is plastic, it shall have a liquid limit not greater than 45 per cent and a plasticity index not grater than 20 per cent determined in accordance with IS:2720 (Part 5). The physical requirements for the material to be treated with cement for use in a base course shall be same as for Grading I Granular Sub-base, Clause 401.2.2. 403.2.2. Cement: Cement for cement stabilisation shalt comply with the requirements of IS: 269, 455 or 1489.
Table 400-4. GRADING LIMITS OF MATERIAL FOR STABILISATION WITH CEMENT IS Slave size
Percentage by mass passing

Sub-base FIner than:
Base Within the range: 100 95-100 45-100

35-100
53.0mm 37.5 mm 19.0 mm 9.5 mm 4.75 mm 600 micron
100 95 45 35
25 X
300 micron 75 micron
5
0
25-100 8-65 5-40

0-10
403.2.3. Lime: If needed for pre-treatment of highly clayey soils, Clause 402.2.2. shall apply. 403.2.4. Quantity of cement in stabilised mix: The quantity of cement to be added as per cent by weight of the dry soil shall be specified in the Contract. Also if lime is used as pretreatment for highly clayey soils, the quantity as per cent by weight of dry soil shall be specified in the Contract. The mix design shall be done on the basis of 7-day unconfined compressive strength (UCS) anWor durability test under 12 cycles of wet-dry conditions. The laboratory strength values shall be at least 1.5 times the minimum field UCS value stipulated in the Contract.
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Section 400
403.2.5. Water: The water to be used for cement stabilisation shall be clean and free from injurious substances. Potable water shall be preferred. 4033. Construction Operations 403.3.1. Weather limitations : Stabilisation shall not be done when the air temperature in the shade is less than 10C. 403.3.2. Degree of pulverisation : For stabilisation, the soil before addition of stabilizer, shall be pulverised, where necessar~, o the extent t that it passes the requirements as set out in Table 400-5 when tested in accordance with the method described in Appendix 3.
TABLE 400.5. SOIL PULVERISATION REQUIREMENTS FOR CEMENT STABILISATION IS Sieve designation 26.5 mm 5.6 mm Minimum per cent by weight passing the IS sieve 100 80
403.3.3. Clauses 402.3.3 to 402.3,5 shall apply as regards spreading and mixing the stabiliser except that cement or lime plus cement as the case may be, shall be used as the stabilising material. 403.3,4. Moisture content for compaction: The moisture content at compaction checked vide IS: 2720 (Part 2) shall not be less than the optimum moisture content corresponding to IS: 2720 (Part 8) nor more than 2 per cent above it. 403.3.5. Rolling: Clause 402.3.8 shall apply except that care shall be taken to see that the compaction of cement stabilised material is completed within two hours of its mixing or such shorter period as may be found necessary in dry weather. 403.3.6. Curing : The sub-base/base course shall be suitably cured for 7 days. Subsequent pavement course shall be laid soon after to prevent the surface from drying out and becoming friable. No traffic of any kind shall ply over the completed sub-base unless permitted by the Engineer. 403.4. Surface Finish and Quality Control of Works The surface finish of construction shall conform to the requirements of Clause 902.
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403.5. Strength Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. Cement treated soil sub-base /base shall be tested for the unconfined compressive strength (UCS) value at 7 days, actually obtained in situ. In case of variation from the design UCS, in situ value being on lower side, prior to proceeding with laying of base/surface cotfrse on it, the pavement design shall be reviewed for actual UCS value. The extra pavement thickness needed on account of lower UCS shall be constructed by the Contractor at his own cost. 403.6. Arrangements for Traffic During the period of construction, arrangement of traffic shall be maintained in accordance with Clause 112. 403.7~ Measurements for Payment Stabilised soil sub-base! base shall be measured as finished work in position in cubic metres. 403.8. Rates The Contract unit rate for cement treated soil sub-base/base with pretreatment with lime if required shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v). 404. WATER BOUND MACADAM SUB-BASFJBASE 404.1. Scope 404.1.1. This work shall consist of clean, crushed aggregates mechanically interlocked by rolling and bonding together with screening, binding material where necessary and water laid on a properly prepared subgrade/ sub-base/ base or existing pavement, as the case may be and finished in accordance with the requirements of these Specifications and in close conformity with the lines, grades, cross-sections and thickness as per approved plans or as directed by the Engineer. 404.1.2. It is, however, not desirable to lay water bound macadam on an existing thin black topped surface without providing adequate drainage faciljty for water that would get accumulated at the interface of existing bituminous surface and water bound macadam.
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404.2. Materials 40&2.I. Coarse aggregates : Coarse aggregates shall be either crushed or broken stone, crushed slag, overburnt (Jhama) brick aggregates or any other naturally occurring aggregates such as kankar and laterite of suitable quality. Materials other than crushed or broken stone and crushed slag shall be used in sub-base courses only. If crushed gravel! shingle is used, not less than 90 per cent by weight of the gravel! shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The aggregates shall conform to the physical requirements set forth in Table 400-6. The type and size range of the aggregate shall be specified in the Contract or shall be as specified by the Engineer. if the water absorption value of the coarse aggregate is greater than 2 per cent, the soundness test shall be carried out on the material deLivered to site as per IS : 2386 (Part 5). 404.2.2. Crushed or broken stone: The crushed or broken stone shall be hard, durable and free from excess flat, elongated, soft and disintegrated particles, dirt and other deleterious material.
TABLE 400.6. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WATER BOUND MACADAM FOR SUB.BASE,BASE COURSES
Test
1.
Test Method Los Angeles

Abrasion value Or Aggregate Impact value IS :2386 (Part-4) IS: 2386 (Part-4) or IS:5640** IS:2386
Requirements
40 per cent (Max)
30 per cent (Max)
2.
Combined
Flakiness and
Elongation Indices (Tetal)
*** *
30 per cent (Max)
(Part-i)
Aggregate may satisfy requirements of either of the
two tests.
Aggregates like brick metal, kankar, laterite etc. which gel softened in presence of waler shall be tested for Impact value under wet conditions in accordance with IS: 5640. The requirement of flakiness index and elongation index shall be enforced only in the case of crushed broken stone and crushed slag.
404.2.3. Crushed slag : Crushed slag shall be made from aircooled blast furnace slag. It shall be of angular shape, reasonably uniform in quality and density and generally free from thin, elongated and soft pieces, dirt or other deleterious materials. The weight of crushed slag shall not he less than ii.2 kN per l11~and the percentage of ~lossy
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Sub-Bases, Bases
(Non-Bituminous) and Shoulders
material shall not be more than 20. It should also comply with the following requirements:
(i) (ii) Chemical stability Sulphur content To comply with requirements of appendix of BS 1047 Maximum 2 per cent Maximum 10 per cent
(iii) Water absorption
404.2.4. Overburnt (Jhama) brick aggregates : Jhama brick aggregates shall be made from overburnt bricks or brick bats and be free from dust and other objectionable and deleterious materials.
404.2.5. Grading requirement of coarse aggregates The coarse aggregates shall conform to one of the Gradings given in Table 400-7 as specified, provided, however, the use of Grading No.1 shall be restricted to sub-base courses only.
TABLE 400-7. GRADING REQUIREMENTS OF COARSE AGGREGATES Grading No. 1. Size Range 90 mm to 45 mm IS Sieve
Designatktn
125 mm 90 rum 63 mm 45 mm 22.4 mm 90 63 53 45 22.4 63 53 45 22.4 11.2 mm mm mm mm mm mm mm mm mm mm
Per cent by weight passing 100
90-100 25-60
0-15 0-5 100
2.
63 mm to 45 mm
90-100
25.75 0-15
0-5
100 95-100
3.
53 mm to 224 mm
65-90
0-10
0.5
100 mm while for
Note : The compacted thickness for a layer with Grading I shall be layer with other Gradings i.e. 2 & 3, ii shall be 75 mm.
404.2.6. Screenings: Screenings to fill voids in the coarse aggregate shall generally consist of the same material as the coarse aggregate. However, where permitted, predominantly non-plastic material such as moorum or gravel (other than rounded river borne material) may be used for this purpose provided liquid limit and plasticity index of such material are below 20 and 6 respectively and fraction passing 75 micron sieve does not exceed 10 per cent.
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Sub-B ases, Bases (Non-Bituminous)
and Shoulders
Section 400
Screenings shall conform to the grading set forth in Table 400-8. The consolidated details of quantity of screenings required for various grades of stone aggregates are given in Table 400-9. The table also gives the quantities of materials (loose) required for 10 m2 for sub-base/base compacted thickness of 100f75 mm. The use of screenings shall be omitted in the case of soft aggregates such as brick metal, kankar, laterites, etc. as they are likely to get crushed to a certain extent under rollers.
TABLE 400-8. GRADING FOR SCREENINGS Grading Classification A Size of Screenings 13.2 mm IS Sieve Designation Per cent by weight passing the IS Sieve 100 95-100 15-35 0-10 100 90-100 15-35
13.2 11.2 5.6 180 11.2 5.6 180
mm mm mm micron mm mm micron
11.2 mm
TABLE 400.9. APPROXIMATE QUANTITIES OF COARSE AGGREGATES AND SCREENINGS REQUIRED FOR I00t75 MM COMMCTEDTHICK. NESS OF WATER ROUND MACADAM (WBM) SUB-BASFIBASE COURSE FOR 10W AREA Screenings Classlfl. catIon Size Range Compacted Loose thickness Qty. Stone Screening Grading ClassI.. ficalion & Size
Grading I
Crushable Type such as Mooruni or Gravel Grading Cfassiticatlon & Size Not uniform -do-doLoose Qty.
For. WBM Sub-base! base course (Loose quantity)
90 mm to 100 mm 45 mm 63 mm to 75 mm 45 mm -do-do-
1.21 to Type A 0.27 to 1.43 mt 13.2 mm 0.30 m1 0.91 to Type A 0,12 so 1.07 m5 13.2 mm 0.15 rn3 -doType B 0.20 to 11.2 mar 0.22 sn -do0.18 to 0.21 mt
030 to
0.32 rn1
Grading 2 -doGrading 3
0.22 to 0.24 & -do-
53 mm to 75 mm 22.4 mm
-do-
-do-
-do-
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404.2.7. Binding material : Binding material to be used for watcr bound macadam as a filler material meant for preventing ravelling, shall comprise of a suitable material approved by the Engineer having a Plasticity lndex(PI) value of less than 6 as determined in accordance with IS: 2720 (Part-5). The quantity of binding material where it is to be used, will depend on the type of screenings. Generally, the quantity required for 75 mm compacted thickness of water bound macadam will be OA)6-0.09 m3/lOm2 and 0.08-0.lOmVlOm2 for 100 mm compacted thickness. The above mentioned quantities should be taken as a guide only, for estimation of quantities for construction etc. Application of binding materials may not be necessary when the screenings used are of crushable type such as moorum or gravel. 4043. Construction Operations 404.3.1. Preparation of base: The surface of the subgrade/ sub-base/base to receive the water bound macadam course shall be prepared to the specified lines and crossfall (camber) and made free of dust and other extraneous material. Any ruts or soft yielding places shall be corrected in, an approved manner and rolled until firm surface is obtained if necessary by sprinkling water. Any sub-base/base/surface irregularities, where predominant, shall be made good by providing appropriate type of profile corrective course (levelling course) to Clause 501 of these Specifications. As far as possible, laying water bound macadam course over an existing thick bituminous layer may be avoided since it will cause problems of internal drainage of the pavement at the interface of two courses. It is desirable to completely pick out the existing thin bituminous wearing course where water bound macadam is proposed to be laid over it. However, where the intensity of rain is low and the interface drainage facility is efficient, water bound macadam can be laid over the existing thin bituminous surface by cutting 50 mm x 50 mm furrows at an angle of 45 degrees to the centre line of the pavement at one metre intervals in the existing road. The directions and depth of furrows shall be such that they provide adequate bondage and also serve to drain water to the existing granular base course beneath the existing thin bituminous surface.
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404.3.2. Inverted choke : If water bound macadam is to be laid directly over the subgrade, without any other intervening pavement course, a 25 mm course of screenings (Grading B) or coarse sand shall be spread on the prepared subgrade before application of the aggregates is taken up. in case of a fine sand or silty or claycy subgrade, it is advisable to lay 100 mm insulating layer of screening or coarse sand on top of fine grainS soil, the gradation of which will depend upon whether it is intended to act as a drainage layer as well. As a preferred alternative to inverted choke, appropriate geosynthetics performing functions of separation and drainage may be used over the prepared subgrade as directed by the Engineer. Section 700 shall be applicable for use of geosynthetics. 404.3.3, Spreading coarse aggregates : The coarse aggregates shall be spread uniformly and eventy upon the prepared subgrade/sub-base/ base to proper profile by using templates placed across the road about 6 in apart, in such quantities that the thicknss of each compacted layer is not more than 1(X) mm for Grading I and 75 mm for Grading 2 and 3, as specified in Clause 404.2.5. Wherever possible, approved mechanical devices such as aggregate spreader shall be used to spread the aggregates uniformly so as to minimise the need for manual rectification afterwards. Aggregates placed at locations which are inaccessible to the spreading equipment, may be spread in one or more layers by any approved means so as to achieve the specified results. The spreading shall be done from stockpiles along the side of the roadway or directly from vehicles, No segregation of large or fine aggregates shall be allowed and the coarse aggregate as spread shall be of uniform gradation with no pockets of fine material. The surface of the aggregates spread shall be carefully checked with templates and all high or low spots remedied by removing or adding aggregates as may be required. The surface shall be checked frequently with a straight edge while spreading and rolling so as to ensure a finished surface as per approved drawings. The coarse aggregates shall not normally be spread more than 3 days in advance of the subsequent construction operations. 404.3.4, Rolling: Immediately following the spreading of the coarse aggregate, rolling shall be started with three wheeled power rollers of 80 to 100 kN capacity or tandem or vibratory rollers of 80 to 100 kN static weight. The type of roller to be used shall be approved by the Engineer based on trial run.
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Section
400
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Except on superelevated portions where the rolling shall proceed from inner edge to the outer, rolling shall begin from the edges gradually progressing towards the centre. First the edge/edges shall be compacted with roller running forward arid backward. The roller shall then move inward parallel to the centre line of the road, in successive passes uniformly lapping preceding tracks by at least one half width, Rolling shall be discontinued when the aggregates are partially compacted with sufficient void space in them to permit application of screenings. However, where screenings are not to be applied, as in the case of crushed aggregates like brick metal, laterite and kankar, compaction shall be continued until the aggregates are thoroughly keyed. During rolling, slight sprinkling of water may be done, if necessary. Rolling shall not be done when the subgrade is soft or yielding or when it causes a wave-like motion in the subgrade or subbase course. The rotted surface shall be checked transversely and longitudinally, with templates and any irregularities corrected by loosening the surface, adding or removing necessary amount of aggregates and re-rolling until the entire surface conforms to desired crossfail (camber) and grade. in no case shall the use of screenings be permitted to make up depressions. Material which gets crushed excessively during compaction or becomes segregated shall be removed and replaced with suitable aggregates. It shall be ensured that shoulders are built up simultaneously along with water bound macadam courses as per Clause 407.4.1. 404.3.5. Application of screenings: After the coarse aggregate has been rolled to Clause 404.3.4, screenings to completely fill the interstices shall be applied gradually over the surface. These shall not be damp or wet at the time of application. Dry rolling shall be done while the screenings are being spread so that vibrations of the roller cause them to settle into the voids of the coarse aggregate. The screenings shall not be dumped in piles but be spread uniformly in successive thin layers either by the spreading motions of hand shovels or by mechanical spreaders, or directly from tipper with suitable grit spreading arrangement. Tipper operating for spreading the screenings shall be so driven as not to disturb the coarse aggregate. The screenings shall be applied at a slow and uniform rate (in three or more applications) so as to ensure filling of all voids. This shall be 118
Sub-Bases, Bases
(Non-Bituminous) and Shoulders
Section 400
accompanied by dry rolling and brooming with mechanical brooms, handbrooms or both. In no case shall the screenings be applied so fast and thick as to form cakes or ridges on the surface in such a manner as would prevent filling of voids or prevent the direct bearing of the roller on the coarse aggregate. These operations shall continue until no more screenings can be forced into the voids of the coarse aggregate. The spreading, rolling, and brooming of screenings shall be carried out in only such lengths of the road which could be completed within one days operation. 404.3.6. Sprinkling of water and grouting : After the screenings have been applied, the surface shall be copiously sprinkled with water, swept and rolled. Hand brooms shall be used to sweep the wet screenings into voids and to distribute them evenly. The sprinkling, sweeping and rolling operation shall be continued, with additional screenings applied as necessary until the coarse aggregate has been thorougl.ly keyed, well-bonded and firmly set in its full depth and a grout has been formed of screenings. Care shall be taken to see that the base or subgrade does not get damaged due to the addition of excessive quantities of water during construction. In case of lime treated soil sub-base, construction of water bound macadam on top of it can cause excessive water to flow down to the lime treated sub-base before it has picked up enough strength (is still green) and thus cause damage to the sub-base layer. The laying of water bound macadam layer in such cases shall be done after the subbase attains adequate strength, as directed by the Engineer. 40&3.7. Application of binding material: After the application of screenings in accordance with Clauses 404.3.5 and 404.3.6. the binding material where it is required to be used (Clause 404.2.7) shall be applied successively in two or more thin layers at a slow and uniform rate. After each application, the surface shall be copiously sprinkled with water, the resulting slurry swept in with hand brooms, or mechanical brooms to fill the voids properly, and rolled during which water shall be applied to the wheels of the rollers if necessary to wash down the binding material sticking to them. These operations shall continue until the resulting slurry after filling of voids, forms a wave ahead of the wheels of the moving roller. 404.3.8. Setting and drying: After the final compaction of water bound macadam course, the pavement shall be allowed to dry overnight. Next morning hungry spots shall be filled with screenings or binding
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material as directed, lightly sprinkled with water if necessary and rolled. No traffic shall be allowed on the road until the macadam has set. The Engineer shall have the discretion to stop hauling traffic from using the completed water bound macadam course, if in his opinion it would cause excessive damage to the surface. The compacted water bound macadam course should be allowed to completely dry and set before the next pavement course is laid over it. 404.4. Surface Finish and Quality Control of Work 404.4.1. The surface finish of construction shall conform to thc requirements of Clause 902. 404.4.2. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 404.4.3. The water bound macadam work shall not be carried out ~shenthe atmospheric temperature is less than 0Cin the shade. 404.4.4. Reconstruction of defective macadam: The finished surface of water bound macadam shall conform to the tolerance of surface regularity as prescribed in Clause 902. However, where the surface irregularity of the course exceeds the tolerances or where the course is otherwise defective due to subgrade soil mixing with the aggregates, the course to its full thickness shall be scarified over the affected area, reshaped with added material or removed and replaced with fresh material as applicable and recompac ted. En no case shall depressions be filled up with screenings or binding material. 404.5. Arrangement for Traffic During the period of construction, the arrangement of traffic shall be done as per Clause 112. 404.6. Measurements for payment Water bound macadam shall be measured as finished work in position in cubic metres. 404.7. Rate The Contract unit rate for water bound macadam sub-base/base course shall be payable in full for carrying out the required operations including full compensation for all components listed in Clause 401.S (i) to (v) including arrangement of water used in the work as approved by the Engineer.
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SubBases, Bases (Nonilituminous) and Shoulders
Section 400
405, CRUSHED CEMENT CONCRETE SUB-BASE/BASE 405.1. Scope This work shall consist of breaking and crushing the damaged cement concrete slabs and recomp~tingthe same as sub-base/base course in one or more layers. Where specified, it shall also include treating the surface of the top layer with a penetration coat of bitumen, The work shall be performed on such widths and lengths as may be specified, in accordance with the requirements of these Specifications and in con formity with the lines, grades and cross-sections shown on the drawings or as otherwise directed by the Engineer. 405.2. Materials 405.2.1. Coarse aggregate : Coarse aggregate for this work shall be hrokcn cement concrete slabs crushed to a size not exceeding 75 mm and as far as possible, conforming to one of the gradings given in Table 4(X)-?. 405.2.2. Key aggregate : Key aggregate for the penetration coat shall consist of crushed stone, crushed gravel, shingle or other stones. it shall be clean, strong, durable, of fairly cubical shape and free of disintegrated pieces, organic or other deleterious matter and adherent coatings. The aggregate shall be hydrophobic and of tow porosity. The aggregate shall be of 11.2 mm size defined as 100 per cent passing through 13.2 mm sieve and retained on 5.6 mm sieve and shall satisfy the physical requirements set forth in Table 500-3. 405.2.3. Binder: Binder for the penetration coat for the top layer shall be bitumen of a suitable grade, as directed by the Engineer and satisfying the requirements of IS: 73,217 or 454, as applicable or any approved cutback or emulsion, satisfying the requirements of IS:8887. 405.3. Construction Operations 405.3.1. General: Crushed cement concrete sub-base/base course may be constructed in one or two layers, depending upon the thickness of the concrete slabs dismantled and crushed. The thickness of each layer shall, however, not exceed 100 mm in case of sub-base and 75 mm in case of base course. The course shall be constructed as water bound macadam to Clause 404, using crushed cement concrete as coarse aggregate except that no screenings or binding material need be applied. Where specified,
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Section 400
the top layer shall be treated with a penetration coat of binder described in Clause 4053.2. 405.3.2. Application of penetration coat over the top layer: Before the application of the penetralion coat, the surface shall be cleaned of dust, dirt and other foreign matter, using mechanical broom or any other equipment specified by the Engineer. Dust removed in the process shall be blown off with the help of compressed air. The binder shall be heated to the temperature appropriate to the grade of bitumen used and sprayed on the dry surface in a uniform manner a~ rate of 25 kg per 10 m2 area in terms of the residual bitumen the with the help of either self-propelled or towed bitumen pressure sprayer with self-heating arrangement and spray nozzle capable of spraying bitumen at specified rates and temperatures so as to provide a uniform, unbroken spread of bitumen. Excessive deposits of binder caused by stopping or starting of the sprayer or through leakage or any other reason shall be suitably corrected. Immediately after the application of binder, the key aggregates, in a clean and dry state shall be spread uniformly on the surface at the rate of 0,13 m3 per 10 m2 area, preferably by means of a mechanical gritter, capable of spreading aggregate uniformly at specified rates or otherwise manually with the approval of the Engineer, so as to cover the surface completely. Immediately after the application of the key aggregates, the entire surface shall be rolled to Clause 506.3.8. 405.4. Surface Finish and Quality Control of Works The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of material and works shall be exercised by the Engineer in accordance with Section 900. 405.5. Arrangements for Traffic During the period of construction, arrangement of traffic shall be done as per Clause 112. 405.6. Measurements for Payment Breaking the existing cement concrete pavement slabs, crushing and recompacting the slab material as sub-base/base course shall be measured as a single item in terms of the volume of sub-base/base laid in position in cubic metres.
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Section 400
Penetration coat shall be measured as finished work in metres. 405.7. Rates
square
405.7.!. The Contract unit rate for crushed cement concrete subbase/base course shalL be payment in full for carrying out the
required operations including full compensation for:
(0
making arrangements for traffic to Clause 112 except for initial verges/shoulders and construction of diversions;
treatment to
(ii) breaking the cement csiricrete slabs, crushing, sieving and recompacting the slab material as suh-base)base course; (iii)
(iv)
all labour, tools, equipment and incidentals to complete the work to the Specifications; and carrying out the work in part widths of road where directed.
405.7.2. The Contract unit rate for penetration coat shalt be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8. 406. WET MIX MACADAM SUB-BASE/BASE 406.1. Scope This work shalt consist of laying and compacting clean, crushed, graded aggregate and granular material, premixed with water, to a dense mass on a prepared subgrade/sub-base/base or existing pavement as the case may be in accordance with the requirements of these Specifications. The material shall be laid in one or more layers as necessary to lines, grades and cross-sections shown on the approved
drawings or as directed by the Engineer.
The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75 mm. When vibrating or other approved types of compacting equipment are used, the compacted depth of a single layer of the sub-base course may be increased to 200 mm upon approval of the Engineer. 406.2. Materials 406.2.!. Aggregates 406.2.1.!. Physical requirements: Coarse aggregates shall be ,rushed stone. If crushed gravel/shingle is used, not less than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shalt have at least two fractured faces. The aggregates shall conform to the physical requirements set forth in Table 400-10 below.
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Section 400
TABLE 400-10.

PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WET MIX MACADAM FOR SUB-BASE/BASE COURSES TestMethod IS: 2386 (Part-4) IS: 2386 (Part-4) or15:5640 IS: 2386 (Part-I) Requirements 40per cent (Max,) 30 per cent (Max.) 30 per cent (Max.)
-
2.
* **
Test *Los Angii Abrasion value or *Aggregate tmpact value Combined Flakiness and Elongation indices (Total)
Aggregate may satisfy requirements of either of the two tests. To determine this combined proportion, the flaky stone from a representative sample should first be separated out Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal. Elongation index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up.
If the water absorption value of the coarse aggregate is greater than 2~ per cent, the soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part-5). 406.2.1.2. Grading requirements : The aggregates shall conform to the grading given in Table 400-11.
TABLE 400-Il. GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX
MACADAM
tS Sieve Designation Percent by weight passing the IS sieve
53.00 45.00
2650
iiiiii
mm mm mm mm mm mm micron micron
100
95-100
22.40
lt.20 4.75 236
60-80 40-60
25-40
15-30
600.00 75.00
8-22
-
0-8
Materials finer than 425 micron shall have Plasticity Index (P1) not exceeding 6. The final gradation approved within these limits shall be wefl graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa. 406.3. Construction Operations 406.3.1. Preparation of base: Clause 404.3.1. shall apply. 406.3,2. Provision of lateral confinement ofaggregates : While constructing wet mix macadam, arrangement shall be made for the lateral
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Section 400
confinement of wet mix. This shall be done by laying materials in adjoining shoulders along with that of wet mix macadam layer and following the sequence of operations described in Clause 407.4.1. 406.3.3. Preparatk)n of mix : Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity having provision for controlled addition of water and forced/positive mixing arrangement like pugmill or pan type mixer of concrete batching plant, For small quantity of wet mix work, the Engineer may permit the mixing to he done in concrete mixers. Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size, While adding water, due allowance should be made for evaporation losses. However, at the time of compaction, water in the wet mix should not vary from the optimum value by more than agreed limits. The mixed material shotild be uniformly wet and no segregation should be permitted. 406.3.4. Spreading of mix Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the prepared subgrade/sub- base/base in required quantities. In no case should these be dumped in heaps directly on the area where these are to be laid nor shall their hauling over a partly completed stretch be permitted. The mix may be spread either by a paver finisher or motor grader. For portions where mechanical means cannot be used, manual means as approved by the Engineer shall be used. The motor grader shall be capable of spreading the material uniformly all over the surface. Its blade shall have hydraulic control suitable for initial adjustments and maintaining the same so as to achieve the specified slope and grade. The paver finisher shall be self-propelled, having the foliowing features
(i)
(ii) Loading hoppers and suitable distribution mechanism The screed shall have tamping and vibrating arrangement for initial compaction to the layer as it is spread without ruuing or otherwise marring the surface profile.
(iii) Ihe paver shall be equipped with necessaly control mechanism so as to ensure that the finished surface is free from surface blemishes.
The surface of the aggregate shall be carefully checked with templates and all high or low spots remedied by removing or adding aggregate as may be required. The layer may be tested by depth blocks during
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Section 400
Sub-B ases, Bases (Non-Bituminous) and Shoulders
construction. No segregation of larger and fine particles should be allowed, The aggregates as spread should be of uniform gradation with no pockets of fine materials. 406.3.5. Compaction: After the mix has been laid to the required thickness, grade and crossfatl/eamber the same shall be uniformly compacted, to the full depth with suitable roller. If the thickness of single compacted layer does not exceed 100 mm, a smooth wheel roller of 80 10 100 kN weight may he used. For a compacted single layer upto 200 mm, the compaction shall be done with the help of vibratory roller of minimum static weight of 80 to 1(X) kN or equivalent capacity roller. The speed of the roller shall not exceed 5 km/h. In portions having unidirectional cross fall/superelevation, rolling shall commence from the lower edge and progress gradually towards the upper edge. Thereafter, roller should progress parallel to the centre line of the road, uniformly over-lapping each preceding track by at least one third width until the entire surface has been rolled. Alternate trips of the roller shall be terminated in stops at least I m away from any preceding stop. In portions in camber, rolling should begin at the edge with the roller running forward and backward until the edges have been firmly compacted. The roller shall then progress gradually towards the centre parallel to the centre line of the road uniformly overlapping each of the preceding track by at least one-third width until the entire surface has been rolled. Any displacement occurring as a result of reversing of the direction of a roller or from any other cause shall be corrected at once as specified and/or removed and made good. Along forms, kerbs, walls or other places not accessible to the roller,
the mixture shall be thoroughly compacted with mechanical tampers
or a plate compactor. Skin patching of an area without scarifying the surface to permit proper bonding of the added material shall not be permitted. Rolling should not be done when the subgrade is soft or yielding or when it causes a wave-like motion in the sub-base/base course or subgrade. If irregularities develop uring rolling which exceed 12 mm when tested with a 3 metre straight edge, the surface should be loosened and prenlixed material added or removed as required before roiling again so as to achieve a uniform surface conforming to the desired grade and
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Sub-B ases, Bases (Non-Bituminous) and
Section 40() Shoulders crossfall. In no case should the use of unmixed material be permitted
to make up the depressions. Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry density for the material as determined by the method outlined in IS: 2720 (Part8) After completion, the surface of any finished layer shall be wellclosed, free from movement under compaction equipment or any conlpaetion planes, ridges, cracks and loose material. All loose,segregated or otherwise defective areas shall be made good to the full thickness of the layer and recompaeted. 406.3.6. Setting and drying: After final compaction of wet mix macadam course, the road shall be allowed to dry for 24 hours. 406.4. Opening to Traffic Preferably no vehicular traffic of any kind should be allowed on the finished wet mix macadam surface till it has dried and the wearing course laid. 406.5. Surface Finish and Quality Control of Work 406.5.!. Surface evenness : The surface finish of construction shall conform to the requirements of Clause 902. 406.5.2. Quality control : Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 406.6. Rectification of Surface Irregularity Where the surface irregularity of the wet mix macadam course exceeds the permissible tolerances or where the course is otherwise defective due to subgrade soil getting mixed with the aggregates, the ftill thickness of the layer shall be scarified over the affected area, reshaped with added premixed material or removed and replaced with fresh premixed material as applicable and recompaeted in accordance with Clause 406.3. The area treated in the aforesaid manner shall not be less than 5 m long and 2 m wide. In no case shall depressions be filled up with unmixed and ungraded material or fines. 406.7. Arrangement for Traffic During the period of construction, arrangement of traffic shall be done as per Clause 112.
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Section 400
406.8. Measurements for Payment Wet mix macadam shall be measured as finished work in position in cubic metres. 406.9. Rates The Contract unit rate for wet mix macadam shall be payment in full for carrying out the required operations including lull compensation for all components listed in Clause 4018. 407. SHOULDERS, ISLANDS AND MEDIAN 407.1. Scope The work shall consist of constructing shoulder (hard/paved! earthen with brick or stone block edging) on either side of the pavement, median in the road dividing the carriageway into separate lanes and islands for channelising the traffic at junctions in accordance with the requirements of these Specifications and in conformity with the lines, grades and cross-sections shown on the drawings or as directed by the Engineer. 407.2. Materials Shoulder on either side of the road may be of selected earth/ granular material/ paved conforthing to the requirements of Clause 305/401 and the median may be of selected earth conforming to the requirements of Clause 305. Median/Traffic islands shall he raised and kerbed at the perimeter and the enclosed area filled with earth and suitably covered with grass turf/shrubs as per Clause 307 and/or paved as per Clause 409.3.4 or 409.3.5. Paved shoulders shall consist of sub-base, base and surfacing courses,
as shown in the drawings and materials for the same shall conform to relevant Specifications of the corresponding items. Where paved or hard shoulders are not provided, the pavement shall be provided with briclistone block edgings as shown in the drawings. The bricks shall conform to Clause 1003 of these Specifications. Stone blocks shall conform to Clause 1004 of these Specifications and shall be of
size 225 mm x 110 mm x 75 mm. 407.3. Size or Shoulders/Median/Islands Shoulder (earthen/hard/paved)/median/traffic island dimensions shall be as shown on ihe drawings or as directed by the Engineer.
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Section 400
407,4. Construction Operations 407.4.1. Shoulder: The sequence of operations shall be such that the construction of paved shoulder is done in layers each matching the thickness of adjoining pavement layer, Only after a layer of pavement and corresponding layers in paved and earth shoulder portion have been laid and compacted, the construction of next layer of pavement and shoulder shall be taken up. Where the materials in adjacent layers are different, these shall be laid together and the pavement layer shall be compacted first. The corresponding layer in paved shoulder portion shall be compacted thereafter, which shall be followed by compaction of earth shoulder layer. The adjacent layers having same material shall be laid and compacted together. In all cases where paved shoulders have to be provided along side of existing carriageway, the existing shoulders shall be excavaled in full width and to the required depth as per Clause 301.3.7. Under no circumstances, box cutting shall be done for construction of shoulders. Compaction requirement of earthen shoulder shall be as per Table 300-2, In the case of bituminous courses, work on shoulder (earthenJ hardJpaved), shall start~only after the pavement course has been laid and compacted. During all stages of shoulder (earthen/hard/paved) construction, the required crossfall shall be maintained to drain off surface water. Regardless of the method of laying, all shoulder construction material shall be placed directly on the shoulder. Any spilled material dragged on to the pavement surface shall be immediately removed, without damage to the pavement, and the area so affected thoroughly cleaned. 407.4.2, Median and Islands : Median and Islands shall be constructed in a manner similar to shoulder up to the road level. Thereafter the median and islands, if raised, shall be raised at least 300 mm by using kerb stones of approved material and dimensions and suitably finished and painted as directed by the Engineer. If not raised, the median and islands shall be differentiated from the shoulder/ pavement as the case may be, as directed by the Engineer. The confined area of the median and islands shall be filled with local earth or granular material or any other approved material and compacted by plate compactor/power rammer. The confined area after filling with earth shall be turfed with grass or planted with shrubs and in case of granular fill it can be finished with tiles/slabs as directed by the Engineer.
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Section
4(X)
SubBases, Bases (Non-Bituminous) and Shoulders
407,4.3, Bricklstone block edging: The bricks/stone blocks shall be laid on edge, with the length parallel to the transverse direction of the road, They shall be laid on a bed of 25 mm sand, set carefully, rolled into position by a light roller and made flush with the finished level of the pavement. 407.5. Surface Finish and Quality Control of Works The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 407.6. Measurements for Payment Shoulder (earthen/hard/paved), island and median construction shall be measured as finished work in position as below:
(i) (ii)
For excavation in cu. m. For earthwork!granular fill in Cu. m,
(iii) For
sub-base, base, surfacing courser in units as for respective items.
(iv) For kerb in running metres.

(v)
For surfing and tilelslab finish in sqm.
(vi) For brick/stone btock edging in sqm.
407.7. Rate The Contract unit rate for shoulder (hard/paved/earthen with brick or stone block edging), island and median construction shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (1) to (v) as applicable. The rate for brick/stone block edging shall include the cost of sand cushion. 408. CEMENT CONCRETE KERB AND KERB WITH CHANNEL 408.1. Scope This work shall consist of constructing cement concrete kerbs and kerbs with channel in the central median and/or along the footpaths or separators in conformity with the lines, levels and dimensions as specified in the drawings. 408.2. Materials Kerbs and kerb with channel shall be provided in cement concrete of Grade M20 in accordance with Section 1700 of these Specifications.
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Sub-Bases, Bases (Non-Bituminous) and Shoukiers
Section 400
408.3. Type of Construction These shall be cast-in-situ construction with suitable kerb casting machine in all situations except at locations where continuous casting with equipment is not practicable. In those situations, precastconcrete blocks shall be used. 408.4. Equipment A continuous kerb casting equipment ofadequate capacity and controls, capable of laying the kerbs in required cross-sections and producing a well-compacted mass of concrete free of voids and honeycombs, shall be used. 408.5. Construction Operations 408.5.1. Kerb shall be laid on firm foundation of minimum 150 mm thicknessof cement concrete of M1O grade cast in-situ or on extended width of pavement. The foundation shall have a projection of 50 mm beyond the kerb stone. Before laying the foundation of lean concrete, the base shall be levelled and slightly watered to make it damp. 408.5.2. In the median portions in the straight reaches, the kerb shall be cast in contintiotis lengths. In the portions where footpath is provided and/or the slope of the carriageway is towards median (as in case of superelevated portions), there shall be sufficient gap/recess left in the kerb to facilitate drainage openings. 408.53. After laying the keibs and just prior to hardening of the concrete, saw cut grooves shall be provided at 5 m intervals or as specified by the Engineer. 408.5.4. Kerbs on the drainage ends such as along the footpath or the median in superelevated portions, shall be cast with monolithic concrete channels as indicated in drawings. The slope of the channel towards drainage pipes shall be ensured for efficient drainageof the road surface. 408.5.5. Vertical and horizontal tolerances with respect to true line and level shall be 6mm. 408.6. Measurements for Payment Cement concrete kerb/kerb with channel shall be measured in linear metre for the complete item of work.
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Section 400
Sub-Bases, Bases (Non-Bituminous) and Shoulders Foundation of kerb, where separately provided shall be measured
in linear metre for complete item of work. 408.7. Rates The Contract unit rates for cement concrete kerb/kerb with channel and foundation for kerb shall be payment in full compensation for furnishing all materials, labour, tools, equipment for construction and other incidental cost necessary to complete the work. 409. FOOTPATHS AND SEPARATORS 409.1. Scope The work shall consist of cctistructing footpaths and/or separators at locations as specified in the drawings or as directed by the Engineer. The lines, levels and dimensions shall be as per the drawings. The scope of the work shall include provision of all drainage arrangements as shown in the drawings or as directed. 409.2. Materials The footpaths and separators shall be constructed with any of the follwing types
-
(a) (b)
Cast-in-situ cesnent concrete of Grade M20 as per Section 1700 of the Specifications. Precast cement concrete blocks/tiles of Grade M20 as per Section 1700 of the specifications. The minimum thickness of the cement concrete block/tile shall be 25 mm and minimum size shall be 300 mm x 300 mm. Natural stone slab cut and dressed from stone of good and sound quality, uniform in texture, free from defects and at least equal to a sample submitted by the Contractor and approved by the Engineer. The minimum thickness of the natural stone slab shall be 25 mm and minimum size shall be 300 mm x 300 mm.
(c)
409.3. Construction Operations 409.3.1. Drainage pipes below the footpath originating from the kerbs shall be first laid in the required slope and connected to the drains/sumps/storm water drain/drainage chutes as per provisions of the drawings, or as specified. 409.3.2. Portion on back side of kerbs shall be filled and compacted with granular sub-base material as per Clause 401 of the Specifleations in specified thickness. 409.33. The base shall be prepared and finished to the required lines, levels and dimensions as indicated in the drawings with the
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Sub-Bases, Bases (Non-Bituminous) and
Shoulders
Section 400
following (a) Minimum 150 mm thick,compacted granular sub-base materialas per Clause 401 (b)
the Specifications. Minimum 25 mm thick cement concrete of Grade M 15.
of
Over the prepared base, precast concrete blocks/tiles/naturalstone slabs and/or east-in-situ slab shall be set/laid as described in Clauses 409.3.4 and 409 4093.4. Precast cement concrete blocks/tiles/natural stone slab: The blocks/tiles/slabs shall be set on a layer ofaverage 12 mm thick cementsand mortar(l:3) laid on prepared base in such a way that there is no rocking. The gaps between the blocks/tiles/slabs shall not be more than 12 mm and shall he filled with cement-sand mortar (1:3). 409.3.5. Cast-in-situ cement concrete: The minimum thicknessof the cement concrete shall be 25 mm and it shall he cast on the prepared base in panels of specified size in a staggered manner. Construction joints shall be provided as per Section 1700 of the Specifications. 409.4. Measurements for Payment Footpaths and separators shall be measured in sqmetr between inside of kerbs, 409.5. Rates Contractunit rates shall he inclusive of full compensation of all labour, materials, tools,equipment and incidentals toconstruction of footpaths. Cost of providing pipes and arrangement for their discharge into appropriate drainage channels shall be incidental to the construction of footpaths. 410. CRUSHER-RUN MACADAM BASE 410.1. Scope This work shall consist of furnishing, placing and compacting crushed stone aggregate sub-base and base courses constructed in accordance with the requirements set forth in this Specification and in conformity with the lines, grades, thicknesses and cross-sections shown on the plans or as directed by the Engine r. 410.2. Materials The material to be used for the work shall be crushed rock, Ifcrushed gravel/shingle is used, not less than 90 percentby weightof the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. It shall be free from any organic matter and other deleterious substances and shall be of such nature that it can be compacted readily under watering and
133
<<
Section 400
rolling to form a firm, stable base. The aggregate shall conform to the grading and quality requirements shown in Tables 400-12 and 400-13. At the option ofthe Contractor, thegrading for either 53 mm maximum size or 37.5 mm maximum size shall be used, except that once a grading is selected, it shall not be changed without the Engineers approval.
TABLE 400.12. AGGREGATE GRADING REQUIREMENTS Sieve size Per cent passing by weight 53mm max. size 37.5mm max. size
mm 100 45 mm 87-lOG tOO 22~4 mm 5O~85 90-tOO 5.6 mm 25-45 35-55 710 micron 10-25 10-30 90 micron 2-9 2-9 TABLE 400-13. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR
CRUSHER-RUN MACADAM BASE Test_-~ 4Los Angeles Abrasion value or *Aggregate Impact value 2. Combined Flakiness and Elongation Indices (Total) **W~t~. absorption liquid Limit of material passing 425 micron Plasticity Index ofmaterial passing 425 micron Test Method IS :2386 (Part-4) IS :2386 (Part.4) or IS : 5640 IS :2386 (Pan-i) IS: 2386 (Part-3) IS : 2720 (Part-5) IS :2720 (Part-5) Requirements 40 maximum 30rnaxirnum
63
30maximum*** 2per cent Maximum Not more than 25 Not more than
3. 4, 5.
~ ~
Aggregate may satisfy requirements of either of the two tests. If the water absorption is more than 2 per cent, soundness test shall be carried out as per IS:2386 (Part-5). To determine this combined proportion, the flaky stone from a representative sample should first be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal, Elongation index is weight of elongated particles divided by total non-flaky partides. The value of flakiness ~rsdex elongation index so found are added up. and
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Section 400
410.3. Construction Operations 410.3.1. Preparation or subgrade: Any ruts, deformations or soft yielding places which occur in the sub-base or subgrade shall be corrected and compacted to the required density before the aggregate base course is placed thereon. 410.3.2, Spreading, watering, mixing and compaction: The aggregate shall be uniformly deposited on the approved subgrade by means of the hauling vehicle with or without spreading devices. Aggregate will be distributed over the surface to the depth specified on the plans or as directed by the Engineer. After the base course material has been deposited, it shall be thoroughly blade-mixed to full depth of the layer by alternately blading the entire layer to the centre and back to the edges of the road. It shall then be spread and finished to the required cross-section by means of a motor grader. Water shall be applied prior to and during all blading and processing operations to moisten the material sufficiently to prevent segregation of the fine and coarse particles. Water shall be applied in sufficient amounts during construction to assist in compaction. Alternatively, mixing of the crusher run material and water may be done in a mixing plant as per Clause 406.3.3. Compaction shall commence immediately after the spreading operation. If the thickness of single compacted layer does not exceed 100 mm, a smooth wheel roller of 80 tolOO kN weight may be used. For a compacted single layer upto 200 mm the compaction shall be done with the help of vibratory roller of minimum static weight of 80 to 100 kN or equivalent capacity roller. The speed of the roller shall not exceed 5 km/h. Each layer of material shall be compacted to riot less than 98 per cent of the maximum density as determined by IS: 2720 (Part.8). 410.4. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900.
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Section 400
410.5. Arrangements for Traffic During the period of construction, arrangement of traffic shall be maintained in accordance with Clause 112. 410.6. Measurements for Payment Crusher-run macadam base shall be measured as finished work in position in cubic metres. 410.7. Rate The Contract unit rate for crusher run macadam base shall be payment in full for carrying out the required operations including full compensation for items as in Clause 401.8 (i) to (v).
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Base and Surface Courses (Bituminous)
500 Base and Surface Courses (Bituminous)
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Section 500
Base and Surface Courses (Bituminous) 501, PREPARATION OF SURFACE 501.1. Scope
Section 500
This work shall consist of preparing an existing granular or blacktopped surface to specified lines, grades and cross-sections in advance of laying a bituminous course. The work shall be performed on such widths and lengths ~s shown in applicable drawing and consist of scarifying and re-laying the granular base course and/or scarifying the existing surface, filling of potholes, sealing of cracks and/or application of a profile corrective course (levelling course) as necessary. 501,2. Materials 501.2.1. For scarifying and re-laying the granular surface The materials used shall be coarse aggregates salvaged from scarification of the existing granular base course supplemented by fresh coarse aggregates and screenings so that aggregates and screenings thus supplemented correspond to Clause 404: Water Bound Macadam or Clause 406: Wet Mix Macadam, as the case may be. 501.2.2. For patching potholes and seating cracks: For patching potholes, approved material having same specification as that of profile corrective course shall be used. For sealing small cracks finer than 3 mm, a fog seal conforming to Section 3000 shall be applied while larger cracks wider than 3 mm shall be treated with an emulsion slurry seal, conforming to Clause 516. 501.2.3. For profile corrective course: Aprofile corrective course (levelling course) is essentially a pavement base material course for correcting the existing pavement profile which has either lost its shape or has to be given a new shape to meet the requirement of specified lines, grades and cross-sections. It shall be differentiated from the strengthening course or other type of structural pavement course needed for upgrading as a remedial measure against inherently deficient and/or distressed pavement. It is meant to remove the irregularity in the existing road profile only. 501.2.4. Profile corrective course and its application: The type of material for profile corrective course shall be as shown on the drawing. If it is to be laid as part of the overlay/strengthening course, the profile corrective course material shall be of the same specification as that of the overlay/strengthening course. However, if provided as a
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Section
500
separate layer, it may be of the same specification as the layer over which it is to be laid or intermediate between underlying and overlying layers, as shown on the Drawing.
(i) Wherever isolated high spots projecting over the pavement surface do exist, the same shalt be cut by milling machine or any other approved method, to minimise the profile corrective course requirensenL If, in the proceas,the bottom layer gets disturbed, the local area shall be cut and filled with profile corrective course mate ral Where the maximum profile corrective course thickness works out to be not more than 40 mm, it shall be done as an integral part of the overlay course. In other cases, the profile corrective course shall be provided as a separate layer a5pting such construction procedures and using such equipment as may be appropriate to the specified type of material and thickness of the course to be provided.
(ii)
501.3. Construction Operations 501.3.1. Preparing existing granular surface : Where the existing surface is granular, all loose and disintegrated materials shall be removed and the surface lightly watered if the profile corrective course to be provided as a separate layer is also granular. If, however, over the existing granular surface, a profile corrective course of bituminous material is to be laid, the existing granular surface shall be primed as per Clause 502. 501.3.2. Scarifying existing bituminous surface Where necessary, the existing bituminous layer in the specified width shall be removed with care without causing undue disturbance to the underlying layer by suitable method approved by the Engineer. After removing it, all loose and disintegrated materials of underlying layer which might have been disturbed in the process of removal shall, before laying of the overlay course, be reset properly by spreading/hand packing of aggregates and compacting with suitable roller/heavy hand rammers/approved mechanical tampei~so that the level of the top surface of such scarified area shall be even and properly graded with respect to adjoining surface.~. Where applicable, the granular surface, after removal of the existing bituminous layer, shalt be primed as per Clause 502 to receive a bituminous profile corrective course. Reusable materials shall be stacked as directed by the Engineer with all lift and lead of 1000 m. 501.3.3. Patching of potholes and sealing of cracks : Before providing profile corrective course on the existing pavement, potholes, if any, shall be drained of water, cut to regular shape with sides vertical upto the affected depth and slightly beyond the limits of affected area and dried. All loose and disintegrated materials fror~ shall be removed. it The potholes shall then be filled with material as per Clause No.
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Section 500
501.2.2 in layers not exceeding 75 mm after painting the sides and bottom with a thin layer of hot straight-run bitumen/emulsion and each layer shall be compacted with approved mechanical tampers! small vibratory roller and the top layer shall be flush with the existing bituminous surface. All loose and/or surplus materials on the surface after making good the potholes, shall be removed. The cracks in the old pavement surface shall be sealed with a fog seal if cracks are small (less than 3 mm width); fog seal shall consist of a spray of a bituminous cutback or a slow-setting bitumen emulsion diluted with an equal amount of water, the rate of spray being 0.5 to 1.0 litre /sq.m depending upon the texture and dryness of the existing bituminous surface. The spray is allowed to set to a firm condition and traffic is allowed only thereafter so as to ensure that the material is not picked up by traffic. For large cracks, the sealing shall be done with emulsion slurry seal as per Clause 516 of these Specifications. 501.3.4. Laying the profile corrective course 501.3.4.1. After preparing the granular surface as in Clauses 501.3.1 and 501 .3.2, the profile corrective course with material as per Clause 501,2.3/501.2.4 shall be laid and compacted to the requirement of particular Specification clause. Where a bituminous profile corredtive course is to be laid over a primed granular surface, a tack coat conforming to Clause 503 shall be applied prior to laying profile corrective course. 501.3.4.2. An existing bituminous surface shall be prepared as per Clause 501.3.3. and after applying a tack coat conforming to Clause 503, the bituminous profile corrective course shall be laid and compacted to the requirement of particular Specjfication clause. 501,3.5. In specific situation of short sags or depressions in the pavement, it may become necessary to provide corrective course in the form of flat wedges, Normally, layers in maximum thickness at any point more than 100 mm shall not be provided. In placing multiple lifts, the lift of shortest length (at the lowest portion of the sag! depression) should be provided first, with successive lifts extending over and fully covering underneath layer, precluding development of a series of joints on the top surfaces, as illustrated in Fig.500- 1. For camber correction or correction of superelevation of the existing carriageway, method as shown in the illustrative Fig. 500-2 shall be adopted depending on the profile of the existing carriageway.
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141
Section 500
Base
and Surface Courses (Bituminous)
LIFTS
EXISTING LAYER
(A)
C~tRECT METHOD
EXISTING

LAYER
2~ 3INCORRECT METHOD
(B)
Note Profile corrective course matenat so ne rn accordance with the tilt Inicieness
Fig. 500-LMethods for providing corrective course for short sags and depressions
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Base and Surface Courses (Bituminous) Section 500

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&
B
E41
0
td)
~ C CO
Ha
a a Cl
a
U
a
0 C) C)
a
0 U
Fig. 500-2. Correction of Camber or Super-Elevation 143
Section 500
Base and Surface Courses (13 ituminous)
501.3.6. Covering the profile corrective course: Work of Profile Corrective Course shall be so planned that it shall be covered by the designed base/wearing course at the earliest, before opening to regular traffic. 501.4. Surface Finish and Quality Control of Work Relevant provisions of Section 900 shall be exercised by the Engineer. 501.5. Arrangement for Traffic During the construction operations, arrangement of traffic shall be done to Clause 112. 501.6. Measurements for Payment 501,6.1. The work of filling potholes shall be considered incidental 10 the construction of Profile Corrective Course/bituminous course for which the existing pavement surface is prepared. The work of filling cracks by applying fog seal or emulsion slurry seal shall be measured in square metres, and paid separately. 501.6.2. Scarifying existing bituminous surface shaU be measured in squ~remetre. 501.6.3. Profile Corrective Course shall be measured as volunie compacted in position in cubic metres or in tonnage as specified in the contract, The volume shall be worked out by plotting the exact profile of Profile Corrective Course as built up at site and superimposed on the existing pavement profile. 501.7. Rates 501.7.1. Contract unit rate for scarifying of existing bituminous surface including repairing/resetting disturbed underlying layer and also removing and stacking reusable/unusable materials shall include cost of all labour, supply of materals needed for repair/resetting, hire charges of tools and plant and transportation of scarified materials with all lifts and upto a lead of 1000 m. 501.7.2. The contract unit rate for Profile Correctiye Course shall be payment in full for carrying out the required operations including full compensMion for:
(i) (ii) Making arrangements for traffic to tlause 112; Providing all materials to be incorporated in she work including any royalties, fees, rents (where applicable) and all leads and lins, unless the contract specifically excludes any item of msteriai required for the work or provides for separate payment in accordance with Clause 514; 144
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Base and Surface Courses (Bituminous) all cleaning operations and application of tack coat;
Section 500
(iii) Preparation of the exposed surface/existing surface including filling of pot holes,
(iv) All labour, tools, equipment and incidentals necessary to complete the work to the Specifications; and
(v)
Carrying out the work in part widths of road where directed by the Engineer.
501.7.3. The contract unit rate for sealing cracks by applying fog seal shall be inclusive of providing all materials and tools arid plant and carrying out the work. The contract unit rate for sealing cracks by providing emulsion slurry seal shall be as set forth in Clause 516.9. 502. PRIME COAT OVER GRANULAR BASE 502.1., Scope This work shall consist of application of single coat of low viscosity liquid bituminous material to an absorbent granular surface preparatory to any superimposed bitUminous treatment or construction. 502.2. Materials 502,2.1. The choice of a bituminous primer shall depend upon the porosity characteristics of the surface to be primed as classified in IRC: 16. These are
(i) (ii)
Surfaces of low porosity; such as wet mix macadam and water bound macadam,
Surfaces of medium porosity; such as cement stabilized soil base,
(iii) Surfaces of high porosity; such as a gravel base.
502.2.2, The different ranges of viscosity requirements for the primers to be used for the different types of surfaces to be primed, as classified in 502.2.1, are given in Table 500-1. TABLE 500-I. VISCOSITY REQUIREMENT AND QUANTITY OF BITUMINOUS PRIMER
Type of surface Kinematic Viscosity of Primer at 60~C Quan tity per 10 sq.m.
(Centistokes)
Low porosity Medium porosity High porosity 30-60 70.140 250-500
( kg)
6 to 9 9 to 12 12 to 15
502.2.3. The bituminous primer shall be Medium Curing Cutback (MC) produced by fluxing, in an approved manner, bitumen of 80/100 penetration grade with kerosene. The cutback shall be free from water and shall not show any signs of separation prior to use. Slow setting Cationic emulsion as per IS: 8887 may also be used, but the particular grade to be used for the work shall be got approved by the Engineer.
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145
Section 500
Sampling and testing of bituminous primer shall be as per IS:2 17. IS:454 and IS:8887. 502.3. Weather and Seasonal Limitations The bituminous primer shall not be applied on a wet surface or during dust storm or when the weather is foggy, rainy or windy. The prime coat for surface treatment should not be applied when the temperature in the shade is less than 10C. 502.4. Construction 502.4,1. Equipment: The primer distributor shall be pneumatic tyred self-propelled pressure distributor equipped for spraying the material uniformly at the specified rates and temperatures. Spraying by manual methods may be allowed for small areas at the discretion of the Engineer. Power broom and/or blowers may be supplemented by hand brooms as directed by the Engineer. 51)2.4.2. Preparation of road surface: The surface to be primed shall be swept clean, free from dust and shall be dry. It shall be shaped to the specified grades and section. It shall also be free from ruts, any other irregularities and segregated materials. Minor depressions and potholes may be ignored until the surface is primed, after which they shall be patched with a suitable premix material prior to the surface treatment. 502.43. Application of bituminous primer: The bituminous primer shall be sprayed/distributed uniformly over the dry surface, prepared as per Clause 502A.2 using self-propelled sprayer equipped with self-heating arrangement, suitable pump, adequate capacity compressor and spraying bar with nozzles having constant volume or pressure system capable of supplying primer at specified rates and temperature so as to provide a uniformly unbroken spread of primer. If the surface to be primed is so dry or dusty as to cause freckling of bituminous material, it shall be lightly and uniformly sprinkled with water immediately prior to priming; however, the bituminous material shall not be applied till such time as no surface water is visible. The primer shall be applied at the rate as specified in Table 500-1. Temperature of application of a primer need only be high enough to permit the primer to be effectively sprayed through the jets of the spray bar and to cover the granular base surface uniformly in the desired quantity.
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146
Base and Surface
Courses (Bifliminous)
Section 500
The desirable range of temperatures at the time of application of MC-30, MC-70 and MC-250 grades shall be 30 to 55C; 50 to 800C and 75 to 100Crespectively. For a bituminous emulsion primer, the range of spraying temperature may be 20 to 60C. Following the application of bituminous material, the surface shall be allowed to cure for at least 24 hours or for any other period so as to allow penetration into the base course and aeration of volatiles from the primer material. If it is not absorbed within 24 hours after application, sand shall be spread over the surface to blot the excess primer. Care shall be taken to prevent over-priming; any pools of excess primer left on any part of the surface shall be swept out over the adjacent surface before spreading sand. The primer coat shall be applied only on the topmost water bound macadam or any granular layer, over which the bituminous base course/wearing course is to be laid. 502.4.4. Curing of primer and opening to traffic: It shall always be ensured that while opening to any kind of traffic, the primed surface is fully cured and is not sticky to avoid being picked up by traffic. Normally, the primed surface shall be allowed to cure for not less than 24 hours and during this period no traffic of any kind shall be permitted. 592.4.5. Laying of bituminous course over primed surface: Bituminous base course or wearing course shall be laid over the primed water bound macadam, wet mix macadam or any other granular base course, in the usual manner as per relevant Specification for the same including the requirement of tack coat as per Clause 503. 502.5. Quality Control of Work Control on the quality of materials and work shall be exercised by the Engineer in accordance with Section 900. 502,6. Arrangement for Traffic During the Construction operations, arrangement of traffic shall be done as per Clause 112. 502.7. Measurements for Payment Prime coat shall be measur~d terms of surface area of application in in square metres.
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Section 500
502.8. Rate The contract unit rate for prime coat shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v) and as applicable to the work specified in these Specifications.
503. TACK COAT

503.1. Scope This work shall consist of application of a single coat of low viscosity liquid bituminous material to an existing road surface preparatory to another bituminous construction over it. 503.2, Materials Binder: The binder used for tack coat shall b~ bituminous emulsion a or cutback as specified in the Contract. 503.3. Construction Operation 503.3.1. Preparation of base: The surface on which the tack coat is to be applied shall be cleaned of dust and any extraneous material before the application of the binder, by using a mechanical broom or any other approved equipment/method as specified by the Engineer. 503.3.2. Application of binder: Binder may be heated to the temperature appropriate to the grade of cutback used and approved by the Engineer and sprayed on the base at the rate specified in Table 500-2. The normal range of spraying temperature for a bituminous emulsion shall be 20C-60C for a cutback 50C-80C RC-70/ and if MC-70 grade is used. It shall be the responsibility of the Contractor to carefully handle the inflammable bituminous cutback material so as to safeguard against any fire mishap. The binder shall be applied uniformly with the aid of either self-propelled or towed bitumen pressure sprayer with self-heating arrangement and spraying bar with nozzles having constant volume or pressure system, capable of spraying bitumen at specified rates and temperature so as to provide a uniformly unbroken spread of bitumen. Work should be planned so that no more than the necessary tack coat for the days operation is placed on the surface. After application and prior to succeeding construction allow the tack coat to cure, without being disturbed, until the water/cutter has completely evaporated, as determined by the Engineer.
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Section 500
TABLE 500.2. RATE OF APPLICATION OF TACK COAT Type Surface Quantity of liquid bituminous mater1i~in kg per 10 sq. m. area 2.0 to 2.5 2.5 to 3.0 2.5 to 3.0
Normal bituminous surfaces Dry and hungry bituminous surfaces iii) Granular surfaces treated with primer iv) Non bituminous surfaces a) Granular base (not primed) b) Cement concrete pavement Note : There is no need to apply a tack coat on a freshly
i)
ii)
3.5 to 4.0 3.0 to 3.5 laid bituminous course if the
subsequent bituminous course is overlaid the same day without opening it to traffic.
503.4. Quality Control of Work Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 503,5. Arrangements for Traffic During the period of construction, the arrangement of traffic shall be done to Clause 112. 503.6. Measurement for Payment Tack coat shall be measured in terms of surface area of application in square metres. 503.7. Rate The contract unit rate for tack coat shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v) as applicable to the work specified in these Specificatiot~s. 504. BITUMINOUS MACADAM 504.1, Scope The work shall consist of construction, in a single course, of compacted crushed aggregates premixed with a bituminous binder, to serve as base/binder course, laid immediately after mixing, on a base prepared previously in accordance with the requirement of these Specifications and in conformity with the lines, grades and cross-sections shown on the drawing or as directed by the Engineer. 504.2. Materials 504.2.1. Bitumen: The bitumen shall be paving bitumen of suitable
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149
Section 400
Sub-Bases, Bases (Non-Bituminous) and S~ou~ders
penetration grade (30/40 to 80/100) as per IS:73. The actual grade of bitumen to be used shall be decided by the Engineer appropriate to the region, traffic, rainfall and other environmental conditions, Guidelines on selection of the grade of bitumen are given in Appendix-4. 504.2.2. Aggregates 504.2.2.1. The aggregates shall consist of crushed stone, crushed gravel/shingleor other stones. They shall be clean, strong, durable, of fairly cubical shape and free from disintegrated pieces, organic or other deleterious matter and adherent coating. If crushed shingle/gravel is used, not less than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The aggregates shall preferably be hydrophobic and of low porosity. If hydrophilic aggregates are to be used, thebitumen shall preferably be treated with anti~stripping agents of approved quality in suitable dose as per Appendix-5. The aggregates shall satisfy the physical requirements set forth in Table 500.3.
TABLE 500.3. PHYSICAL REQUIREMENTS OF AGGREGATES FOR IUTUMINOUS MACADAM
S,No, Test Test Method Requirement 5 IS:2386(Part..4) 40per cent Maximum 1. Los Angeles Abrasion Value 2. Aggregate Impact Value5 IS:2386 ~Part-4) 30 per cent Maximum 3. Flakiness and Elongation55 IS:238$(Part-1) 30 per cent Maximum Indices (Total) 4. Coating and Stripping of AASI ITO T 182 Minimum retained Bitumen Aggregate Mixtures coating 95 percent 5. Soundness IS:23 86 (Part-5) (i) Loss with Sodium 12 per cent Maximum Sulphate 5 cycles (ii) Loss with Magnesium IS per cent Maximum Sulphate 5 cycles 6 Waterabsorptian IS:2386(Patt-3) ZpercentMaximum * Aggregates may satisfy requIrements 01 eitfler at the two tests. ~ To determine this combined proportion, the flaky stone from a representative sample should first be separated out. Flakiness index is weight of flaky stone
metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal. Ebngaflon index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up. Note: If crushed slag is used, Clause 404.2.3. shall apply.
504.2.2.2. The aggregate for bituminous macadam shall conform to one of the two gradings in Table 500-4, depending on the compacted thickness; the actual grading shall be as specified in the Contract. 504.2.3. Proportioning of materials: The bitumen content for premixing shall be 3 to 3.5 per cent by weight of the total mix except when otherwise directed by the Engineer.
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Section 500
TABLE 500~2.RATE OF APPLICATION OF TACK COAT Type Surface Quantity ef liquId bItuminous material In kg per 10 sq. m. area 2.0 to 2.5 2.5 to 3.0
i) ii) iii) iv)
Normal bitsaninous surfaces Dry and hungry bituminous surfaces Granular surfaces treated with primer Non bituminous surfaces a) Granular base (not primed) b) Cement concrete pavement
2.5 to 3.0
3.5 to 4,0 3.0 to 3.5
Note
There is no need to apply a tack coat on a freshly laid bituminous course if the subsequent bituminous course is overlaid the same day without opening it to traffic.
503.4. Quality Control of Work Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 503.5. Arrangements for Traffic During the period of construction, the arrangement of traffic shall be done to Clause 112. 503.6. Measurement for Payment Tack coat shall be measured in terms of surface area of application in square metres. 503.7, Rate The contract unit rate for tack coat shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v) as applicable to the work specified in these Specifications. 504. BITUMINOUS MACADAM 504.1. Scope The work shall consist of construction, in a single course, of compacted crushed aggregates premixed with a bituminous binder, to serve as base/binder course, laid immediately after mixing, on a base prepared previously in accordance with the requirement of these Specifications and in conformity with the lines, grades and cross-sections shown on the thawing or as directed by the Engineer. 504.2. Materials 504.2.1. Bitumen: The bitumen shall be paving bitumen of suitable
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149
Base and Surface Courses
(Bituminous)
Section 500
Per cent by weight passing the sieve Grading I GradIng 2
TABLE 500.4. AGGREGATE GRADING FOR BITUMINOUS MACADAM IS Sieve DesIgnation
45.0 26.5 22.4 11.2 5.6 2.8
90.0
mm mm mm mm mm mm micron
100
75.100
100
75.100 50-85 20-40 5-20 0-5
60-95
30.55 15-35 5.20
0-5
The maximum compacted thickness of a layer shall be 100 mm. The quantities of aggregates to be used shall be sufficient to yield the specified thickness after compaction. 504.2.4. Variatioii in proportioning of material: The Contractor shall have the responsibility for ensuring proper proportioning of materials and producing a uniform mix. A variation in binder content 0.3 per cent by weight of total mix shall, however, be permissible for individual specimens taken for quality control tests vide Section 900, 504.3. Construction Operations 504.3.1. Weather and seasonal limitations : The work of laying shall not be taken up during rainy or foggy weather or when the base course is damp or wet, or during dust storm or when the atmospheric temperature in shade is 10Cor less. 504.3.2. Preparation of the base: The base on which bituminous macadam is to be laid shall be prepared, shaped and conditioned to the specified lines, grades and cross-sections in accordance with Clause 501, and a priming coat where needed shall be applied in accordance with Clause 502 as directed by the Engineer. 504.3.3. Tack coat: A tack coat as per Clause 503 shall be applied over the base. 504,3.4. Preparation and transport of mix: Bituminous macadam mix shall be prepared in a hot mix plant of adequate capacity and capable of yielding a mix of proper and uniform quality with thoroughly coated aggregates. Hot mix plant shall be of suitable capacity preferably of batch mix type. Total system for crushing of stone aggregates and feeding of aggregate fractions in required proportions to achieve the desired mix, deployed by the Contractor must be capable of meeting the overall
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151
Section 500
Specification requirements under stringent quality control. The plant shall have the following essential features:
A-General (a) (b) The plant shall have coordinated set or essential units capable of producing sxsifonn mix as per the job mix formula. cold aggregate feed system with minimum 4 bins having belt conveyor arrangement for initial proportioning of aggregates from each bin in the required quantities. In order to have free flow of fines from the bin, it is advisable to have vibrator fitted on bin to intenninently shake it, Belt convryers below each bin shoold have variable speed drive motors. There should be electronic load sensor on the main conveyer for measuring the flow of aggregates. Dryer unit with burner capable of heating the aggregate to the required temperature. without any visible unbumt fuel or carbon residue on the aggregate and reducing the moisture content of the aggregate to the seecified minimum. The plant shall be fitted with suitable type of thermometric instruments at appropriate places so as to indicate or record/register the temperature of heated aggregate, bitumen and mix. Bitumen supply unit capable of heating, measuring/metering and spraying of bitumen at specified temperature with automatic synchronisation of bitumen and aggregate feed in the required proportion. A filler system suitable to receive bagged or bulk supply of filler material and its incorporation to the mix in the correct quantity wherever required. A suitable built-in dust control system for the dryer to contain/recycle permissible fines into the mix. It should be capable of preventing the exhaust of fine dust into atmosphere for environmental control wherever so specified by the Engineer. The plant should have centralised control panel/cabin capable of presetting, controlling/synchronising all operations starting from feeding of cold aggregates to the discharge of the hot mix to ensure proper quality of mix. It should have indicators for any malfunctioning in the operation. Every hot mix plant should be equipped with siren or horn so that the operator may use the same before starting the plant every time in the interest of safety of staff.
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(c)
(d)
(e)
(f)
(g) (h)
(i)
(j)
B (i)
For Batch Type Plant Gradation control unit having minimum four deck vibratory screens for accurate sizing of hot aggregate and storing them in separate bins. This unit should be fully covered to reduce the maintenance cost and for better environmental condition. Proper arrangement for accurate weighing of each size of hot aggregate the control panel before mixing. from
(ii)
(iii) Paddle mixer unit shall be capable of prodlicing a homogeneous mix withuniform coating of all particles of the mineral aggregate with binder.
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152
Base and Surface Courses (Bituminous) C (i)

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Section 500
For Continuous Type Plant Gradation control unit having vibratory screens for accurate sizing of hot aggregate and storing them in separate bins. This unit should be fully covered to reduce the maintenance cost and for better environmental condition. There should be appropriate arrangement for regulating and volumetric control of the flow of hot aggregate from each bin to achieve the required proportioning.
(ii)
(iii) Paddle mixer unit shall be capable of producing a homogeneous mix with uniform coating of all particles of the mineral aggregate with binder. D (i)
.
For Drum MIx Plant It is a prerequisite that only properly screened and graded materials are fed to the bins. If required, a vibratory screening unit shall be installed at the plans site to ensure the same. A primary 4-deck vibratory screening unit shall be installed before the multiple bin cold feed system for screening the aggregates and grading sbe same.
(ii)
Belt conveyers below each bin should have variable speed drive motors. There should be electronic load sensor on the main conveyer for measuring the flow of aggregate.
(iii) There should be arrangement to measure moisture content of the aggregate(s) so that moisture correction may be applied for working out requirements of binder and filler.
The temperature of binder at the time of mixing shall be in the range of 15&C to 163C and that of the aggregate in the range of 155C 163C.provided that the difference in temperature between the binder and aggregate at no time exceeds 14C. Mixing shall be thorough to ensure that a homogeneous mixture is obtained in which all particles of the aggregates are coated uniformly, and the discharge temperature of mix shall be between 130C to 160 C. The mixture shall be trinsported from the mixing plant to the point of use in suitable tipper vehicles. The vehicles employed for transport shall be clean and be covered in transit if so directed by the Engineer. Any tipper causing excessive segregation of materials by its spring suspension or other contributing factors or that which shows undue delay shall be removed from the work until such conditions are corrected. 504.3.5. Spreading: The mix transferred from the tipper at site to the paver shall be spread immediately by means of self-propelled me~hanicalpaver with suitable screeds capable of spreading, tamping, and finishing the mix true to the specified lines, grades and crosssections. The paver finisher shall have the following essential features:
-
(a)
Loading hoppers and suitable distributing mechanism.
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153
Section 500 (b) (c) (d)
All drives having hydrostatic drive/control. The machine shall have a hydraulically extendable screed for appropriate width requirement. The screed shall have tamping and vibrating arrangement for initial compaction so the layer as it is spread without rutting or otherwise marring the surface. It shall have adjustable amplitude and variable frequency. The that The and paver shall be equipped with necessary control mechanism so as to ensure the finished surface is free from surface blemishes. paver shall be fitted with an electronic sensing device for automatic levelling profile control within the specified tolerances,
(e) (I) (g) (h) (i)
The screed shall have the intemat heating arrangement. The paver shall be capable of laying either 2.5 to 4.0 m width or 4.0 to 7.0 m width as stipulated in the Contract. lhe paver shall be so designed as so eliminate skidding/slippage of the tyres during operation.
However, in restricted locations and in narrow widths where the available plant cannot be operated in the opinion of the Engineer, he may permit manual laying of the mix. The temperature of the mix at the time of laying shall be in the range of 120Cto 160C. In multi-layer construction, the longitudinal joint in one layer shall offset that in the layer below by about 150 mm, However, the joint in the top-most layer shall be at the lane line of the pavement. Longitudinal joints and edges shall be constructed true to the delineating line parallel to the centre line of the road. All joints shall be cut vertical to the full thickness of the previously laid mix and the surface painted with hot bitumen before placing fresh material. Longitudinal and transverse joints shall be offset by at least 250 mm from those in the loWer courses and the joint on the topmost layer shall not be allowed to fall within the wheel path. All transveme joints shall be cut vertically to the full thickness of the previously laid mix with asphalt cutter/pavement breaker and surface painted with hot bitumen before placing fresh material. Longitudinal joints shall be preferably hot joints. Cold longitudinal joints shall be properly heated with joint heater to attain a suitable temperature of about 80Cbefore laying of adjacent material. 504.3.6. Compaction: After the spreading of mix, rolling shall be done by 80 to 100 kN rollers or other approved equipment. Rolling shall start as soon as possible after the material has been spread deploying a sct of rollers as the rolling is to be completed in limited time frame.
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54
Base and Surface
Courses (Bituminous)
Section 500
The roller shall move at a speed not more than 5 km/h. Rolling shall be done with care to avoid unduly rougheniitg of the pavement surface. Rolling of the longitudinal joints shall be done immediately behind thr paving operation. After this, the rolling shall commence at the edges and progress towards the centre longitudinally except that on ~uperelevated and uni-directional cambered portions, it shall progress from the lower to the upper edge parallel to the centre line of the pavement. The initial or break.down rolling shall be done with 80 100 kN static weight smooth wheel roller (3 wheels or tandem), as soon as it is possible to roll the mix without cracking the surface or having the mix pick up on the roller wheels, The second or intermediate rolling shall follow the break-down rolling with vibratory roller of 80 to 100 kN static weight or pneumatic tyred roller of 150 to 250 kN weight, with minimum 7 wheels and minimum tyre pressure of 0.7 MPa as closely as possible to the paver and be done while the paving mix is still at a temperature that will result in maximum density. The final rolling shall be done while material is still workable enough for removal of roller marks, with 60 80 kN tandem roller. During the final rolling, vibratory system shall be switched ofL The joints and edges shall be rolled with a 80 to 100 kN static roller. When the roller has passed over the whole area once, any high spots or depressions which become apparent shall be corrected by removing or adding mix material. The rolling shall then be continued till the entire surface has been rolled to 95 per cent of the average laboratory density (obtained from Marshall specimens compacted as defined in Table 500-10), there is no crushing of aggregates and all roller marks have been eliminated. Each pass of the roller shall uniformly overlap not less than one-third of the track made in the preceding pass. The roller wheel shall be kept damp if necessary to avoid bituminous material from sticking to the wheels and being picked up. In no case shall fuel, lubricating oil be used for this purpose, nor excessive water poured on the wheels. Rolling operations shall be completed in every, respect before the temperature of the mix falls below 100C. Roller(s) shall not stand on newly laid material while there is a risk that surface will be deformed thereby. The edges along and transverse of the bituminous macadam laid and compacted earlier shall
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155
Section 500
be cut to their full depth so as to expose fresh surface which shall be painted with a thin surface coat of appropriate binder before the new mix is placed against it. 504.4. Surface Finbh and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902, Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 504.5. The bituminous macadam shall be covered with either the next pavement course or wearing course, as the case may be, without any delay. If there is to be any delay, the course shall be covered by a seal coat to the requirement of Clause 513 before allowing any traffic over it. The seal coat in such cases shall be considered incidental to the work and shall not be paid for separately. 504.6. Arrangements of Traffic During the period of construction, arrangement of traffic shall be done to Clause 112. 504.7. Measurements for Payment The work shall be measured as finished work in cubic metres or by weight in metric t9nnes as provided in the Contract. 504.8. Rate The contract unit rate for the work shalt be payment in full for carrying out the required operations including full compensation for:
(I) (ii) Making arrangements for traffic to Clause 112 excex for initial treatment to verge, shoulders and construction of diversions; Preparation of base except for laying of profile corrective course but including filling of potholes;
(iii) Providing all materials to be incorporated in the work including arrangement for stock yards, all royalties, fees, rents where necessary and all leads and lifts; (iv) All labour, tools, equipment, plant including installation of hot mix plant, power supply units and all machineries, incidental to complete the work to the Specifications; (v) Carrying out the work in pan widths of the road where directed;
(vi) Carrying out all tests for control of quality; and

(vii)
The rate shall cover the provision.of bitumen at 3.25 per cent of weight of total mix, with the provision that the variation of quantity of bitumen will be asseased and the payment adjusted as per the rate of bitumen quoted.
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156
Section 500
The roller shall move at a speed not more than 5 km/h. Rolling shall be done with care to avoid unduly roughenir~gof the pavement surface. Rolling of the longitudinal joints shall be done immediately behind thr paving operation. After this, the rolling shall commence at the edges and progress towards the centre longitudinally except that on ~uperelevated and uni-directional cambered portions, it shall progress from the lower to the upper edge parallel to the centre line of the pavement. The initial or break-down rolling shall be done with 80 100 kN static weight smooth wheel roller (3 wheels or tandem), as soon as it is possible to roll the mix without cracking the surface or having the mix pick up on the roller wheels. The second or intermediate rolling shall follow the break-down rolling with vibratory roller of 80 to 100 kM static weight or pneumatic tyred roller of 150 to 250 kM weight, with minimum 7 wheels and minimum tyre pressure of 0.7 MPa as closely as possible to the paver and be done while the paving mix is still at a temperature that will result in maximum density. The final rolling shall be done while material is still workable enough for removal of roller marks, with 60 80 kN tandem roller. During the final rolling, vibratory system shall be switched off. The joints and edges shall be rolled with a 80 to 100 kN static roller. When the roller has passed over the whole area once, any high spots or depressions which become apparent shall be corrected by removing or adding mix material. The rolling shall then be continued till the entire surface has been rolled to 95 per cent of the average laboratory density ~obtainedfrom Marshall specimens compacted as defined in Table 500-10), there is no crushing of aggregates and all roller marks have been eliminated. Each pass of the roller shall uniformly overlap not less than one-third of the track made in the preceding pass. The roller wheel shall be kept damp if necessary to avoid bituminous material from sticking to the wheels and being picked up. In no case shall fuel, lubricating oil be used for this purpose, nor excessive water poured on the wheels. Rolling operations shall be completed in every, respect before the temperature of the mix falls below 100C, Roller(s) shall not stand on newly laid material while there is a risk that surface will be deformed thereby. The edges along and transverse of the bituminous macadam laid and compacted earlier shall
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Base and Surface
Section 500
505. BITUMINOUS PENETRATION MACADAM 505.1. Scope

The work shall consist of construction of one or more layers of compacted crushed coarse aggregatts with alternate applications of bituminous binder and key aggregates in accordance with the requirements of these Specifications to serve as base,thinder course and in conformity with the lines, grades arid cross-sections shown on the drawings or as directed by the Engineer. Thickness of an individual course shall not exceed 75 mm. 505.2. Materials 505.2.1. Bitumen: The binder shall be paving bitumen of suitable penetration grade within the range of S-35 to 8-90 or A-35 to A90 (30/40 to 80/I 00) as per Indian Standards Specifications for Paving Bitumen IS ;73, or apprcWed cutbacks satisfying the requirements of IS 73, 217 or 454. The actual grade of bitumen or cut backs to be used shall be decided by the Engineer, appropriate to the region, traffic, rainfall and other environmental conditions. Guidance in this regard may be obtained from Appendix-4. 505.2.2. Aggregates 505.2.2.1. The aggregates shall satisfy the physical requirements set forth in Clause 504.2.2.1 and Table 500-3. 505.2.2.2. The coarse and key aggregates shall conform to the grading given in Table 500-5. 505.2.3. Quantities of materials: The quantities of materials used for this work shall be as specified in Table 500-6. 505.3. Construction Operations 505.3.1. Weather and seasonal limitations: Clause No. 504.3.1 shall apply. 505.3.2. Preparation of the base: The base on which the Penetration macadam course is to be laid shall be prepared, shaped and conditioned to the specified lines, grades and sections to Clause 501 or as directed by the Engineer. A priming coat where needed shall be applied over the base in accordance with Clause 502 or as directed by the Engineer. A tack coat as per Clause 503 shall be applied.
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157
Section 500
~iase and Surface Courses (Bituminous)
TABLE 500.5. GRADING REQUIREMENTS OF COARSE AGGREGATES AND KEY AGGREGATES FOR BITUMINOUS PENETRATION MACADAM Per cent by weight passing the Steve
For 50 mm compacted
for 75 mm compacted
thickness Coarse Aggregate Key Aggregate

thickness Coarse Aggregate

~
IS Steve
Key
Design.
atlon 63 53 mm mm 45 mm 26.5 mm 22.4 mm 132 mm 11.2 mm 5.6mm 2.8 mm
Aggregate
~
100
100 37-72
58-82
100
50-75
100
5-27
,
2-20

50-75
5-25
0-5
5-25 0-5
0-5
0-5
TABLE 500.6. QUANTITIFS OF MATERIALS REQUIRED FOR 10 sq.m.OF ROAD SURFACE FOR BITUMINOUS PENETRATION MACADAM BASFJ BINDER COURSE Compacted thickness
Binder Straight Coarse Aggregate 0.60 cu.m. 0.90 cu.m. Key Aggregate 0.15 en. m. 0.18 cc. m.
run bitumen
50 mm 75 mm 50 kg 68 kg
505.3.3.. Spreading and compacting coarse aggregates: The coarse aggregate in a dry and clean form shall be spread uniformly and evenly at the rate specified in Table 500-6 preferably with the help of a self-propelled or tipper tail mounted aggregate spreader capable of spreading aggregate uniformly at the specified rates over the required widths. The surface of the layer shall be carefully checked with camber templates and all high and low spots remedied by removing or adding aggregates as may be required. The spreading shall be carried no further in advance of the rolling and penetrating operations than can be completed in one average days work. Segregated aggregates or aggregates mixed with earth or other foreign substances shall be removed and replaced with graded aggregates. 505.3.4. Compaction: After the spreading of coarse aggregates, dry rolling shall be done by 80 100 kN smooth-wheeled steel roller. Rolling shall start as soon as possible after the material has been spread. The rolling shall commence at the edges, parallel to the centre line of the road and progress towards the centre longitudinally except
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on superelevated and uni-directional cambered portions, where it shall progress from the lower to the upper edge after the edges have been rolled. For superelevated portions, the overlapping should be approximately one-third of the width of the rear wheel on each trip. After initial dry rolling, the surface shall be checked with a crown template and a 3 metre straight-edge. The surface shall not vary more than 10 mm from the template or straight-edge. All surface irregularities exceeding the above lirnit shall be corrected by removing or adding aggregates as required. The rolling shall be done until the compacted coarse aggregate has firm surface true to the cross section shown on the plans and that it has a texture that will allow free and uniform penetration of the bituminous material. 505,3.5. Application of bituminous material: After the coarse aggregate has been rolled and checked, the bituminous binder shall be applied at specified temperatures as directed by the Engineer. The rate of application shall be as specified in Table 500-6. At the time of applying the binder, the aggregates shall be surface dry for full depth of the layer. The bituminous material shall preferably be applied by a pressure distributor uniformly over the surface at the specified rate. Over small areas, where the use of a spray bar is impracticable, the bituminous material shall be applied by the nozzle attachment. Only when permitted, pouring pots may be used according tc~the directions of the Engineer. 505.3.6. Application of key aggregates: Immediately after the first penetration of bitumen, the key aggregates in a clean and dry state shall be spread uniformly over the surface by means of an approved mechanical spreader or by approved manual methods at the rate specified in Table 500-6. If necessary, the surface shall be broomed to ensure uniform application of the key aggregates. The entire surface shall then be rolled with a 80 100 kN smooth steel wheel roller (along with vibratory roller if available) to the Specifications conforming to Clause 505.3.4. 505.4. Surface Finish and Quality Control The surface finish of construction shall conform to the requirements of Clause 902.
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Controls on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 505.5. The Penetration Macadam shall be provided with final surfacing (binderlwearing course) without any delay. If there is to be any delay, the course shall be covered by a seal coat to the requirements of Clause 513 before allowing any traffic over it. The seal coat in such cases shall be considered incidental to the work and shall not be paid for separately. 505.6. Arrangements for Traffic During the period of construction, arrangements for traffic shall be done to Clause 112. 505.7. Measurements for Payment Penetration Macadam Base/Binder Course shall be measured as finished work in square metres. 505.8. Rate The contract unit rate for Penetration Macadam Course shall be payment in full for carrying out the required operations including full compensation for all components ~isted in Clause 504.8 (i) to (vi). 506. BUILT-UP SPRAY GROUT 506.1. Scope This work shall consist of a two-layer composite construction of compacted crushed coarse aggregates with application of bituminous binder after each layer and key aggregates bn top for the second layer, ih accordance with the requirements of these Specifications to serve as a base course and in conformity with the tines, grades and cross-sections shown on the drawings or as directed by the Engineer. Thickness of the course shall be 75 rum. Built-up spray grout shall be used in a single course in a pavement structure. 506,2. Materials 506.2.1. Bitumen: Clause 504.2.1 shall apply. 506.2.2. Aggregates: The coarse aggregate shall conform to Clause 504.2.2.1. The aggregate shall satisfy the physical requirements set out in Table
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500-3. The coarse and key aggregates for built-up spray grout shall conform to the grading given in Table 500-7.
TABLE 500-7. GRADING REQUIREMENTS OF COARSE AND KEY GGREGATES FOR BUILT-UP SPRAY GROUT Per cent by weight passing the Sieve IS Sieve Designation Coarse Aggregate tOO 40-75
Key Aggregate

53.0 mm 26.5 mm 22.4 mm

13.2 mm 5.6 mm
lOt)
0-20
40-75
0-20
2.8 mm
0-5
0-5
506.3. Construction Operations 506.3.1. Weather and seasonal limitations: Clause 504.3,1 shall apply. 506.3.2. Preparation of base: The base on which the b.uilt-up spray grout course is to be laid shall be prepared, shaped and conditioned to the specified lines, grades and cross-sections in accordance with Clause 501. A priming coat where needed shall be applied in accordance with Clause 502 with suitable primer as directed by the Engineer. 506.3.3. Jack coat: A tack coat over the base shall be applied as per Clause 503. 506.3.4. Spreading and rolling coarse aggregates for the first layer: Immediately after the application of tack coat, the coarse aggregates in a dry and clean form shall be spread uniformly and evenly preferably by mechanical means at the rate of 0.5 cu.m. per 10 sq.rr. area. The surface of the layer shall be carefully checked with ten3plates and all high and low spots remedied by removing or adding aggregates as may be required. Immediately after spreading of the aggregates, the entire surface shall be rolled with a 80 100 kN smooth-wheeled roller. Rolling shall commence at the edges and progress towards the centre except in superelevated and uni-directional cambered portions where it shall proceed from the lower edge to the higher edge. Each pass of the roller shall uniformly overlap not less than one-third of the track made in the preceding pass. After initial rolling, the surface shall be checked transversely and longitudinally with templates and any irregularities corrected by loosening
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Scction 5(X)
Base
the surface, adding or removing necessary amounts of aggregate, followed by rolling. Rolling shall be stopped before voids in the aggregate layer are closed to such an extent as to prevent free and uniform penetration of the binder. 506.3-5. Application of binder first spray: The binder shall 1* heated to the temperature appropriate to grade of bitumen approved by the Engineer and sprayed on aggregate layer at the rate of 15 kg/ 10 sq. m. (in terms of straight-run bitumen) in a uniform manner with the help of mechanical sprayers capable of spraying bitumen uniformly at specified rates and temperatures. Excessive deposits of binder caused by stopping or starting of the sprayers or through leakage or any other reason shall be corrected promptly. 506.3.6. Spreading and rolling of coarse aggregate for the second layer: Immediately after the first application of the binder, the second layer of coarse aggregates shall be spread and rolled to Clause 506.3.4. 506.3.7. Application of binder-second spray: The second aggregate layer shall then be given a binder spray at the rate of 15 kg! 10 sq. m. (in terms of straight-run bitumen) to Clause 506.3.5. 506.3.8. Application of key aggregate: Immediately after second application of the binder, key aggregates in a clean and dry state shall he spread uniformly and evenly, preferably by mechanical means at the rate of 0.13 cu.m./10 sq. m. so as to cover the surface completely. If necessary, the surface shall be broomed to ensure uniform application of the key aggregates. The entire surface shall then be rolled with a 80-100 kN smooth-wheeled roller to Clause 506.3.4. While rolling is in progress, additional key aggregates, where required, shall be spread by hand. Rolling shall continue until the entire course is thoroughly compacted and the key aggregates are firmly in position.
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506.4. Surface Finish and Quality Control The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 506.5. The built-up-spray-grout shall be provided with final surfacing without any delay. If there is to be any delay, the course shall be covered by a seal coat to the requirement of Clause 513 before
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Section 5(X)
allowing any traffic over it, The seal coat in such cases shall be considered incidental to the work and shall not be paid for separately. 506.6. Arrangements for Traffic During the period of construction, atrangement of traffic shall be done to Clause 112. 506.7. Measurements for Payment Built-up spray grout shall be measured as finished work in square metres. 506.8. Rate The cutract unit rate for built-up spray grout shall be payment in full for caying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi). 597. DENSE BITUMINOUS MACADAM 507.1. Scope This work shall consist of construction in a single course of 50 to 100 mm thick base/binder course to the following Specifications on a previously prepared base. 507.2. Materials 507.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration Grade S 65 or A 65 (60/70) as per Indian Standard Specifications for Paving Bitumen IS: 73. In case of non- availability of bitumen of this grade, S 90 (80/100) grade bitumen may be used with the approval of the Engineer. Guidance to selection of the grade of bitumen may he taken from Appendix-4. 507.2,2. Coarse aggregates : The coarse aggregates shall consist of crushed stone, crushed gravel/shingle or other stones. They shall be clean, strong, durable, of fairly cubical shape and free from disintegrated pieces, organic or other deleterious matter and adherent coating. The aggregates shall preferably be hydrophobic and of low porosity. If hydrophilic aggregates are to be used, the bitumen shall be treated with antistripping agents of approved quality in suitable doses. The aggregates shall satisfy the physical requirements set forth in Table 500-8. If crushed gravel/shingle is used, not less than 90 per cent by weight ol the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The portion of the total aggregate passing
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Base and
Surface
4.75 mm sieve shall have a sand equivalent value of not less than 50 when tested in accordance with the requirement of IS: 2720 (Part-37). The plasticity index of the fraction passing the 425 micron sieve shall not exceed 4.
TABLE 500.5. PHYSICAL REQITIREMENTS OF AGGREGATES FOR DENSE UtTUMINOUS MACADAM
S.No,
I 2. 3. 4 5,
Test [AssAngetes Abrasion Valuet Aggregate Impact valuet Flakiness and Elongauon Indices (loial) tt
Tess Method 15~2386 ~Part4) IS:2386(Pars-4) 15:2386 (Pan-i) AASItTO T 182 IS:2386(Pan-5) S cycles 5 cycles 15:2386 (l5art-3)
Requirement 40 per cent maximum 30perceat Maximum 30 per cent Maximum Minimum retained coating 95 per cent 12 per cent Maximum 18 per cent Maximum 2 per cent Maximum
(oaring and Stripping of Bitumen Aggregate Mixtures Scsindness (i) Inst with Sodium Sulphate (ii) l,o.ss with Magncsium Sulphate Water ahsoption
5.
* **
Aggregates may satisfy requirements of either of the two tests To determine this combined proportion, the flaky stone from a representative sample should first be separated out, Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal Elongation index is weight of elongated parlicles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up.
507.2.3. Fine aggregates: Fine aggregates shall be the Fraction passirtg 2.36 mm sieve and retained on 75 micron sieve, consisting of crusher-run screening, gravel, sand or a mixture of both. These shall he clean, hard, durable, ttncoated, dry and free from any injurious, soft or flaky pieces and organic or other deleterious suhstances. 507.2.4. Filler: Filler shall consisl of finely divided mineral matter such as rxk dust, hydraled lime or cement as approved by the Engineer. The filler shall be graded within the following limits
tS Sieve 601) micron 3(X) micron 75 micron
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Per cent passing by weight 100 95-1(X) 85-100
The filler shall be free from organic impurities and have a Plasticity Index not greater than 4. The Plasticity Index requirement shall not apply if filler is cement or lithe. When the coarse aggtregate is gravel,
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2 per cent by mass of total aggregate of portland cement or hydrated lime shall be added and the percentage of fine aggregate reduced accordingly. Cement or hydrated lime is not required when the gravel is limestone. 507.2.5. Aggregate gradation : The combined coarse and fine aggregates and filler (when used) shall produce a mixture to conform to the grading set forth in Table 500-9.
TABLE 500-9. AGGREGATE GRADATION FOR DENSE
BITUMINOUS MACADAM
Sieve Designation 37.5 26.5 13.2 4,75 2.36 mm mm mm mm mm Percentage passing the sieve by weight 100 90-100 56-80 29-59 19-45 5-17 1-7
300
75
micron
micron
The aggregate mix, as used in work, shall not vaty from the low limit on one sieve to the high limit on the adjacent sieve but shall be well graded.
507.3.
Mix Design
507.3.!. Requirement of mix: Apart from conformity with grading and quality requirements of individual ingredients, the mix shall meet the requirements set out in Table 500-10.
TABLE 500-10. S.No. Description 1. Marshall stability (ASTM Designaiion-D-l559) determined an Marshall specimens compacted by 75 conipaction blows on each end Marshall flow (mm) Per cent Air voids Minimum voids in m.intral aggregates (VMA) Per cent voids in mineral aggregates filled by bitumen (VFB) Binder content per cent by weight of total mix REQUIREMENTS OF DENSE BITUMINOUS MACADAM MIX Requirements
820 kg (1800 Ib) minimum

2-4 3-5 10 per cent 65-75
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2. 3. 4. 5. 6.
12 per cent
Not less than 4.0 per cent
507.3.2. Binder content: The binder content shall be so fixed as to achieve the requirements of the mix set out in Table 500-10. Marshall method for arriving at the binder content shall be adopted, replacing the aggregates retained on 26.5 mm sieve by the aggregates passing 265 mm sieve and retained on 22.4 mm sieve.
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507.3.3. Job mix formula : The Coffiractor shall intimate to the Engineer in writing, atleast 20 days before the start of the work, the job mix formula proposed to be used by him for the work and shall give the following details:
(i) (ii) Source and location of all materials; Proportions of all materiaLs expressed as follows (a) (b) (iii) A Binder, as percentage by weight of to4al mix; Coarse aggregatelFine aggregate/Mineral filler as percentage by weight of total aggregate including mineral filler~ single definite percentage passing each sieve for the mixed aggregate; where each is applicahle~:
(iv) The results of tests enumerated in Table 50010 as obtained by the Contractor; (v) Test results of physical charaeristics of aggregates to be used; (vi) Mixing temperature and compacting temperature.
While working out the job mix formula, the Contractor shall ensure that it is based on a correct and truly representative sample of the materials that will actually be used in the work and that the mix and its different ingredients satisfy the physical and strength requirements of these Specifications. Approval of the job mix formula shall be based on independent testing by the Engineer for which samples of all ingredients of the mix shall be furnished by the Contractor as required by the former. The approved job mix formula shall remain effective unless and until modified by the Engineer. Should a change in the source of materials be proposed, a new job mix formula shall be established and got approved from the Engineer before actually using the materials. 507.3,4. Permissible variation from job mix formula: It shall be the responsibility of the Contractor to produce a uniform mix conforming to the approved job mix formula subject to the permissible variations of the individual percentages of the various ingredients in the actual mix from the job mix formula to be used within the limits as specified in Table 500-Il. These variations are intended to apply to individual specimens taken for quality control tests vide Section 900.
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Base and Surface
Section 500
TABLE 500.11. PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA S.~4o, Description
0f Ingredients
Permissible variation by weight of total mix-in per cent 8 7 6 S 4 2 0.3
Aggregate passing
2. 3. 4.
5.
6. 7. 8,
13.2 men sieve and larger sieves Aggregate passing 112mm sieve and 5.6 mm sieve Aggregate passing 2.80 mm sieve and 1.40 mm sieve Aggregate passing 710 micron seive and 355 micron sieve Aggregate passing 180 micron sieve Aggregate passing 90 micron sieve Binder Mixing temperature
10C
507.4. Construction Operations 507.4.1. Weather and seasonal limitations: Clause 504.31. shall apply. 507.4.2. Preparation of base: The base on which Dense Bituminous Macadam is to be laid shall be prepared, shaped and conditioned to the specified lines, grades and cross sections in accordance with Clause 501 or as directed by the Engineer. The surface shall be thoroughly swept clean free from dust and foreign matter using mechanical broom and dust removed or blown off by compressed air. In portions where mechanical means cannot reach, other approved method shall be used. A priming coat where needed, shall be applied in accordance with Clause 502 or as directed by the Engineer. 507.4.3. Tack coat: A tack coat over the base shall be applied as per Clause 503. 507.4.4. Preparation of mix: Clause 504.3.4 shall apply. .507,4.5, Spreading: The mix transported from the hot mix plant to the site shall be spread by means of a self-propelled paver with suitable screeds capable of spreading, tarnping and finishing the mix to specified grade, lines and cross-section. Paver Finisher shall have the essential features as spelt out in Clause 504.3.5. However, in restricted locations and in narrow widths where the available equipment cannot be operated in the opinion of the Engineer, he may permit manual laying of the mix. Similarly for smaller jobs, mechanical paver may be used with the approval of the Engineer. The temperature of mix at the time of laying shall be in the range of 120-160C. Mixes with a temperature of less than 120Cshall not be put into paver spreader. Longitudinal joints and edges shall be constructed
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true to the delineating lines parallel to the centre line of the road. Longitudinal and transverse joints shall be offset by at least 250 mm from those in the lower courses and the joint on the top most layer shall not be allowed to fall within the wheel path. All lransverse joints shall be cut vertically to the full thickness of the previously laid mix with asphalt cutter and the surface painted with hot bitumen before placing fresh material. Longitudinal joints shall be preferably hot joints. Cold longitudinal joints shall he properly heated with joint heater to attain a suitable temperature of about 80Cbefore laying of adjacent material.
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507.4.6. Rolling : After spreading the mix by paver, it shall be thoroughly compacted by rolling with a set of rollers moving at a speed not more than 5 km/h, immediately following close to the paver. Generally the initial or breakdown rolling shall he done with 80-100 kN static weight smooth-wheeled roller. The intermediate rolling shall be done with 80 -100 kM static weight vibratory roller or with a pneumatic tyred roller of 150-250 kM weight having a tyre pressure of at least 0.7 MPa. The finish rolling shall be done with 60 8OkN weight smooth wheeled tandem roller. All the compaction operations, i.e., breakdown roiling and intermediate rolling can be accomplished by using vibratory tandem roller of 80-100 kN static weight. During initial breakdown rolling and finish rolling, no vibratory compaction shall be resorted to. The exact pattern of rolling shall be established after trial compaction as approved by the Engineer. Any displacement occurring as a result of reversing of the direction of a roller or from any other cause shall be corrected at once as specified and/or removed and made good. The rollers shall not be permitted to stand on pavement which has not been fully compacted and where temperature is still more than 70C.Necessary precautions shall be taken to prevent dropping of oil, grease, petrol or other foreign matter on the pavement either when the rollers are operating or standing. The wheels of roller shall be kept moist to prevent the mix from adhering to them. But in no case shall fuel/lubricating oil be used for this purpose nor excessive water poured on the wheels, Rolling shall commence longitudinally from edges and proceed towards the centre, except that on superelevated and unidirectional cambered portions, it shall progress from the lower to upper edge parallel to the centre line of the pavement. The roller shall proceed on the fresh material with rear or fixed wheel leading so as to minimise the
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pushing of the mix and each pass of the roller shall overlap the preceding one by half the width of the rear wheel. Rolling shall be continued till the density achieved is at least 98 per cent of that of laboratory Marshall specimen (compacted as defined in Table 500-10) and all roller marks are eliminated. Skin patching of an area that has been rolled, will not be permitted. Rolling operations shall be completed in all respects before the termperature of the mix f~.illsbelow 100C. 507.5. Opening to Traffic Traffic may be allowed after completion of the final rolling when the mix has cooled down to the surrounding temperature. The Dense Bituminous Macadam shall be provided with an appropriate wearing course as early as possible prior to regular opening to normal traffic and! or impending rain. 507.6. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 507.7. Arrangements for Traffic During the period of construction, arrangements for the traffic shall be done to Clause 112, 507.8. Measurements for P~~~ne~t Dense Bituminous Macadam shall be measured as finished work in cubic metres or tonnes as directed by the Engineer. 507.9. Rate
The contract unit rate for Dense Bituminous Macadam shall be
payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi). The rate shall cover the provision of bitumen in the mix at 4,5 per cent of the weight of the total mix, with the provision that the variation of quantity of bitun~n be assessed and the payment adjusted will as per the rate of bitumen quoted.
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508.
SURFACE DRESSING
508.1. Single and Two-Coat Surface Dressing using Bitumen 508.1.1. Description: This work shall consist of the application of one coat or two coats of surface dressing, each coat consisting of a layer of bituminous binder sprayed on base prepared previously, followed by a cover of stone chippings properly rolled to form a wearing course to the requirements of these Specifications. 508.1.2. Materials 508.1.2.1. Binder : The binder shall be straight-run bitumen of a suitable grade appropriate to the region, traffic, rainfall and other environmental conditions as directed by the Engineer and conforming to IS: 73. Guidance in this regard may be obtained from Appe,idix4. 508.1.2.2. Stone chippings : The stone chippings shall conform to Clause 504.2.2.1. The Stone Polishing Value as measured by BS 812 (Part 114), shall not he less than 55. The stone chippings shall also conform to the quality requirements of Table 500-3 except that water absorption shall be restricted to a maximum of I per cent. The size of stone chippings shall be in accordance with Table 500-12. 508.1.2.3. Quantities of materials: The quantities of materials used tbr this wofk shall be as specified in Table 500-13.
TABLE 500-12. SIZE REQUIREMENTS OF STONE CHIPPINGS FOR SURFACE DRESSING USING BITUMEN S. Type of construction No. 1. Single coat surface dressing or the first coat of two-coat surface dressing Second coat of two-coat surface dressing (also used as a renewal coat) Normal size or stone chipplngs 13.2 mm Specifications 100 per cent passing through 22.4mm sieve & retained on 11.2 mm sieve., 100 per cent passing through 13.2 mm sieve and retained on 5.6 mm sieve,
2.
11.2 mm
TABLE 500-13. S.No. 1. 2. Type
QUANTiTIES OF MATERIALS REQUIRED FOR 10 sq. ns.OF ROAD SURFACE FOR SURFACE DRESSING USING BITUME~
or construction
Binder
Stone chlppings 015 cu.m. 0.10 cu.m.
Single coat surface dressing or the first coat of the twocoat surface dressing Second coat of the two-coat surface dressing (also used as a renewal coat) 70
18.0 kg 10.0 kg
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508,1.3. Construction operations 508.1.3.1. Weather and seasonal limitations: Clause 504.3.1 shall apply. 508.1.3.2. Preparation of base : The base on which the surface dressing is to be laid shall be prepared, shaped and conditioned to the specified lines, grade and cross-section in accordance with Clause 501 and as directed by the Engineer. Priming coat, where needed, shall be provided as per Clause 502 and as directed by the Engineer. Where the existing surface shows signs of fatting up, this shall be rectified. The bituminous primed surface to be dressed shall be thoroughly cleaned either by using a mechanical broom or any other approved equipment/ method as specified by the Engineer. Dust removed in the process shall be blown off with the help of compressed air. 508.1.3.3. Application of binder: Bitumen shall be heated to l50~-.163C sprayed on the dry surface in a uniform manner with and the help of self-propelled mechanical sprayers having self-heating arrangement and bitumen pressure pump and spraying bar with nozzles having constant volume or pressure system capable of spraying bitumen uniformly at the rates specified in Table 500-13 and above mentioned temperature. Excessive deposits of binder caused by stopping or starting of the sprayer or through leakages or any other reason shall he corrected by blotting with sand before the stone chippings are spread. 508.1.3.4. Application of stone chippings: Immediately after the application of binder, stone chippings in a dry and clean state shall he spread uniformly on the surface by means of a self-propelled or towed mechanical grit spreader capable of spraying uniformly at rates specified in Table 500-13 so as to cover the surface completely. If necessary, The surface shall be broomed to ensure uniform spread of chippings. 508.1.3,5. RoIling: Immediately after the application of the cover material, the entire surface shall be rolled with a 80-100 kN smooth wheeled steel roller, 80-100 kN static weight vibratory roller, or other approved equipment. Rolling shall commence at the edges and progress towards the centre except in superelevated and uni-directional cambered portions where it shall proceed from the lower edge to the higher edge. Each pass of the roller shalt uniformly overlap not less
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than one-third of the track made in the preceding pass. While rolling is in progress, additional chippings shall be spread by hand in necessary quantities required to make up irregularities. Rolling shall continue until all aggregate particles are firmly embedded in the binder and present a uniform closed surface. 508.1.3.6. Application of second coat of surface dressing Where surface dressing in two coats is specified, the second coat shall he applied immediately after laying of the first coat. The construction operations for the second coat shall be the same as described in Clauses 508.1.3.3 to 508.1.3.5. 508.1.4. Opening to traffic : Traffic shall not be permitted to run on any newly surface dressed area until the following day. in special circumstances, however, the Engineer may open the road to traffic immediately after rolling, but in such cases traffic speed shall be limited to 16 km per hour till the following clay. 508.1.5. Surface finish and quality control of work: The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 508.1.6. Arrangements for traffic : During the period of construction, arrangement of traffic shall be done as per Clause 112. 508.1.7. Measurements for payment: Each coat of surface dressing shall be measured as finished work in square metres. 508.1.8. Rates: The contract unit rate for each coat of surface dressing shall be payment in full for carrying out the required operations including full compensation for all components listed it Clause 504.8 (i) to (vi). 508.2. TwoCoat Surface Dressing Using Cationic Bitumen Emulsion 508.2.!, Scope 508.2.1.1. This work shall consist of two-coat surface dressing, each coat consisting of a layer of cationic bitumen emulsion binder sprayed on a base prepared previously, followed by a cover of stone aggregate, properly roiled to form a wearing course to the requirements of these Specifications. 508.2.1.2. It shall, however, not be applicable to a single coat surface dressing using cationic bitumen emulsion.
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508.2.2. Material 508.2.2.1. Binder: The binder shall be a Cationic type bitumen emulsion of Rapid Setting ~RS)grade complying with 1.5. 8887 and having bitumen content 60 per cent minimum by weight. 508.2.2.2. Aggregate
(A)~General Requtrements: Clause 508.1.2.2. shall apply except the size requirement which shall be as given in Table 500-14. Wet aggregates can be used for surface dressing with Cationic bitumen emulsions and when aggregates are dusty, they should be cleaned by washing or by sprinkling water copiously. If the road surface is thy, a light sprinkling with waler shall be done. (B) Size: The aggregates shalt conform to the size given in Table 500-14,
TABLE 500.14. REQUIREMENTS OF STONE dIPPINGS FOR SURFACE DRESSING USING BITUMEN EMULSION I. .For first coat-13.2 mm size 2. Passing 22.4 mm sieve and retained on 11.2 mm sieve.
Ior second coat-6.7 mm size Passing 9.5 mm sieve and retained on 2.36 mm sieve. (C) QuantIties of Materials: The quantities of materials used for this work shalt be as given in Table 500-15. TABLE 50045. REQUIREMENTS OF MATERIALS USING BITUMEN EMULSION
MaterIal For 10 sq. m. area Cationic Bitumen Emulsion Aggregates
For FIrst Coat 12 to 14 kg 0.10 so 0.12 cu.m,
For Second Coat 16 to 18 kg 0.06 to 0.08 cu.m.
508.2.3. Construction operations 508.2.3.!. Weather limitations: Cationic bitumen emulsions should not normally be stored below 0C. However, surface dressing with Cationic bitumen emulsion should be carried out only when the atmospheric temperature is above 10C.The work can be carried out when the base is damp. All standing water in depressions shall, however, be removed. 508.2.3.2. Preparation of base: The existing base on which surface dressing is to be laid shall be prepared, shaped and corrected to a uniform grade and camber in accordance with Clause 501. The surface shall be cleaned to remove all loose particles, dust and loreign matter. It is preferable to spray water on the surface to settle the loose dust and also to expose clean surface of aggregates in the case of granular base courses. 508.2.33. Preparation of binder: Before opening, the Cationic bitumen emulsion drums should be rolled at slow speed, to and fro,
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Section 500
for a distance of about 10 metres, 5 to 6 times to mix the contents properly. 508.2.3.4. First Coat
(A) Application of Binder: Cationic bitumen emulsion binder can be applied on wet road surface. If the road surface is dry, light sprinkling with water shall he done. Cationic bitumen emulsion shall be sprayed uniformly on the prepared base by mechanical sprayers. In exceptional cases spraying from a spraying can may he resorted to at directed by the Engineer. The spraying can should have 6 mm diameter holes spaced 30 mm apart to prevent clogging. An emulsion tank of 30 litres capacity pressurized by compressed air from a hand pump and a 12 mm flexible pipe with a spray nozzle is a simple and efficient arrangement for spraying. (B) Application of aggregate: Immediately after spraying of Cationic emulsion, aggregate of 13.2 rum size shall be spread uniformly and evenly by mechanical means to cover the surface completely and evenly. Any oversize aggregate, if seen, shall be removed. (C) Rolling : Immediately after the application of cover material, the surface shall be rolled with 80-100 kN roller preferably by smooth wheeled tandem type. The rolling shall begin at the edge and proceed towards the centre, parallel so the centre line except in superelevated and unidirectional -.ambered porsionr where it shall proceed from the lower edge to the higher edge. While rolling, aggregates shall be added or removed so as to ensure a unifonnly covered surface. Each-pass of roller shall uniformly overlap not less than one third ol the track made in the preceding pass. Rolling shall continue for just enough time to embed the aggregates in the binder and present a uniform closed surface. Excessive rolling, resulting in crushing of aggregates shall be avoided.
508.2.3.5.
Second coat
(A) rune interval : The second coat of surface dressing shall be applied on the same day as the Isrst coat but at least not earlier than one hour after finishing the rolling of the first coat. (B) Application of emulsion: Traffic shall not be allowed on the first coat before the appi ication of second coat. If the aggregates of the first coat appear to be loose and unbonded - in few spots, the same shall not be disturbed. [he Caliortic bitumen emulsion for secoqd coat shall be sprayed by mechanical sprayer or in exceptional cases by using pouring can with the approval of the Engineer, taking care not to disturb the first layer while walking over it. (C) Application of aggregate: Immediately after the application of emulsion, 6.7 mm size aggregates shall be spread uniformly by mechanical means to cover the whole surface evenly. (II) Rolling: Rolling shall start soon after spreading the aggregates and all operations carried out as per Clause 508.2.3.4 (C) to achieve a uniform closed surface.
(E) Finishing: After one pass of the roller, depressions shall be filled with 6.7 mm size aggregate. If excess of aggregate is found in isolated spots, the bigger size aggregates shall be removed to give a uniform surface. Finish rolling on the next day helps to give a firm surface.
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Section 500
508.2.4. Opening to traffic: The road may be opened to traffic 4 hours after completing rolling of the second coat, but preferably the next day alter 24 hours. Where the road width is single lane, traffic can be allowed at slow speed of not more than 10 km per hour making sure to add aggregates and emulsion wherever the surface has been picked up by traffic. 508.2.5. Surface finish and quality control of work : The surface finish of construction shall conform to the requirements of Clause 902, Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 508.2.6. Arrangements for traffic : During the period of construction, arrangement of traffic shall be done to Clause i 12. 508.2.7. Measurements for payment : Two coats of surface dressing shall be measured as a fmished work in square metres, 508.2.8. Rate: The contract unit rate for two coats of surface dressing shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi). 508.3. Surface Dressing with Precoated Aggregate using Bitumen 508.3.1. Scope 508.3.1.1. The work shall consist of application of either a single coat or two coats of surface dressing over a previously prepared base, each coat consisting of application of bituminous binder sprayed on a base previously prepared followed by a cover of precoated materials properly rolled to form a wearing course to the requirements of these Specifications. 508.3.1.2. This Specification may be adopted in lieu of the conventional surface dressing to Clause 508.1, in situations where better adhesion is required between the aggregates and binder during construction and later in service. The technique is basically the same as conventional surface dressing except that a small quantity of binder is used for precoating the aggregates. However,., it is quite different from premix construction.
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Section 500
508.3.2. Materials 508.3.2.1. Bind~r:The binder shall be straight run bitumen of a suitable grade appropriate to the region, traffic and other environmental conditions and as directed by the Engineer and conforming to IS:73. 508.3.2,2. Aggregates : The aggregaS shall conform to Clause 504.2.2. They shall conforni to the quality requirements of Table 5(X)3 except that the water absorption shall be restricted to maximum of I per cent. The Stone Polishing Value as measured by BS 812 (Part114) shall not be less than 55. The size of the aggregates shall be .in accordance with Table 500-12. 508.3.2.3. Quantities of materials: The quantities of materials used for this work shall be as specified in Tables 500-12 and 500-13. 508.3.2.4. Precoating: The aggregates shall be precoated with 0.75 to 1.00 per cent of their weight with binder and shall not be precoated simultaneously with the surface dressing operation. The precoated aggrcgates shall be allowed to cure for at least one week so that they become non-sticky to facilitate easy spreading like normal uncoated aggregates. The aggregates, free of dust or fine parlicles shall be preheated to 160Cfor pr~coatingand then mixed with bitumen binder (0.75 to 1.00 per cent hy weight of aggreg~fte) heated to its application temperature. The aggregates and binder shall be thoroughly mixed in a mixer of approved type till the aggregates are uniformly coated. 508.3.3. Construction operations 508.3.3.1 Weather and seasonal limitations: Clause 504.3.1 shall apply. 508.3.3.2. Preparation of base: Clause 508.1.3.2 shall apply. 508.3.3.3. Application of binder: After deducfing the binder quantity consumed in precoating aggrega~e~ [or:.first coat in terms of para 508.3.2.4 from the quantities spn:sfiecl in Table 500-13, remaining binder of first coat shall be heated to 150-165C sprayed on the and clean and dry surface in a uniform manner preferably with the help of mechanical sprayers having self-heating arrangement, bitumen, pressure pump anti spray nozzle bar capable of spraying bitumen uniformly at tha4xates and temperatures specified above. Excessive deposits of binder caused by stoppage or starting of sprayer or through leakage or any other reason shall be corrected before stone chip~ingsare spread.
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Base
Section 500
508.3.3.4. Application of aggregates : Immediately after the application of binder, aggregates in a dry and clean state shall be spread uniformly on the surface preferably by means of a mechanical griLLer capable of spreading uniformly at the rates specified in Table 500-14 so as to cover the surface completely. If necessary, the surface shall be broomed mechanically or manually to ensure uniform spread of aggregates. 508.3.3.5. RoIling: Clause 508.1.3.5 shall apply. 508.3.3.6. Application of second coat of surface dressing : The second coat of surface dressing, where specified, shall be applied immediately after the first coat or soon after, depending upon the conditions at site and type of binder used. The construction operations for the second coat shall be the same as described in Clause 508.3.3.3. to 508.3.3.5. except that the rate of application of aggregates and binder for secnd coat shall be as specified in Table 500-13 after deducting binder consumed for precoating the aggregates required for second coat vide Clause 508.3.2.4. 508.3.4. Opening to traffic : Clause 508.1.4. shall apply. 508.3.5. Surface finish and quality control of work: The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 508.3.6. Arrangements for traffic : During the period of construction, arrangement of traffic shall be done to Clause 112, 508.3.7. Measurements for payment: Each coat of surface dressing .shall be measured as finished work in square metres. 508.3.8. Rates: The contract unit rate for each coat of surface dressing shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi). 509. OPEN-GRADED PREMIX CARPET 509.1. Open-graded Premix Carpet using Bitumen 509.1.1. Scope : This work shall Consist of laying and compacting an open-graded carpet of 20 mm thickness in a single course composed of suitable small-sized aggregates premtxed with a bituminous binder on a previously prepared base, in accordance with the requirements of these Specifications, to serve as a wearing course.
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Section 500
(Bituminous)
509.1.2. Materials 509.1.2.1. Binder: The binder shall be bitumen of a suitable grade appropriate to the region, traffic, rainfall anl other environmental conditions, as directed by the Engineer and satisfying the requirements of IS 73, 217, 454 or other approved cuthack as applicable. Guidance in this regard may be taken from Appendix 4.
-
509.1.2.2. Aggregates: The coarse aggregates shall conform to Clause 504.2.2.l.The Stone Polishing Value as measured by BS:812(Part 114) shall not be less than 55. The aggregates shall satisfy the quality requirements set forth in Table 500-3 except that the water absorption shall be limited to a maximum of I per cent. 509.1.2.3. Proportioning of materials: The materials shall be proportioned as per quantities given in Table 500-16.
TABLE 500.16. 2 OF ROAD QUANTITIES OF MATERIAlS REQUIRED FOR 10 m SURFACE FOR 20 mm THICK OPEN-GRADED PREMIX CARPET USING BITUMEN
Aggregates for Carpet

(a) (b) Stone chippinga-13.2 mm size; passing 22.4 mm steve and retained on 11.2 mm sieve Stone chippings-I1.2mm size passing 13.2 mm sieve and retained on 5.6 mm sieve Total Binder for Prembdng (quantities in terms of straight run bitumen) (a) (b) For 018 m5 of 13.2 mm size stone chippmgs at 52 kg per m 0.18m5
0.09s&
0.27&
9.5 kg 5.1 kg
14.6 kg.
For 0.09 m3 of 11.2 mm size stone chippings at 56 kg per m3

Total
509.13. Construction operations 509.13.1. Weather and seasonal limitations: Clause 504.3.1 shall apply. 509.1.3.2. Preparation of base: The underlying base on which the bituminous carpet is to be laid shall be prepared, shaped and conditioned to the specified lines, grade and cross-section in accordance with Clause 501. A prime coat where needed shall be applied in accordance with Clause 502 as directed by the Engineer.
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Section 500
509.1,3.3. Tack coat : A tack coat complying with Clause 503, shall be applied over the base preparatory to laying of the carpet. 509.1.3.4. Preparation of premix: Hot mix plant of appropriate capacity and type shall be used for the preparation of mix material. The hot mix plant shall have separate dryer arrangement for heating aggregates and pugmill for mixing aggregates and binder. The temperature of binder at the time of mixing shall be in the range of 150C to 163C and that of the aggregates in the range of 1550 C to 163C provided that the difference in temperature between the binder and aggregates at no time exceeds 14C. Mixing shall be thorough to ensure that a homogeneous mixture is obtained in which all particles of the aggregates are coated uniformly and the discharge temperature of mix shall be between 130C and 160C. The mix shall be immediately transported from the mixer to the point of use in suitable vehicles or wheel barrows. The vehicles employed for transport shall be clean and the mix being transported covered in transit if so directed by the Engineer. 509.13.5. Spreading and rolling: The mixed material shall be spread by suitable means. As soon as sufficient length of bituminous material has been laid, rolling shall commence with 80-100 kN rollers, preferably of smooth wheel tandem type, or other approved equipment. Rolling shall begin at the edge and progress toward the centre longitudinally, except that on the superelevated and uni-directional cambered portions, it shall progress from the lower to upper edge parallel to the centre line of the pavement. When the roller has passed over the whole area once, any high spots or depressions which become apparent shall be corrected by removing or adding premixed materials. Rolling shall then be continued until the entire surface has been rolled to compaction and all the roller marks eliminated. In each pass of th~ roller, preceding track shall be overlapped uniformly by at least 1/3 width. The roller wheels shall be kept damp to prevent the premix from adhering to the wheels and being picked up. In no case shall fuel/lubricating oil be used for this purpose. Excess use of water for this purpose shall be avoided. Rollers shall not stand on newly laid material while there is a risk that it will be deformed thereby. Rolling operations shall be completed in every respect before the temperature of the mix falls below l000C,
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Section 500
The edges along and transverse of the carpet lai,d and compacted earlier shall be cut to their full depth so as to expose fresh surface which shall be painted with a thin surface coat of appropriate binder before the new mix is placed against it. 509.1.3.6. Seal coat: A seal coat conforming to Clause 513 shall be applied to the surface immediately after laying the carpet. 509.1.4. Opening to traffic: No traffic shall be allowed on the road tilt the seal coat has been laid. After the seal coat is laid, the road shall be opened to traffi~ according to Clause 513.4. 509.1.5. Surface finish and quality control of work: The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 509.1.6. Arrangements for traffic: During the period of construclion, arrangement of traffic shall be done to Clause 112. 509.1.7. Measurements for payment: Open graded premix carpet shall be measured as finished work in square metres. 509.1.8. Rate: The contract unit rate for open-graded premix carpet shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8. 509.2. 20mm Thick Premix Carpet using Cationic Bitumen Emul.. sion .509.2.1. Scope: This work shall consist of laying and compacting an olen graded premix carpet of 20mm thickness with Cationic bitumen emulsion placed on a previously prepared base in accordance with the requirements of these Specifications to serve as a wearing course. 509.2.2. Materials 509,2.2.1. Binder: The binder shall be Cationic bitumen emulsion of Medium Setting (MS) grade complying with IS: 8887 and having bitumen content 60 per cent minimum by weight. For liquid seal coat MS grade can be used, but it is preferable to use Rapid Setting (RS) grade of Cationic bitumen emulsion. However, for premix seal coat Stow Setting (SS) grade Cationic bitumen emulsion shall be used. 509.2.22. Coarse aggregates : C!ause 509.1.2.2. shall apply. Aggregates should be cleaned by washing or by spriniding water copiously. The coarse aggregates shall satisfy the quality requirements set forth
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Section 500
in Table 500-3, except that the water absorption value shall be limited to a maximum of I per cent. Stripping value is not to be considered unless directed by the Engineer. Water absorption up to 2 per cent may be permitted in exceptional cases only. 509.2.2.3. Fine aggreg~tes~ Fine aggregates for seal coat shall be crushed stone chips or coarse sand, clean, uncoated and free from clay, dust and other deleterious matter. 509.2.3. Quantities of materials required: The materials shall be proportioned as per quantities given in Tables 500-17 and 500-18.
TABLE 500.17. QUANTITIES OF AGGREGATES FOR 10 nsa AREA (A) Prembi Carpet
(a)
Coarse aggregate 13.2 mm size; passing 0.18 m 0.09 in
Is 22.4 mm sieve and retained on IS 11.2 mm sieve (b) Coarse aggregate 11.2 mm size; passing Is 13.2 mm sieve and retained on IS 5.6 mm sieve (B) For Seal Coat:
(a) Liquid seal coat:~
Crushed fine aggregates 6.7 mm size; passing IS 9.5 mm sieve and retained on Is 2.36 mm sieve
(b) Premix seal coat: Coarse sand or stone grit passing 2.36 mm sieve and retained on 180 micron sieve TABLE 500.18. QUANTITIES OF BINDER
0.06 m
0.06 rn~
(A) For Tack Coat (i) (ii) Normal bituminous surfaces Dry and hungry bituminous surface
For 10m2 area 2.0 to 2.5 kg 2.5 to 3.0 kg 2.5 to 3.0 kg 3.5 to 4.0 kg 2.5 to 4.0 kg 20 to 23 kg 12 to 14 kg 10 to 12 kg
(iii) Granular surfaces treated with primer (iv) Non bituminous surfaces:
(a) (b) (B) Granular base (not primed) Cement concrete surface
For Premix Carpet: (a) (b) for liquid seal coat for premix seal coat
(C) For Seal Coat:
509.2.3,1. Aggregates 509.2.4. Construction operations 509.2.4.1. Weather limitations: Cationic bitumen emulsions shall
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Section500
(Bituminous)
not normally be stored below 0C.However, premix carpet work with Cationic emulsion shall be carried out only when the atmospheric temperature is above 10C. 509.2.4.2. Preparation of base: The underlying base on which the premix carpet is to be laid shall be prepared, shaped and conditioned to the specified lines, grades and cross-sections in accordance with Clause 501. The cleaned surface can be finally washed with water, if it is readily available. 509.2.4.3. Preparation of binder: Clause 508.2.3.3 shall apply. 509.2.4.4. Tack coat: Clause 508.2,3.4 (A) shall apply. Tack coat shall be applied not earlier than 10 minutes before spreading the premix. On water bound macadam surface, water shall be sprayed to make the surface damp before applying tack coat. 509.2.4.5. Preparation of premix: Premixing of Cationic bitumen emulsion and aggregates can be done in a suitable mixer such as cold mixing plant as per IS~ 5435 (Revised) or concrete mixer or by shovels in exceptional cases with the approval of the Engineer. However, for large works, continuous mixing operation can be done either in batch or continuous mixer units suitable for. emulsion mixes. When using concrete mixer for preparing the premix, 0.135 cu.m. (0.09 cu.m. of 13.2 mm size and 0.045 cu.m. of 11.2 mm size) of aggregates per batch may be used as this quantity will cover 5 sq.m. of road surface with 20 mm average thickness. The aggregates required for one batch should be kept ready near the mixer. The aggregates shall be cleaned free from dust and dirt, if any, by dipping or washing or copiously sprinkling water. First the coarse aggregates of 13.2 mm size shall be charged into the mixer followed by 5 to 6.5 kg of Cationic bitumen emulsion and then 11,2 mm size aggregates are added, followed by 5 to 6.5 kg of Cationic bitumen emulsion. After the materials have been mixed thoroughly, the mix shall be immediately transported to the laying site in suitable vehicles. Too much mixing shall be avoided as it may result in decoaiing of aggregates. Because of ease of mixing, Cationic bitumen emulsion and aggregates can be mixed manually by shovels when mechanical mixer is not available or when the work is too small, with the approval of the Engineer. 0.06 cu. m. of aggregates can be conveniently mixed in one heap, with appropriate quantity of emulsion. It is preferable to
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Base and Surface
Section 500
make the aggregates damp before mixing as it reduces the effort required for mixing and also helps to get better coating of aggregates. The 13.2 mm size aggregates and emulsion are mixed first and then the 11.2 mm size aggregates and remaining quantity of emulsion are added and mixed. Too much mixing shall be avoided as it will result in decoaiing of aggregates. 509.2.4.6. Spreading of mix: The premixed caiionic bitumen emul. sion and aggregates shall be spread within 10 minutes of applying the tack coat. The mix is easily workable for about 20 minutes after mixing and hence all levelling, raking, etc., should be completed within this time for easy workability. The mix should be spread uniformly to the desired thickness,
grades and crossfall (camber) making due allowance for extra quantity
required to fill
up depressions, if any. The crossfall
should be
checked by means of camber boards and inequalities evened out. Too
much use of blades or rakes should be avoided. 509.2.4,7. Rolling: The rolling shall start immediately after laying the premix. Smooth wheeled tandem roller of 80.100 kN shall be used preferably, though three wheeled steel roller of equivalent capacity can also be used. While rolling, wheels of roller should be clean and kept moist to prevent the premix from adhering to the wheels and being picked up. In no case shall fuel/lubricating oil be used for this purpose. Excessive use of water for this purpose shall also be avoided. Rolling shall commence at the edges and progress towards the centre longitudinally except in case of superelevated and uni-directional cambered sections where rolling shall be done from lower edge towards the higher edge parallel to the centre line of the road. After one pass of roller over the whole area, depressions or uncovered spots should be corrected by adding premix material. Rolling shall be continued until the entire surface has been rolled to compaction and all the roller marks eliminated. In each pass of the roller, preceding track shall be overlapped uniformly by at least 1/3 width, Roller(s) shall not stand on newly laid material while there is a risk that it will be deformed thereby. At joints, the edges along the transverse of the carpet laid and compacted earlier shall be cut to their full depth so as to expose fresh surface which shall be painted with a thin surface coat of binder before the new mix is placed against it. 509.2.4.8. Seal coat: A seal coat, liquid or premix type, shall be applied 4 to 6 hours after laying the premix carpet.
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Section 500
(Bituminous)
Liquid seal coat: Quantities of the materials required are given in Tables 500-17 and 500-18.
For application of binder Clause 508.2.3.4 (A) shall apply.
Immediately after spraying emulsion, stone chips in a clean state shall be spread uniformly, preferably by means of a mechanical gritter, otherwise manually so as to cover the surface completely. Start rolling with 60-80 kN roller soon after spreading the chips. The rolling operation shall be as indicated in 509.2.4.7 as far as applicable. Premix seal coat: The quantities of aggregate and binder to be used shall be as given in Tables 500-17 and 500-18. Grit or sand used for premix seal coat should be made thoroughly wet with wat~rbefore mixing with emulsion of slow setting grade. The mixing, spreading and rolling etc. shall be carried out as per Clauses 509.2.4.5 to 509.2.4.7 except for the quantities and materials which shall be for premix seal coat. Rolling shall be continued till the premi~material completely seals the voids in the premix carpet and smooth uniform surface is obtained. 509.2.5. Opening to traffic : Traffic should not be allowed over the premix surface with or without seal coat, for 6 to 8 hours after rolling. In case of single lane roads, traffic may be allowed at slow speed not exceeding 10 km per hour. If any premix material gets picked tip by vehicle tyres, the spot shall be filled up by new mix. It is preferable to open the road to traffic the next day after 24 hours. 509.2.6. Surface finish and quality control : The surface finish of construction shall conform to the requirements of Clause 902. The control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900, 509.2.7. Arrangements for traffic : During the period of construction, arrangement of traffic shall be done to Clause 112. 509.2.8. Measurements for payment : The premix carpet and seal coat shall be measured as finished work in square metres. 509.2.9. Rates : The contract unit rate for premix carpet arid seal coat shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi).
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Base and Surface Courses (Bituminous) 510. MIX SEAL SURFACING
Section 500
510,1. Scope 510.1.1. This work shall consist of laying and compacting mix seal surfacing in a single course composed of suitable aggregates premixed with a bituminous binder on a previously prepared base, in accordance with the requirements of these Specifications, to serve as a wearing course. 510.1.2. Mix seal surfacing shall be of Type A or Type B as specified. 510.2. Materials 510.2.1. Binder: Clause 509.1.2.1 shall apply. 510.2.2. Coarse aggregates: Clause 509.1.2.2 shall apply. 510.2.3. Fine aggregates: The fine aggregates shall consist of crusher run screening, natural gravel/sand or a mixture of both. These shall be clean, hard, durable, uncoated, dry and free from injurious, soft or flaky pieces and organic or deleterious substances. 510,2.4. Aggregates gradation: The coarse and fine aggregates shall be so graded or combined as to conform to the grading set forth in Table 500-19.
TABLE 500.19. AGGREGATES GRADATION IS Sieve Designation
FOR MIX SEAL SURFACING
Per cent by weight p asslng the steve For Type A Mtx Seal Surfacing For Type B Mix Seal Surfacing
13.2 mm 11.2 mm 5.6 mm 2.8 mm 90 micron
100 88.100
31-52 5-25 0.5
100
52-88 14-38 0.5
510.2.5. Proportioning of materials : The total quantity of aggregates used for Type A or B mix seal surfacing shall be 0.27 cubic metre per 10 square metres area. The quantity of binder used for premixing in terms of straight-run bitumen shall be 22.0 kg and 19.0 kg per 10 square metres area for Type A and Type B surfacing respectively. 510.3. Construction Operations Clause 509.1.3.1 through 509.1.3.5 shall apply.
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Section 500
510.4. Opening to Traffic Traffic may be allowed after completion of the final rolling when the mix has cooled down to the surrounding temperature. 510.5. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 510.6. Arrangements for Traffic During the period of construction, arrangement of traffic shall be done to Clause 112. 510.7. Measurements for Payment Mix seal surfacing, Type A or 13 shall be measured as finished work in square metres. 510.8. Rate The contract unit rate for mix seal surfacing, Type A or B shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi), 511. SEMI-DENSE BITUMINOUS CONCRETE 511.1. Scope This work shalt consist of construction in a single course of semidense bituminous concrete binder/wearing course on a previously prepared bituminous base to the requirements of the Specifications. 511.2. Materials 511.2.1. Binder: Clause 504.2.1 shalt apply 511,2.2. Coarse aggregates: Clause 504.2.2 shall apply. The Stone Polishing Value as measured by BS 812 (Part114) shall not be less than 55. The aggregates shall satisfy the physical requirements as given in Table 500-3 except that the maximum value of water absorption shall be I per cent. However, water absorption upto a maximum of 2 per cent may be permitted in exceptional cases only. 51 1.2.3. Fine aggregates: Clause 507.2.3 shalt apply 511.2.4. Filler: Clause 507.2.4 shall apply. 511.2.5. Aggregates gradation: The mineral aggregates including
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Section 500
filler shall be so graded or combined as to conform to the grading set forth in Table 500-20.
TABLE 500.20. AGGREGATES GRADATION FOR SEMI-i)ENSE B11UMINOUS
CONCRETE
IS Sieve Designation 22.4 mm 13.2 mm 11.2 mm Per cent by weight passing the IS sieve Grading_1
.
Grading_2 100 85-100 70-92 42-64 22-38 11-24 7-18 5-13 3-9
Grading_3 100
79-100 68-90
100
88-100
42-64 22-38 11-24 7-18 5-13 3-9
5,6 mm
2.8 710 355 mm micron micron micron micron
33.55
22-38 6-22 4-14 2-9
180
90 Note:
0-5
Grading 1 shall be adopted for 25 mm compacted thickness and Grading 2/3 for higher thicknesses.
511.3. Mix Design
511.3.1. Requirements of mix: Semi-dense bituminous concrete mix shall he properly designed so as to satisfy the criteria laid down in Table 500-21.
TABLE
1. 500-21.
REQUIREMENTS OF SEMI-DENSE BITUMINOUS CONCRETE MIX

820 kg (1800 lIss) Minimum
2-4 3-5 13.15 (for 13.2 mm max size) 11-13 (for 22.4 mm max size) 65-75 Not less than 4.0 per cent
Marshall Stability (ASTM Designation: D 1559) determined on Marshall specimens compacted with 75 compaction blows on each end Marshall flow (mm) Per cent air voids in mix Per cent air voids irs mineral aggregate (VMA) (Minimum)
2. 3. 4.
5. 6.
Per centage voidt in mineral aggregates filled with bitumen
(VFB)
Binder content, per cent by weight of mix
Notet : 1. 2. 3.
Higher stability values consistent with other requirements should be achieved as far as possible. At bus stops, parking areas and roundabouts near minimum flow value should be adopted. Attempt should be to have well graded aggregates and the per cent voids in the mix closer t.o the lower limit. 187
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Base and
Surface Courses (Bituminous)
511.3.2. Binder content: The binder content shall be so fixed as to achieve the requirements of the mix set forth in Table 5002!. Marshall Method for arriving at the binder content shall be adopted. 511.3.3. Job mix formula: Clause 507.3.3 shall apply. 511.3.4. Permissible variation from job mix formula: The Contractor shall have the responsibility of ensuring proper proportioning of materials in accordance with the approved job mix formula and producing a uniform mix. The permissible variations of the individual percentages of the various ingredients in the ac.tual mix from the job mix formula may be within the limits as specified in Table 500-22. These variations are intended to apply to individual specimens taken for quality control tests vide Section 900.
TA BLE 500-22. S,No.
PERMISSIBLE VARIATIONS FROM JOB MiX FORMULA

PennSslble jariatlon by weight ci total mix In percentage 8 7 6 5 4 2 0.3 10C
Description of ingredient
I. 2. 3. 4.
5.
6. 7. 8.
Aggregate passing 13,2 mm sieve and larger sieves Aggregate passing 11.2 mm sieve and 5.6.mm sieve Aggregate passing 2.8 nun sieve and 1.40 mm sieve Aggregate passing 710 micron sieve and 355 micron sieve Aggregate passing 180 micron sieve Aggregate passing 90 micron sieve Bitumen Mixing Temperature
511.4. Construction Operations 511.4.1. Weather and seasonal limitations: Clause 504.3.1 shall apply. 511.4,2. Preparation of base : The base on which semi-dense bituminous concrete is to be laid.shall be prepared, shaped and conditioned to the specified lines, grades and cross-sections in accordance with Clause 501 or as directed by the Engineer. 511.4.3. Tack coat : A tack coat as per Clause 503 shall be applied on the base. 511.4.4. Preparation of mix: Clause 507.4.4 shall apply. 511.4.5. Spreading of mix: Clause 507.4.5 shall apply. 511.4.6. Itolling: Clause 507.4,6 shall apply. 511.5. opening to Traffic Traffic may be allowed after completion of the final rolling when the mix has cooled down to the surrounding temperature.
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511.6. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 511.7. Arrangements for Traffic During the period of construction, arrangement of traffic shall be done to Clause 112. 511.8. Measurements for Payment Semi-dense bituminous concrete shall be measured as finished work in cubic metres or tonnes as directed by the Engineer. 511.9. Rate The contract unit rate for semi-dense bituminous concrete shall be payment in full for carrying out the required operations including full compensation for aH components listed in Clause 504.8 (i) to (vi). The rate shall cover the provision of bitumen in the mix at 4.5 per cent of the weight of the total mix, with the provision that the variation of quantity of bitumen will be assessed and the payment adjusted as per the rate of bitumen coated. 512. BITUMINOUS CONCRETE 512.1. Scope This work shall consist of constructing in a single layer, bituminous concrete (asptialtic concrete) of thickness 25 100 mm on previously prepared bituminous course to the requirements of these Specifications. 512,2. Materials
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512.2.1. Bitumen: Clause 507.2.1 shall apply. 512.2.2. Coarse aggregates : Clause 507.2.2 shall apply. The Stone polishing Value as measured by BS : 812 (Part 114) shall not ~e les~thai 55. The aggregates shall satisfy the physical requirements as given i~ Table 50~-8except that the maximum value for the water absorption should be I per cent 512.2.3. Fine aggregates : Clause 507.2.3 shall apply. 512.2.4. Filler : Clause 507.2.4 shall apply. 512.2.5. Aggregates gradation : The mineral aggregates, including
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thineral filler shall be so graded or combined as to conform to the grading set forth in Table 500-23.
TABLE 500-23.
AGGREGATES
GRADATiON FOR BITUMINOUS CONCRETE Per cent passing the sieve by weight
15 Sieve Designation 26.5 19 9.5 4.75 2.36 300 mm mm mm mm mm micron micron
100
90-100 56-80 35-65 23-49 5-19 2-8
75
512.3. Mix Design 512.3.1. Requirement of mix: Apart from conformity with the grading and quality requirements of in~1ividualingredients, the mix shall meet the requirements set forth in Table 500-24.
TABLE 500.24. REQUIREMENTS OF BITUMiNOUS
S,No. L Description Marshall stability (ASTM Designation: D-1559) determined on Marshall specimens compacted by 75 compaction blowt on each end Marshall flow (mm) Per cent Per cent Per cent filled by air voids in mix voids in mineral aggregate (VMA) voids in mineral aggregates bitumen (VFB) CONCRETE
MIX
Requirements 820 kg (1800 Ib) Minimum 2-4 3-5
2. 3. 4. 5. 6. 7. 8.
Minimum 11-13 per cent 65-75 Minimum 4,5 Mm. 75 per cent retained strength 1.5 per cent Max,
Binder content, per cent by weight of total mix Water Sensitivity (ASTM D1075) Loss of stability on immersion in water at 60C Swell Test (Asphalt Instt, MS-2, No, 2)
512.3.2. Binder content: The binder content shall be so fixed as to achieve the requirements of the mix set forth in Table 500-24. Marshall method for arriving at the binder content shall be adopted. 512.3.3. Job mix formula: Clause 507.3.3 shall apply except that the requirement of Bituminous Concrete mix shall be as per Table 50024. 512.3.4. Permissible variations from the job mix formula: The Contractor shall have the responsibility of ensuring proper proportioning of materials in accordance with the approved job mix formula
and producing a uniform mix. The permissible variations of individual
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percentages of various ingredients in the actual mix from the job mix formula may be within the limits as specified in Table 5O0~l . These 1 variations are intended to apply to individual specimens taken for quality control tests vide Section 900. 512.4. Construction Operations 512.4.1. Weather and seasonal limitations: Clause 504.3.1 shall apply. 512.4.2. Preparation of base: The base on which bituminous concrete is to be laid shall be prepared, shaped and conditioned to the specified levels, grade and crossfall (camber) in accordance with Clause 501 or as directed by the Engineer. The surface shall be thoroughly swept clean free from dust and foreign matter using mechanical broom and dust removed by mechanical means or blown off by compressed air. In portions where mechanical means cannot reach, other approved method shall be used. 512.4.3. Tack coat: A tack coat complying with Clause 503 shall be applied over the base. 512.4.4. Preparation of mix: Clause 5074.4 shalt apply. 512.4.5. Spreading: Clause 507.4.5 shall apply. 512,4.6. Rolling: Clause 5074.6 shall apply. 512.5. Opening to Traffic Traffic may be allowed immediately after completion of the final rolling when the mix has cooled down to the surrounding temperature. 512.6. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shalt be exercised by the Engineer in accordance with Section 900. 512,7. Arrangements for Traffic During the period of construction, arrangement of traffic shall be done to Clause 112. 512.8. Measurements for Payment Bituminous concrete shall be measured as finished work in cubic metres or tonnes as provided in the Contract.
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Section 500 512.9. Rate
The contract unit rate for bituminous concrete shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi). The rate shall cover the provision of bitumen in the mix at 5.0 per cent of the weight of the total mix with the provision that variation of quantity of bitumen wilt be assessed and the payment adjusted as per the rate of bitumen quoted. 513. SEAL COAT 513.1. Scope 513.1.1. This work shall consist of application of a seal coat for sealing the voids in a bituminous surface laid to the specified levels, grade and cross fall (camber). 513.1.2. Seal coat shall be of either of the two types as specified below:
(A) Liquid seal coat comprising of an application of a layer of bituminous binder followed by a cover of stone chippings. (B) Prernixed seal coat comprising of a thin application of fine aggregates premixed with bituminous binder.
513.2. Materials
513.2.1. Binder: Clause 509.i.2.1 shalt apply. The quantity of bitumen shall be 9.8 kg and 6.8 kg per 10 square metres area for Type (A) and Type (B) seal coat respectively. 513.2.2. Stone chippings for type (A) seal coat : The stone chippings shall consist of angular fragments of clean, hard, tough and durable rock of uniform quality throughout. They should be free of elongated or flaky pieces, soft or disintegrated stone, organic or other deleterious matter. Stone chippings shalt be of 6.7 mm size defined as 100 per cent passing through 112 mm sieve and retained on 2.36 mm sieve. The quantity used for spreading shall be 0.09 cubic metre per 10 square metres area. The chippings shall satisfy the quality requirements spelt out in Table 500-3 except that the upper limit for water absorption value shall be 1 per cent. 513.2.3. Aggregates for type (B) seal coat : The aggregates shall be sand or grit and shall consist of clean, hard, durable, uncoated dry particles and shall be free from dust, soft or flaky/ elongated material, organic matter or other deleterious substances.
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The aggregate shall pass 2.36 mm sieve and be retained on 180 micron sieve. The quantity used for premining shall be 0.06 cubic metre per 10 square metre area. 513.3. Construction Operations 513.3.1. Preparation of base: The seal coat shall be applied immediately after the laying of bituminous course which is required to be sealed. Before application of seal coat materials, the surface shall be cleaned free of any dust or other extraneous matter. 513.3.2. Construction of type (A) seal coat: The binder shall be heated in boilers of suitable design, to the temperature appropriate to the grade of bitumen approved by the Engineer, and the seal coat applied in accordance with the construction operations described in Clauses 508.1.3.3 through 508.1.3.5. 513.3.3. Construction of type (B) seal coat: Mixer of appropriate capacity and type shall be used for preparation of mix material. The plant shall have separate dryer arrangement for heating aggregate and pugmill for mixing aggregate and binder. The binder shall be heated in boilers of suitable design, to the temperature appropriate to the grade of bitumen approved by the Engineer. Also the aggregates shall be dry and suitably heated to a temperature directed by the Engineer before the same are placed in the mixer. Mixing of binder with aggregates to the specified proportions shall be continued till the latter are thoroughly coated with the former. The mix shall be immediately transported from the mixing plant to the point of use and spread uniformly on the bituminous surface to be sealed. As soon as sufficient length has been covered with the premixed material, the surface shall be rolled with 80-100 kN smooth-wheeled roller. Rolling shall be continued till the premixed material completely seals the voids in the bituminous course and a smooth uniform surface is obtained. 513.4. Opening to Traffic In the case of type (B) seal coat, traffic may be allowed soon after final rolling when the premixed material has cooled down to the surrounding temperature. However, as regards type (A) seal coat, Clause
508.1.4 shall apply.
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513.5. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 513.6. Arrangements for Traffic During the period of construction, arrangement of traffic shall be done to Clause 112. 513.7. Measurements for Payment Seal coat, Type (A) or (B) shall be measured as finished work in square metres. 513.8. Rate The contract unit rate for seal coat, Type (A) or (B) shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (i) to (vi). 514. SUPPLY OF MINERAL AGGREGATES FOR PAVEMENT COURSES 514.!. Scope These Specifications shall apply to works where it is intended only to collect, transport and stack the mineral aggregates and mineral filler for use in pavement courses. The actual work of laying the courses shall, however, be governed by the Specifications for the same, given elsewhere in these Specifications. The size and quantities of the aggregates to be supplied shall be so selected by the Engineer that the grading requirements set forth in these Specifications for the courses for which the supply is intended are satisfied. All the materials shall be procured from approved sources and shall conform to the physical requirements, specified in the respective Specifications for the individual items given elsewhere in these
Specifications.
514.2. Sizes of Mineral Aggregates The mineral aggregates shall be designated by their standard sizes in the Contract and shall conform to the requirements set forth in Table 500-25.
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TABLE 500-25. SIZE REQUIREMENTS FOR MINERAL AGGREGATES Coarse Aggregate S.No. Standard size of aggregates Designation of sieve through which the aggregates shall wholly pass 106 mm 90mm 53 mm 45 mm 26.5 mm 22.4 mm 13.2 mm 11.2 mm Designation of
sieve on which the aggregates

shall wholly be retained 63 mm 53mm 26.5 mm 22.4 mm 13.2 mm 11.2 mm 6.7 mm 2.8 mm
(i) (ii) (iii) (iv) (v)

(Vi)
75 mm 63mm 45 mm 26.5 mm 22.4 mm 13.2 mm 11.2 mm 6.7 mm
(vii) (viii)
514.3. Stacking 1. Coarse Aggregates Only the aggregates satisfying the Specification requirements shall be conveyed to the roadside and stacked. Each size of aggregate shall be stacked separately. Likewise, materials obtained from different quarry sources shall be stacked separately. 2. Fine Aggregates : As given in relevant Specifications. The aggregates shall be stacked entirely clear of the roadway on even ground, or platform prepared in advance for the purpose by the Contractor at his own cost and in a manner that permits of correct and ready measurement. Materials shall not be stacked in locations liable to inundation or floods. The dimensions of the stacks and their location shall be as approved by the Engineer. Where the material is improperly stacked, the Engineer shall have the right to order complete re-stacking of the materials to specifications at the cost of the Contractor. Mineral filler shall be supplied in dry state in bags or other suitable containers approved by the Engineer and shall be protected from weather dampness, etc., so as to prevent deterioration in quality.
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514.4. Quality Conlrol of Materials The Engineer shall exercise control over the quality of the materials
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so as to ascertain their conformity with the Specification requirements, by carrying out tests for the specified properties. Testing shall be to the following frequencies and the Engineer shall have the right to modify these according to the needs.
Coarse and fine aggregates Mineral filler : One test for each specified property per 50 m 3 of material. One test for each specified property for every five tonnes, subject to a minimum of one test for each consignman.
Materials not conforming to the Specification requirements shall not be brought to the work site. 514.5. Measurements for Payment Coarse and fine aggregates supplied at site of works shall be paid for in cubic metres. The actual volume of the aggregates to be paid for shall be computed after deducting the specified percentages from the volume computed by stack measurements in Table 500-26.
TABLE 500.26. PER CENT REDUCTION IN VOLUME OF AGGREGATES S.No. Standard size of aggregates 75 mm and 63 mm 45 mm and 26.5 mm 22.4 mm, 13.2 mm, Fine aggregate 11.2 mm and 6.7 mm Percentage reduction In volume computed by stack meamrensents to arrive at the volume to be paid for 123 10.0 5.0 5.0
1. 2. 3. 4.
Unless otherwise directed, measurements shall not be taken until sufficient materials for use on the road have been collected and stacked. Immediately after measurement, the stacks shall be marked by white wash or other means as directed by the Engineer. Mineral filler as delivered at site of works shall be measured in tonnes. 514.6. Rates The contract unit rates for different sizes of coarse aggregates, fine aggregates and mineral filler shall be payment in full for collecting, conveying and stacking or storing at site of works including full compensation for
(i) (ii) all royalties, fees, rents where necessary; all leads and lips; and
(iii) all labour, tooIs..equipi~ents and incidentals to complete the work to the Speci. fications.
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Base and
Surface Courses (Bituminous) 515. BITUMEN MASTIC
Section 500
515.1. Scope 515.1.1. This work shall consist of constructing a single layer of 25 mm to 50 mm thick Bitumen Mastic wearing course for road pavements and bridge decks. The bitumen mastic shall be laid over a Dense Bituminous Macadam base in case of road pavements and over a Cement Concrete base in bridge decks. 515.1.2. The Bitumen Mastic is an intimate homogeneous mixture of selected well-graded aggregates and bitumen in such proportions as to yield a plastic and voidless mass, which when applied hot can be trowelled and floated to form a very dense impermeable surfacing 515.2. Materials 515.2. 1. Bitumen: The binder shall be straight-run bitumen of a suitable grade satisfying the requirements of IS:73 or industrial bitumen as per IS:702. It shall be paving bitumen of Grade S 35 (30/40 penetration grade) or any other appropriate grade as directed by the Engineer. The requirements of physical properties of bitumen are as given in Table 500-27.
TABLE 500.27. REQUIREMENTS OF PHYSICAL PROPERTIES OF BITUMEN S.No. 1. 2. 3. 4. 5. Characteristic Penetration at 25C (in 1/100 cm) Softening point (Ring and Ball Method) Ductility at 27C(Minimum) Loss on heating (Maximum) Solubility in CS 2 (Minimum) Requirement 20 to 40 50C to 90C 10 cm 3 per cent 99 per cent Method of tests IS; 1203 IS; 1205 15: 1208 IS: 1212 IS; 1216
515.2.2. Coarse aggregates: The coarse aggregates shall consist of hard, durable crushed stones, which shall be clean, strong, free of disintegrated pieces, organic and other deleterious matter and adherent coatings. They shall be hydrophobic and of low porosity and shall satisfy the physical requirements given in Table 500-3 except that the maximum value of water absorption shall be 1 per cent. The percentage and grading of the coarse aggregates to be incorporated in the bitumen mastic depending upon the thickness of the finished course shall be as in Table 500-28.
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500
Type of work Thickness of Finished Course (mm)
Base and Surface Courses (Bituminous) GRADING AND PERCENTAGE OF COARSE AGCREGATES Percentage of Coarse Aggregates Grading of Coarse Aggregates Passing ts. Sieve Percentage 100 88-96 0-5
TABLE 500.28. S.No.
1.
Wearing course for pavement & bridge deck
(a) (b)
2.5-40 41.50
(a) (b)
30-40 40-50
19 mm 13.2 mm 2.36 mm
515.2.3. Fine aggregates: The fine aggregates shall be the fraction passing 2.36 mm and retained on 75 micron sieve consisting of crusher run screening, natural sand or a mixture of both. These shall be clean, hard, durable, uncoated, dry and free from any injurious soft or flaky pieces and organic or deleterious substances. 515.2.4. Filler: The filler shall be limestone powder passing 75 micron sieve and shall have a calcium carbonate content of not less than 80 per cent by weight when determined in accordance with IS: 1195. The grading of the fine aggregates inclusive of filler shall be as given in Table 500-29.
TABLE 500-29. GRADING OF FINE AGGREGATES (INCLUSIVE OF FILLER) S.No. 1 2 3 4 IS. Sieve Passing 2.36 600 212 75 mm micron micron micron IS. Seive Retained 600 212 75 micron micron micron
Percentage by Weight 0.25 5-35 10-20 30-50 14-17
Bitumen Binder
515.3. Mix Design 515.3.1. Hardness number : The bitumen mastic shall have a hardness number of 60 to 80 at 25Cwithout coarse aggregates and 10 to 20 at 25C after adding coarse aggregates. The hardness number shall be determined in accordance with the method specified in IS: 1195. 515.3.2. Binder content: The binder content shall be so fixed as to achieve the requirements of the mix set forth in Clause 5 15.3.1. and shall be in the range of 14 to 17 per cent by weight of total mix as indicated in Table 500-29. 515.3.3. Job mix formula: The Contractor shall intimate the
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(Bituminous)
Section 500
Engineer in writing at least 20 days before the start of the work, the job mix formula proposed to be used by him for the work, indicating the source and location of all materials, proportions of all materials such as binder and aggregates, single definite percentage passing each sieve for the mixed aggregates and results of the tests recommended in various Tables and Clauses of this Specification. 515.4. Construction Operations 515.4.1. Weather and seasonal limitations: Clause 504.3.1 shall apply. 515.4.2. Preparation of the base: The base on which bitumen mastic is to be laid shall be prepared, shaped and conditioned to the specified levels, grade and crossfall (camber) in accordance with Clause 501 or as directed by the Engineer. In case of a cement concrete base, the surface shall be thoroughly swept and scraped clean and free of dust and other deleterious matter. Under no circumstances shall bitumen mastic be spread on a base containing a binder which will soften under high application temperatures. if any such spots or area are there, the same shall be cut out and repaired before the bitumen mastic is laid. 515.4.3. Tack coat : A tack coat as per Clause 503 shall be applied on the base or as directed by the Engineer: 515.4.4. Preparation of bitumen mastic : Preparation of bitumen mastic consists of two stages. The first stage shall be mixing of filler and fine aggregates and then heating the mixture to a temperature of 170Cto 200C~equired quantity of bitumen shall be heated to 170C R to 180C and added to the heated aggregate. They shall be mixed and cooked in an approved type of mechanically agitated mastic cooker for some time till the materials are thoroughly mixed. Initially the filler alone is to be heated in the cooker for an hour and then h~iJfhe quantity t of binder is added. After heating and mixing for some time, the tine aggregates and the balance of binder are to be added and further cooked for about one hour. The second stage is incorporation of coarse aggregates and cooking the mixture for a total period of 3 hours. During cooking and mixing, care shall be taken to ensure that the contents in the cooker are at no time heated to a temperature exceeding 200C. In case where the material is not required for immediate use it shall be cast into blocks with filler, fine aggregates and binder, weighing about 25 kg each. These blocks when required to be used, have to
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Base
and Surface Courses (B iturninous)
be reheated in the mechanically agitated cooker to a temperature of not less than 170Cand not more than 200C,thoroughly incorporated with the requisite quantity of coarse aggregates and mixed continuously for not less than an hour. Mixing shall be continued until laying operations are completed so as to maintain the coarse aggregates in suspension. At no stage during the process of mixing shall the temperature exceed 200C. The bitumen mastic blocks (without coarse aggregates) shall show on analysis a composition within the limits as given in Table 500-30.
TABLE 500.30. COMPOSITION OF BITUMEN MASTIC -BLOCKS WITHOUT COARSE AGGREGATES I.SSieve Passing 236 600 212 75 mm micron micron micron IS. Sieve Retained 600 212 75
Percentage by weight
.
Minimum micron micron micron 0 4 8 25 14
Maximum 22 30 18 45 17
Bitumen Content
The mix shall be transported to the laying site in a towed mixer transporter having arrangement for stirring and keeping the mix hot during transportation. 515.4.5. Spreading: The bitumen mastic shall be deposited directly on the prepared base immediately in front of the spreader where it is spread uniformly by means of wooden floats to the required thickness. The mix shall be laid in one metre width cOntained between angle iron of sizes suitable to retain the required thickness. The temperature of the mix at the time of laying shall be around 170C.In case blowing takes place while laying the bitumen mastic, the bubbles shall be punctured while it is hot and the surface treated well. 5 15.4.6. Joints: It shall be ensured that all construction joints are properly and truly made. These joints shall be made by warming existing bitumen mastic by the application of excess quantity of the bitumen mastic mix which afterwards shall be trimmed off to make it flush with the surfaces on either side. 515.4.7. Surface finish: The bitumen mastic surface can be slippery after floating; in order to provide resistance to skidding, the bitumen mastic after spreading, while still hot, and in plastic condition shall be covered with a layer of stone aggregates of 9.5 mm size (passing
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13.2 mm sieve and retained on 6.7 mm sieve). Hard stone chips of approved quality precoated with bitumen at the rate of two per cent of S-65 to S-90 penetration grades at 25Cat the rate of 0.005 cu.m. per 10 sq.m. shall be rolled or otherwise pressed into the surface of the mastic layer when the temperature of bitumen mastic is between 80C and 100C. 515.5. Opening to Traffic The traffic may be allowed after completion of the work when the bitumen mastic has cooled down to the surrounding temperature. 515.6 Quality Control of Work The type and grade of bitumen; the quality, grade and percentage of coarse and fine aggregates and tiller; the temperature control for heating the materials/mix, laying, floating and compacting, hardness number of the bitumen mastic, etc., should be strictly followed as indicated in the various Clauses of this Specification or as directed by the Engineer. The quality control tests for coarse and fine aggregates shall be exercised by the Engineer in accordance with Section 900. For mineral filler, one test for each property for every 5 tonnes, subject to a minimum of one test for each consignment shall be carried out. The surface of the bitumen mastic tested with a straight edge 3.0 m long, placed parallel to the centre line of the carriageway shall have no depression greater than 4 mm. The same limit shall also apply in case of transverse profile when tested with a camber template. 515.7. Arrangements for Traffic During the period of construction, arrangement of traffic shall be done to Clause 112. 515.8. Measurements for Payment Bitumen mastic shall be measured as finished work in square metres or by weight in metric tonnes as provided in the Contract. 515.9. Rate The contract unit rate for bitumen mastic shall he payment in full for carrying out the required operations including full compensation for all components listed under Clause 504.8 (i) to (vi).
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Base and Surface
516. SLURRY SEAL 516.1. Scope

-
This work shall consist of mixing emulsified bitumen, well-graded fine aggregates (with mineral filler) and water, spreading the mixture and rolling on a pavement surfacing as a surface treatment.
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516.2. Materials The materials for slurry seal immediately prior to mixing shall conform to the following requirements: 516.2.1. Emulsified bitumen : The emulsified bitumen shall be a Cationic rapid setting type as approved by the Engineer, conforming to the requirements as per IS: 8887. It shall be capable of producing a slurry as would develop early resistance to traffic and rain and is sufficiently stable to permit mixing with the specified aggregates, without breaking during the mixing and laying processes. If approved by the Engineer, a slow setting emulsion may be used. 516.2.2. Water: Water shall be of such quality that the bitumen will not separate from the emulsion before the slurry seal is in place of work. 516.2.3. Aggregates: The aggregates shall be crushed igneous rock, limestone or slag and may be blended, if required, with clean, sharp, naturally occurring sand free from silt, clay or other tine material to produce a grading as given in Table 500-31. It shall meet the requirements of the film stripping test (-IS: 6241) and suitable amount and type of anti-stripping agent added, as may be i~eeded.
TABLE 500-31. AGGREGATES GRADING FOR SLURRY SEAL Sieve size Percentage by mass passing Finished thickness of sealing 3mm 1.5mm 4.75 mm 3.35 mm 2.36 mm 1.18 mm 600 300 150 75 micron micron micron micron 100 80-100 75-100 55-90 35-70 20-45 10-25 5-15
100 95-100 70-95 55-75 30-50 10-30 5-15
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516.3. Proportioning The mixed material shall consist of aggregates, water and emulsified! bitumen (about 180-250 litres per tonne of dry aggregates) and where necessary, Portland cement as an additive. The proportion of the additive (portland cement) shall not normally exceed 2 per cent by weight of dry aggregates. The precise proportion of each constituent should be selected by laboratory tests and trials. 516.4. Mixing The various constituents shall be weighed in the needed proportions and mixed in a mechanical mixer so that all particles of the aggregates are uniformly coated and the slurry is of such consistency as can be satisfactorily laid. It shall be a semi-fluid, homogeneous mass with no emulsion run-off. 516.5. Site Preparation The pavement surface shall be suitably prepared by removing any loose material, dust and vegetation after patching up any potholes, depressions etc. All manhole covers, inspection covers and gully gratings should be masked. 516.6. Laying If required, a tack coat shall be applied. The rate of spread of tack coat shall depend on the surface to be treated: for bituminous surfaces, at the rate of 0.15 to 0.30 litreWsq.m. and for concrete surfaces at the rate of 0.4 to 0.6 litres/sq.m. Spreading shall be carried out by mechanical means. Spreading shall not be undertaken when the ground temperature falls below 4Cor wher the surface contains standing water. The slurry shall be spread at a rate such that the cover of aggregates (dry mass equivalent ) is 4-6 kg! sq.m. for 3 mm thick work and 24 kg/sq.m. for 1.5 mm thick work. The slurry shall be rolled by a pneumatic tyred roller having an individual wheel load between 7.5 and 15.0 kN making at least six passes or as may be directed by the Engineer. Rolling shall commence as soon as the slurry has set sufficiently to ensure that rutting or excessive movement will not occur. Adequate steps shall be taken to avoid damage by traffic until such time that the mixture has cured sufficiently so that the slurry seal will not adhere to and be picked up by the tyres of vehicles.
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516.7. Surface Finish and Quality Control of Work The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 516.8. Measurements for Payment Slurry seal shall be measured as finished work in square metres. 516.9. Rate The contract unit rate for slurry seal shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 504.8 (1) to (vi). 517. RECYCLING OF BITUMINOUS PAVEMENT 517.1. Scope This Specification covers the recycling of existing bituminous pavement materials towards upgrading an old bituminous pavement which has served its first-intended purpose. The work shall be performed on such widths and lengths as may be directed by the Engineer and may consist of pavement removal, stockpiling of materials from the old pavement, addition of new bitumen and untreated aggregates in the requisite proportions, mixing, spreading and compaction of the blended materials. 517.2. Materials 517.2.1. Materials for recycled pavement: The recycled materials shall be a blend of reclaimed and new materials proportioned to achieve a paving mixture with specified engineering properties. The reclaimed materials shall be tested and evaluated to find the optimum blend meeting the mix requirements. Such testing and evaluation shall be carried out on representative samples obtained by the random sampling technique. 5 17.2.2. Extraction : ASTM Designation D-2172 shall be adopted to quantitatively separate aggregates and bitumen from any representative sample of reclaimed bitumen pavement. 517.2.3. Aggregates evaluation : Mechanical sieve analysis (IS: 2386, Part 1) shall be performed on the aggregates portion of the reclaimed bituminous pavement sample to determine the gradation. Any deficiencies shall be made up by suitably blending the needed sieve fractions of new and/or reclaimed aggregates with reclaimed
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bituminous pavement aggregates. 517.2.4. Evaluation of bitumen: Based on the relative weights of extracted aggregates and bitumen in the reclaimed bituminous pavement, the bitumen content shall be determined at 60C to estimate the required amount and grade of bitumen to be used in the recycled mix design. 517.2.5. New bitumen: In order to increase the bitumen content to meet the recycled mix design requirements and also to blend with the aged bitumen in the reclaimed portion of the mixture to yield a bitumen content meeting the design specifications, new low-viscosity bitumen shall be added. The new bitumen used for this purpose are penetration grades 80/100, 120/150 or 200/300 i.e. viscosity grades AC-JO, AC-5, AC2.5 (AR-4000, AR-2000, AR-bOO), as approved by the Engineer. 517.2.6. Recycling agents: These are organic materials with chemical and physical characteristics selected to restore aged asphalt to desired specification of viscosity of combined aged asphalt and recycling agent. 517.2.7. Untreated aggregates: If necessary, fresh untreated aggregates shall be added to the reclaimed bitumen pavement to produce a mix with the desired gradation. Reclaimed aggregates materials, if any, or any aggregates normally used for the desired bituminous mix or both may be used for this purpose. 517.2.8. Combined aggregates: The blend of reclaimed and new aggregates shall meet specified gradation criteria as approved by the Engineer. The blend of aggregates shall be checked for quality requirements, including resistance to stripping as per Table 500-3. 517.3. Mix Design The gradation requirement and bitumen, content in the final mix shall conform to Clause 504, 507 or 512, depending upon whether the final desired bituminous material is bituminous macadam, dense bituminous macadam or bituminous concrete respectively. The mix design shall be done as per the Marshall method, the requirements conforming to the values as set out in the above Clauses. 517.4. Reclaiming Old Pavement Materials The removal of pavement materials to the required depth shall be
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accomplished either at ambient temperature (cold process)or at an elevated temperature (hot process), as approved by the Engineer. 517.4.1. Cold process of removal: In the cold process, the ripping and crushing operations shall be carried out using scarifiers, grid rollers, or rippers or by any other means as directed by the Engineer. The removed materials shall be loaded and hauled for crushing to the size as directed by the Engineer. Alternatively, cold milling or planing machines can be used to reclaim asphalt pavement to controlled depths. After the asphalt treated layers are removed, any remaining aggregate materials that are to be incorporated in the recycled hot mix shall be scarified and removed. When the pavement material removal is completed, any drainage deficiencies shall be corrected. After that, the base/sub-base as the case may be shall be cut, graded and compacted to proper grade, cross-section and profile. 517.4.2. Hot process of removal: In this process, the road surface shall be heated, usually by LPG or any other suitable means as approved by the Engineer, before scarification. A travelling plant shall be used and a milling drum that follows the planer, removes the heated soft bituminous layer. The depth, width and speed of travel shall be adjusted to suit specific ~requirements directed by the Engineer. as 517.4.3. Stockpiling: In the cold process, the reclaimed asphalt pavement material shall be stockpiled with the height of stockpiles not exceeding 3 m. The reclaimed untreated aggregates base/sub-base material shall be stockpiled in the same manner as new aggregates. The number and location of stockpiles shall be carefully planned for efficient operation of the hot-mix plant. 517.5. Mixing and Laying 517.5.!. Preparation of in ix: The mixing of recycled aggregates, ~~ew aggregates and bitumen shall be done in a hot mix plant of suitable capacity which shall be either batch type or drum-mix type, capable of meeting the overall Specification requirements under stringent quality control. The Plant shall have the features as given in Clause 504.3.4. The temperature of binder at the time of mixing shall be 150-163 Cand that of aggregate in the range of 155-163 C. Provided also that at no time shall the difference in temperature between the aggregates and binder exceed 14 C. The temperature of both the aggregates and the bitumen at the time of mixing shall be in accordance
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with the job mix formula and strictly controlled. All overheated and carbonized mixture, shall be rejected. .Mixing shall be thorough to ensure that a homogeneous mixture is obtained in which all particles of the mineral aggregates are coated uniformly. Any tipper causing excessive segregation of materials by its spring suspension or other contributing factors or that showing undue delays shall be removed from the work until such conditions are corrected. 517.5.2. Spreading: The mix transported from the hot mix plant to the site shall be spread by means of a self-propelled mechanical paver with suitable screeds capable of spreading, tamping and finishing the mix to specified grade, lines and crosssection. Paver Finisher shall have the essential features as spelt out in Clause 504.3.5. However, in restricted locations and in narrow width where the available equipment cannot be operated in the opinion of the Engineer, he may permit manual laying of the mix. Mixes with a temperature of less than 120 Cshall not be put into paver spreader. Longitudinal joints and edges shall be constructed true to the centre line of the road. Longitudinal and transverse joints shall be offset by at least 250 mm from those in the lower courses and the joints on the top most layer shall not be allowed to fall within the wheel path. All transverse joints shall be cut vertically to the full thickness of the previously laid mix with pneumatic cutter and the surface painted with hot bitumen before placing fresh material. Longitudinal joints shall be preferably hot joints. Cold longitudinal joints shall be properly heated with joint heater to attain a suitable temperature of about 80 C before laying of any adjacent material. 517.5.3. Compaction: Clause 507.4.6 shall apply. 517.5.4. Opening to traffic: Traffic may be allowed after completion of the final rolling when the mix has cooled down to the surrounding temperature. 517.6. Surface Finish and Quality Control The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900.
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517.7. During be done to 517.8.
Arrangement for Traffic the period of construction, arrangement for the traffic shall Clause 112. Measurements for Payment
The recycled pavement work shall be measured in cubic metres or tonnes of finished work as provided by the Contract. 517.9. Rate The contract unit rate for recycled pavement shall be payment in full for carrying out the required operations including full compensation for
(I) (ii) Making arrangements for traffic to Clause I 12,. Providing all materials to be incorporated in the work, including all royalties. fees, rents where necessary and all leads and hiss;
(iii) All labour, tools, equipment, plant and incidentals to complete the work to the Specification; (iv) Cariying (v) out the work in part width of the road where directed~and Carrying our tests to control the quality of the work.
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600 Concrete Pavement
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601. DRY LEAN CEMENT CONCRETE SUB-BASE 601.1. Scope 601.1.1. The work shall consist of construction of dry lean concrete subbase for cement concrete pavement in accordance with the requirements of these Specifications and in conformity with the lines, grades and cross-sections shown on the drawings or as directed by the Engineer. The work shall include furnishing of all plant and equipment, materials and labour and performing all operations, in connection with the work, as approved by the Engineer. 601.1.2, The design parameters of dry lean concrete sub-base, viz,, width, thickness, grade of concrete, details of joints, if any, etc. shall be as stipulated in the Contract drawings. 601.2. Materials 601.2.1. Source of Materials: The Contractor shall indicate to the Engineer the source of all materials with relevant test data to be used in the lean concrete work sufficiently in advance and the approval of the Engineer for the same shall be obtained at least 45 days before the scheduled commencement of the work. If the Contractor later proposes to obtain the materials from a different source, he shall notify the Engineer for his approval at least 45 days before such materials are to be used. 601.2.2. Cement: Any of the following types of cement may be used with prior approval of the Engineer:
(i) Ordinary Portland Cement (ii) Portland Slag Cement (iii) Portland Po~zolana Cement IS IS : IS 269 455 1489
If the subgrade is found to consist of. soluble suiphates in a concentration more than 0.5 per cent, cement used shall be sulphate resistant and shall conform to IS: 6909. Cement to be used may preferably be obtained in bulk form. It shall be stored in accordance with stipulations contained in Clause 1014 and shall be subjected to acceptance test prior to its immediate use. 601.2.~. Aggregates: 601.2.3.1. Aggregates for lean concrete shall be natural material complying with IS: 383. The aggregates shall not be alkali reactive.~Th limits
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of deleterious materials shall not exceed the requirements set out in IS: 383. In case the Engineer considers that the aggregates are not free from dirt, the same may be washed and drained for at least 72 hours before batching, as directed by the~ Engineer. 601.2.3.2. Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces. The maximum size of the coarse aggregate shall be 25 mm. The coarse aggregate shall comply with Clause 602.2.4.2. 601.2.3.3. Fine aggregate: The fine aggregate shall consist of clean, natural sand or crushed stone sand or a combination of the two and shall conform to IS: 383. Fine aggregate shill be free from soft particles, clay, shale, loam, cemented particles, mica, organic and other foreign matter, The fine aggregate shall comply with Clause 602.2.4,3. 601.2.3.4. The coarse and fine aggregates may be obtained in either of the following manner:
(i) (ii) In separate nominal sizes of coarse and fine aggregates and mixed Logether intimately before use, Separately as 25 rem nominal single size, 12.5 mm nominal size graded aggregates and fine aggregate of crushed stone dust or sand or a combination of these two.
The material after blending shall conform to the grading as indicated in Table 600-I.
TABLE 600.1. AGGREGATE GRADATION FOR DRY LEAN CONCRETE Sieve Designation Percentage passIng the sieve by welghh ~ 100 80-100 55.75 35-60 1045 0-8
26.50 19.00 9.50 4.75 600.00 75.00
mm mm mm mm micron micron
601.2.4. Water: Water used for mixing and curing of concrete shall be clean and free from injurious amounts of oil, salt, acid, vegetable matter or other substances harmful to the finished concrete. It shall meet the requirements stipulated in IS : 456. 601.2.5. Storage of materials: All materials shall be stored in accordance with the provisions of Clause 1014 of these Specifications and
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other relevant IS Specifications. All efforts must be made to store the materials in proper places so as to prevent their deterioration or contamination by foreign matter and to ensure their satisfactory quality and fitness for use in the work. The storage place must also permit easy inspection, removal and stor~t~ materials. All such materials even of though stored in approved godo~. must be subjected to acceptance test ns immediately prior to their use. The requirement of storage yard specified in Clause 602.2.9 shall also be applicable. 601.3. Proportioning of Materials for the Mix 601.3.1. The mix shall be proportioned with a maximum aggregate cement ratio of 15 : 1. The w~aercontent shall be adjusted to the optimum as per Clause 601.3.2 for facilitating compaction by rolling. The strength and density requirements of concrete shall be determined in accordance with Clause 601.6 by making trial mixes, 601.3.2. Moisture content: The right amount of water for the lean concrete in the main work shall be decided so as to ensure full compaction under rolling and shall be assessed at the time of rolling the trial length. Too much water will cause the lean concr~t~io heaving up before be the wheels and picked up on the wheels of the roller and too little will lead to inadequate compaction, a low rn-situ strength and an open-textured surface. The optimum water content shall be determined and demonstrated by rolling during trial length construction and the optimum moisture content and degree of compaction shall be got approved from the Engineer. While laying in the main work, the lean concrete shall have a moisture content between the optimum and optimum +2 per cent, keeping in view the effectiveness of compaction achieved and to compensate for evaporation losses. 6~I1.3.3.Cement content: The minimum cement content in the lean concrete shall not be less than 150 kg/cu.ni. of concrete. If thi~ minimum cement content is not sufficient to produce concrete of tht specified strength, it shall be increased as necessary without additional cost compensation to the Contractor. 601,3.4. Concrete strength: The average compressive strength of each consecutive group of 5 cubes made in accordance with Clause 903.5.1.1 shall not be less than 10 MPa at 7 days. In addition, the minimum compressive strength of any individual cube shall not be less than 7.5 MPa at 7 days. The design mix complying with the above Clauses
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shall be got approved from the Engineer and demonstrated in the trial length construction. 601.4. Subgrade The subgrade shall conform to the grades and cross sections shown on the drawings and shall be uniformly compacted to the design strength in accordance with these Specifications and Specification stipulated in the Contract. The lean concrete subbase shall not be laid on a subgrade softened by rain after its final preparation; surface trenches and soft spots, if any, must be properly back-filled and compacted to avoid any weak or soft spot. As far as possible, the construction traffic shall be avoided on the prepared subgrade. A day before placing of the sub-base, the subgrade surface shall be given a fine spray of water and rolled with one or two passes of a smooth wheeled roller after a lapse of 2-3 hours in order to stabilise loose surface. If Engineer feels it necessary, another fine spray of water may be applied just before placing sub-base. 6013. Construction 601.5.1. General: The pace and programme of the lean concrete subbase construction shall be matching suitably with the programme of consi~ruction of the cement concrete pavement Over it. The sub-base shall be overlaid with cement concrete pavement only after 7 days after sub-base construction. 601.5.2. Batching and mixing: The batching plant shall be capable of proportioning the materials by weight, each type of material being weighed separately in accordance with Clause 602.9.3.2. The cement from the bulk stock shall be weighed separately from the aggregates. The capacity of batching and mixing plant shall be at least 25 per cent higher than the proposed capacity for the laying arrangements. The batching and mixing shall be carried out preferably in a forced action central batching and mixing plant having necessary automatic controls to ensure accurate proportioning and mixing. Other types of mixers shall be permitted subject to demonstration of their satisfactory performance during the trial length. The type and capacity of the plant shall be got approved by the Engineer before commencement of the trial length. The weighing balances shall be calibrated by weighing the aggregates, cement, water and admixtures physically either by weighing with large weighing machine or in a weigh bridge. The accuracy of weighing scales of the batching plant shall be within 2 per cent in the case of aggregates and 1per cent in the case of cement and water.
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The design features of Batching Plant should be such that the shifting operations of the plant will not take very long time when they are to be shifted from place to place with the progress of the work. 601.5.3. Transporting: Plant mix lean concrete shall be discharged immediately from the mixer, transported directly to the point where it is to be laid and protected from the weather by covering the tippers! dumpers with tarpaulin during transit. The concrete shall be transported by tipping trucks, sufficient in number to ensure a continuous supply of material to feed the laying equipment to work at a uniform speed and in an uninterrupted manner. The lead of the batching plant to paving site shall be such that the travel time available from mixing to paving as specified in Clause 60 1.5.5.2 will be adhered to. 601.5.4. Placing: Lean concrete shall be laid/placed by a paver with electronic sensor. The equipment shall be capable of laying the material in one layer in an even manner without segregation, so that after compaction the total thickness is as specified. The paving machine shall have high amplitude tamping bars to give good initial compaction to the sub-base. The laying of the two-lane road subbase may be done either in full width or lane by lane. Preferably the lean cdncrete shall be placed and compacted across the full width of the road, by constructing it in one go or in two lanes running forward simultaneously. Transverse and longitudinal construction joints shall be staggered by 500-1000 mm and 200-400 mm respectively from the corresponding joints in the overlaying concrete slabs. 601.5.5. Compaction 601.5.5.1. The compaction shall be carried out immediately after the material is laid and levelled. In order to ensure thorough compaction which is essential, rolling shall be continued on the full width till there is no further visible movement under the roller and the surface is closed. The minimum dry density obtained shall be 97 per cent of that achieved during the trial length construction vide Clause 601.7. The densities achieved at the edges i.e 0.5 m from the edge shall not be less than 95 per cent of that achieved during the trial construction vide Clause 601.7. 601.5.5.2. The spreading, compacting and finishing of the lean concrete shall be carried out as rapidly as possible and the operation shall be so arranged as to ensure that the time between the mixing of the first batch of concrete in any transverse section of the layer and
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the final finishing of the same shall not exceed 90 minutes when the concrete temperature is above 25 and below 30 degree Celsius and 120 minutes if less than 25 degree Celsius. This period may be reviewed by the Engineer in the light of the results of the trial run but in no case shall it exceed 2 hours. Work shall not proceed When the temperature of the concrete exceeds 30 degree Celsius. If necessary, chilled water or addition of ice may be resorted to for bringing down the temperature. It is desirable to stop concreting when the ambient temperature is above 35C. After compaction has been completed, roller shall not stand on the compacted surface for the duration of the curing period except during commencement of next days work near the location where work was terminated the previous day. 601.5.5.3. Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 kN static weight are considered to be suitable for rolling dry lean concrete. In case any other roller is proposed, the same shall be got approved from the Engineer, after demonstrating its performance, The number of passes required to obtain maximum compaction depends on the thickness of the lean concrete, the compactibility of the mix, and the weight and type of the roller etc., and the same as well as the total requirement of rollers for the job shall be determined during trial run by measuring the in-situ density and the scale of the work to be undertaken. 601.5.5.4. In addition to the number of passes required for compaction there shall be a preliminary pass without vibration to bed the lean concrete down and again a final pass without vibration to remove roller marks and to smoothen the surface. Special care and attention shall be exercised during compaction near joints, kerbs, channels, side forms and around gullies and manholes. In case adequate compaction is not achieved by the roller at these points, use of plate vibrator shall be made, if so directed by the Engineer. 601.5.5.5. The final lean concrete surface on completion of compaction and immediately before overlaying, shall be well closed, free from movement under roller and free from ridg~s,low spots, cracks, loose material, pot holes, ruts or other defects. The final surface shall be inspected immediately on completion and all loose, segregated or defective areas shall be corrected by using fresh lean concrete material laid and compacted as per Specification. For repairing honeycombed surface, concrete with aggregates of size 10 mm and below shall be spread and compacted. It is necessary to check the level of the rolled
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surface for compliance. Any level/thickness deficiency should be corrected after applying concrete with aggregates of size 10 mm and below after roughening the surface. Similarly the surface regularity also should
be checked with 3m straight edge. The deficiency should be made up with concrete with aggregates of size 10 mm and below. 601.5.5.6. Segregation of concrete in the dumpers shall be controlled by premixing each fraction of the aggregates before loading in the bin of the batching plant, by moving the dumper back and forth while discharging the mix on it and other means. Even paving operation shall be such that the mix does not segregate. 601,5.6. Joints: Contraction and longitudinal joints shall be provided as per the drawing. At longitudinal or transverse construction joints, unless vertical forms are used, the edge of compacted material shall be cut back to a vertical face where the correct thickness of the properly compacted material has been obtained. 601.5.7. Curing: As soon as the lean concrete surface is compacted, curing shall commence. One of the following two methods shall be adopted:
(a) The initial curing shaH be done by spraying with liquid curing compound. The curing compound shall be white pigmented or transparent type with water retention indea of 90 per cent when tested in accordance with BS 7542. Curing compound shall be sprayed immediately after rolling is complete. As soon as the curing compound has loss its tackiness, the surface shall be covered with wet hessian for three days. Curing shall be done by covering the surface by gunny bagslhessian, which shall be kept continuously moist for 7 days by sprinkling waler.
(b)
601.6. Trial Mixes The Contractor shall make trial mixes of dry lean concrete with moisture contents like 5.0, 5.5, 6.0, 6.5 and 7.0 per cent using cement content specified and the specified aggregate grading but without violating the requirement of aggregate-cement ratio specified in Clause 601.3.1. Optimum moisture and density shall be established by preparing cubes with varying moisture contents. Compaction of the mix shall be done in three layers with vibratory hammer fitted with a square or rectangular foot as described in Clause 903.5.1.1. After establishing the optimum moisture, a set of six cubes shall be cast at that moisture for the determination of compressive strength on the 3rd and the seventh day. Trial mixes shall be repeated if the strength is not satisfactory either by
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increasing cement content or using higher grade of cement. After the mix design is approved, the Contractor shall construct a trial Section in accordance with Clause 601.7. If during the construction of the trial length, the optimum moisture content determined as above is found to be unsatisfactory, the Contractor may make suitable changes in the moisture content to achieve a satisfactory mix, The cube specimens prepared with the changed moisture content should satisfy the strength requirement. Before production of the mix, natural moisture content of the aggregate should be determined on a clay-to-day basis so that the moisture content could be adjusted. The mix finally designed should neither stick to the rollers nor become too dry resulting in ravelling of surface. 601.7. Trial Length 601.7.1. The trial length shall be constructed at least 14 days in advance of the proposed date of commencement of work. At least 30 days prior to the construction of the trial length, the Contractor shall submit for the Engineers approval a Method Statement giving detailed description of the proposed materials, plar~t,equipment, mix proportion, and procedure for batching, mixing, laying, compaction and other construction procedures. The Engineer shall also approve the location and length of trial construction which shall be a minimum of 60 m length and for full width of the pavement. The trial length shall contain the construction of at least one transverse construction joint involving hardened concrete and freshly laid sub-base. The construction of trial length will be repeated till the Contractor proves his ability to satisfactorily construct the subbase. 601.7.2. In order to determine and demonstrate the optimum moisture content which results in the maximum dry density of the mix compacted by the rolling equipment and the minimum cement content that is necessary to achieve the strength stipulated in the drawing, trial mixes shall be prepared as per Clause 601.6. 60 1.7.3. After the construction of the trial length, the in-situ density of the freshly laid material shall be determined by sand replacement method with 20 cm dia density cone. Three density holes shall be made at locations equally spaced along a diagonal that bisects the trial length; average of these densities shall be determined. These main density holes shall not be made in the strip 50 cm irom the edges. The average density obtained from the three samples collected shall be the reference density and is considered as 100 per cent. The field density of regular
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work will be compared with this reference density in accordance with Clauses 601.5.5.1 and 903.5.1.2. A few cores may be cut as per the instructions of the Engineer to check segregation or any other deficiency. 601.7.4. The hardened concrete shall be cut over 3 m width and reversed to inspect the bottom surface for any segregation taking place. The trial length shall be constructed after making necessary changes in the gradation of the mix to eliminate segregation of the mix, The lower surface shall not have honey-combing and the aggregates shall not be held loosely at the edges. 601.7.5. The trial length shall be outside the main works. The main work shall not start until the trial length has been approved by the Engineer. After approval has been given, the materials, mix proportions, moisture content, mixing, laying, compaction plant and construction procedures shall not be changed without the approval of the Engineer. 601.8. Tolerances for Surface Regularity, Level, Thickness, Density and Strength The tolerances for surface regularity, level, thickness, density and strength shall conform to the requirements given in Clause 903.5. Control of quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 601.9. Traffic No heavy commercial vehicles like trucks and buses shall be permitted on the lean concrete sub-base after its construction. Light vehicles if unavoidable may, however, be allowed after 7 days of its construction with prior approval of the Engineer. 601.10. Measurement~ Payment for The unit of measurement for dry lean concrete pavement shall be the cubic metre of concrete placed, based on the net plan areas for the specified thickness shown on the drawings or as directed by the Engineer. 601,11. Rate The Contract unit rate payable for dry lean concrete sub-base shall be payment in full for carrying out the required operations including full compensation forall labour, materials and equipment, mixing, transport, placing, compacting, finishing, curing, testing and incidentals to complete the work as per Specifications, all royalties, fees, storage and rents where necessary and all leads and lifts.
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Section 600
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602. CEMENT CONCRETE PAVEMENT 602.1. Scope 602.1.1. The work shall Consist of construction of unreinforced, dowel jointed, plain cement concrete pavement in accordance with the requirements of these Specifications and in conformity with the lines, grades and cross sections shown on the drawings. The work shall include furnishing of all plant and equipment, materials and labour and performing all operations in connection with the work, as approved by the Engineer. 602.1.2. The design parameters, viz., thickness of pavement slab, grade of concrete, joint details etc. shall be as stipulated in the drawings. 602.2. Materials 602.2.1. Source of materials: The Contractor shall indicate to the Engineer the source of all materials to be used in the concrete work with relevant test data sufficiently in advance, and the approval of the Engineer for the same shall be obtained at least 45 days before the scheduled commencement of the work. If the Contractor later proposes to obtain materials from a different source, he shall notify the Engineer for his approval, at least 45 days belore such materials are to be used with relevant test data. 602.2.2. Cement : Any of the following types of cement capable of achieving the design strength may be used with prior approval of the Engineer, but the preference should be to use at least the 43 Grade or higher.
(i) (ii) Ordinary Portland Cement, 33 Grade, IS Ordinary Portland Cement, 43 Grade IS 269. 8112. 12269.
(iii) Ordinary Portland Cement, 53 Grade, IS
If the soil around has soluble salts like sulphates in excess of 0.5 per cent, the cement used shall be sulphate resistant and shall conform to IS: 12330. Guidance may be taken from IS: SP: 23, Handbook for Concrete Mixes for ascertaining the minimum 7 days strength of cement required to match with the design concrete strength. Cement to be used may preferably be obtained in bulk form. If cement in paper bags are proposed to be used, there shall be bag-splitters with the facility to separate pieces of paper bags and dispose them of suitably. No paper pieces shall enter the concrete mix. Bulk cement shall be stored in
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accordance with Clause 1014. The cement shall be subjected to acceptance test just prior to its use. 602.23. Admixtures : Admixtures conforming to !S:6925 and IS: 9103 shall be permitted to improve workability of the concrete or extension of setting time, on satisfactory evidence that they will not have any adverse effect on the properties of concrete with respect to strength, volume change, durability and have no deleterious effect on steel bars. The particulars of the admixture and the quantity to be used, must be furnished to the Engineer in advance to obtain his approval before use. Satisfactory performance of the admixtures should be proved both on the laboratory concrete trial mixes and in trial paving works. If air entraining admixture is used, the total quantity of air in air-entrained concrete as a percentage of the volume of the mix shall be 5 per 1.5 cent for 25 mm nominal size aggregate. 602.2.4. Aggregates 602.2.4.1. Aggregates for pavement concrete shall be natural material complying with IS : 383 but with a Los Angeles Abrasion Test result not more than 35 per cent. The limits of deleterious materials shall not exceed the requirements set out in IS : 383. The aggregates shall be free from chert, flint, chalcedony or other silica in a form that can react with the alkalies in the cement. In addition, the total chlorides content expressed as chloride ion content shall not exceed 0.06 per cent by weight and the total sulphate content expressed as sulphuric anhydride (SO3) shall not exceed 0.25 per cent by weight. 602.2.4.2. Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces. The maximum size of coarse aggregate shall not exceed 25 mm for pavement concrete. Continuously graded or gap graded aggregates may be used, depending on the grading of the fine aggregate. No aggregate which has water absorption more than 2 per cent shall be used in the concrete mix. The aggregates shall be tested for soundness in accordance with IS: 2386 (Part -5). After 5 cycles of testing the loss shall not be more than 12 per cent if sodium sulphate solution is used or 18 per cent if magnesium sulphate solution is used. Dumping and stacking of aggregates shall be done in an afiproved manner. In case the Engineer considers that the aggregates are not free
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Section
600
Concrete Pavement
from dirt, the same may be washed and drained for at least 72 hours before batching as directed by the Engineer. 602.2.4.3. Fine aggregate: The fine aggregate shall consist of clean natural sand or crushed stone sand or a combination of the two and shall conform to IS : 383. Fine aggregate shall be free from soft particles, clay, shale, loam, cemented particles, mica and organic and other foreign matter. The fine aggregate shall not contain deleterious substances more than the following
Clay lumps Coal and lignite Material passing IS Sieve No. 75 micron 4.0 per cent 1.0 per cent 4.0 per cent
602.2.5. Water: Water used for mixing and curing of concrete shall be clean and free from injurious amount of oil, salt, acid, vegetable matter or other substances harmful to the finished concrete. It shall meet the requirements stipulated in IS: 456, 602.2.6. Mild steel bars for dowels and tie bars : These shall conform to the requirements of IS : 432, IS : 1139 and IS : 1786 as relevant. The dowel bars stiall conform to Grade S 240 and tie bars to Grade S 415 of l.S. 602.2.7. Premoulded joint filler: Joint tiller board for expansion joints which are proposed for use only at some abutting structures like bridges and culverts shall be of 20-25 mm thickness within a tolerance of 1.5 mm and of a firm compressible material and complying with the requirements of IS:1838, or BS Specification Clause No. 2630 or Specification for Highway Works, Vol. I Clause 1015. It shall be 25 mm less in depth than the thickness of the slab within a tolerance of 3 mm and provided to the full width between the side forms. It shall ke in suitable lengths which shall not be less than one lane width. Holes to accommodate dowel bars shall be accurately bored or punched out to give a sliding fit on the dowel bars. 602.2.8. Joint sealing compound: The joint sealing compound shall be of hot poured, elastomeric type or cold polysulphide type having flexibility, resistance to age hardening and durability. If the sealant is of hot poured type it shall conform to AASHTO M282 and cold applied sealant shall be in accordance with BS 5212 (Part 2). 602.2.9. Storage of materials: All materials shall be stored in accordance with the provisionsof Clause 1014 of the Specifications and other relevant IS Specifications. All efforts must be made to store the materials in proper places so as to prevent their deterioration or
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contamination by foreign matter and to ensure their satisfactory quality and fitness for the work. The platform where aggregates are stock piled shall be levelled with 15 cm of watered, mixed and compacted granular sub-base material. The area shall have slope and drain to drain off rain water. The storage space must also permit easy inspection, removal and storage of the materials. Aggregates of differentsizes shall be stored in partitioned stack-yards. All such materials even though stored in approved godowns must be subjected to acceptance test as per Clause 903 of these Specifications immediately prior to their use. 602.3. Proportioning of Concrete 602.3.1. After approval by the Engineer of all the materials to be used in the concrete, the Contractor shall submit the mix design based on weighed proportions of all ingredients for the approval of the Engineer. The mix design shall be submitted at least 30 days prior to the paving of trial length and the design shall be based on laboratory trial mixes using the approved materials and methods as per IS:10262 (Recommended Guidelines for Mix Design) or on the basis of any other rational method agreed to by the Engineer. Guidance in this regard can also be obtained from IS:SP:23 Handbook on Concrete Mixes. The target mean strength for the design mix shall be determined as indicated in Clause 903.5.2. The mix design shall be based on the flexural strength of concrete. 602.3.2. Cement content: The cement content shall not be less than 350 kg per cu.m.of concrete. If this minimum cement content is not sufficient to produce in the field, concrete of the strength specified in the ddiwings/design, it shall be increased as necessary without additional compensation under the Contract. The cement content shall, however, not exceed 425 kg per cu.m. of concrete. 602.3.3. Concrete strength 602.3.3.1. While designing the mix in the laboratory, correlation between flexural and compressive strengths of concrete shall be established on the basis of at least thirty tests on samples. However, quality control in the field shall be exercised on the basis of flexural strength. It may, however, be ensured that the materials and mix proportions remain substantially unaltered during the daily concrete production. The water content shall be the minimum required to provide the agreed workability for full compaction of the concrete to the required density as determined by the trial mixes or other means approved by the Engineer and the maximum free water cement ratio shall be 0.50.
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Section 600
Concrete Pavement
602.3.3.2. The ratio between the 7 and 28 day strengths shall be established for the mix to be used in the slab in advance, by testing pairs of beams and cubes at each stage on at least six batches of trial mix. The average strength of the 7 day cured specimens shall be divided by the average strength of the 28 day specimens for each batch, and the ratio R shall be determined. The ratio ~Rshall be expressed to three decimal places. If during the construction of the trial length or during normal working, the average value of any four consecutive 7 day test results falls below the required 7 day strength as derived from the value of R, then the cement content of the concrete shall, without extra payment, be increased by 5 per cent by weight or by an amount agreed by the Engineer. The increased cement content shall be maintained at least until the four corresponding 28 day strengths have been assessed for its conformity with the requirements as per Clause 602.3.1. Whenever the cement content is increased, the concrete mix shall be adjusted to maintain the required workability. 602.3.4. Workability 602.3.4.1. The workability of the concrete at the point of placing shall be adequate for the concrete to be fully compacted and finished without undue flow. The optimum workability for the mix to suit the paving plant being used shall be determined by the Contractor and approved by the Engineer. The control of workability in the field shall be exercised by the slump test as per IS :1199. 602.3.4.2. The workability requirement at the Batching Plant and paving site shall be established by slump tests carried during trial paving. These requirements shall be established from season to season and also when the lead from Batching plant site to the paving site changes. The workability shall be established for the type of paving equipment available. A slump value in the range of 30 15 mm is reasonable for paving works but this may be modified depending upon the site requirement and got approved by the Engineer. These tests shall be carried out on every truck/dumper at Plant site and paving site initially when the work commences but subsequently the frequency can be reduced to alternate trucks or as per the instructions of the Engineer. 602.3.5. Design mix 602.3.5.1. The Contractor shall carry out laboratory trials of design mixes with the materials from the approved sources to be used. Trial
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mixes shall be made in presence of the Engineer or his representative and the design mix shall be subject to the approval of the Engineer. They shall be repeated if necessary until the proportions that will produce a concrete which complies in all respects with this Specification, and conforms to the requirement of the design/drawings have been determined. 602.3.5.2. The proportions determined as a result of the laboratory trial mixes may be adjusted if necessary during the construction of the trial length. Thereafter, neither the materials nor the mix proportions shall be varied in any way except with the written approval of the Engineer. 602.3.5.3. Any change in the source of materials or mix prop~tions proposed by the Contractor during the course of work shall be assessed by making laboratory trial mixes and the construction of a further trial length unless approval is given by the Engineer for minor adjustments like compensation for moisture content in aggregates or minor fluctuations in the grading of aggregate. 602.4. Sub-base The cement concrete pavement shall be laid over the sub-base constructed in accordance with the relevant drawings andSpeificalions contained in Clause 601. If the sub-base is found damaged at some places or it has cracks wider than 10 mm it shall be t~epairedwith fine cement concrete or bituminous concrete before laying separation layer Pnor to laying of concrete it shall be ensured that the separation membrane as per Clause 602.5 is placed in position and the same is clean of dirt or other extraneous materials and free from any daniage. 602.5. Separation Membrane A separation membrane shall be used between the concrete stab and the subbase Separation membrane shall be impermble plastic sheeting 125 microns thick laid flat without creases Before placing the separation membrane, the sub-base shall be swept clean Of ~ll the extti~neus materials using air compressor. Wherever overlap of plastic sheets is necessary, the same shall be at least 300 mm and an~ damaged sheeting shall be replaced at the Contractors expense. The separation membrane may be nailed to the lower layer with concrete nails. 602.6. Joints 602 6 1 The location and type of Joints shall be as shown in the drawing. Joints shall be constructed depending upon thfr Thnctlonl
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Section 600
Concrete Pavement
requirement as detailed in the following paragraphs.The location of the joints should be transferred accurately at the site and mechanical saw cutting of joints done as per stipulated dimensions. It should be ensured that the full required depth of cut is made from edge to edge of the pavement. Transverse and longitudinal joints in the pavement and subbase shall be staggered so that they are not coincident vertically and are at least I m and 0.3 m apart respectively. Sawing of joints shall be carried out with diamond studded blades soon after the concrete has hardened to take the load of the sawing machine and personnel without damaging the texture of the pavement. Sawing operation could start as early as 6-8 hours depending upon the season. 602,6.2. Transverse joints 602.6.2.1. Transverse joints shall be contraction and expansion joints constructed at the spacing described in the Drawings. Transverse joints shall b~ straight within the following tlerailces along the intended line of joints which is the straight line transverse to the longitudinal axis of the carriageway at the position proposed by the Contractor and agreed to by the Engineer, except at road junctions or roundabouts where the position shall be as described in the drawings:
(i) (ii) Deviations of the filler board in the case of expansion joints from the intended line of the joint shall not be greater than 10mm. The best fit straight line through the joint grooves as constructed shall he not more than 25 mm from the intended line of the 3oInL
(iii) Deviations of the joint groove from the best fit straight line of the joint shall not be greater than 10 miii (iv) Transv~rseoints on each tide of the longitudinal joint shall be in line with each j other and of the same type and width, Transverse joints shall have a sealing groove which shall be sealed in compliance with Clause 602.11.
602.6.2.2. Contraction joints: Contraction joints shall consist of a mechanical sawn Joint groove 3 to 5 mm wide and 1/4 to 1/3 depth of the stab mm or as stipulated in the drawings and dowel bars 5 complying with Clause 602 65 and as detailed in the drawings The conti~action:~::jointshall be cut as soon as the concrete has s undergone initial hardening and is hard enough to take the load of joint sawing machine without causing damage to the slab. 602.6.2.3. E~ :i~ii~ joints: The expansion joints shall consist of a joint filler board complying with Clause 602.2.7 and dowel bars complyir~gwith Cl~use,6O~$.5,; as detailed in the drawings. The filler board and sha~l e positioi~ed b vcrtieally with the prefabricated joint assemblies along
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Section 600
the line of the joint within the tolerances given in Clause 602,6.2. l~ and at such depth below the surface as will not impede the passage of the finishing straight edges or oscillating beams of the paving machines. The adjacent slabs shall be completely separated from each other by providing joint filler board. Space around the dowel bars, between the sub-base and the filler board shall be packed with a suitable compressible material to block the flow of cement slurry. 602.63. Transverse construction joint: Transverse construction joints shall be placed whenever concreting is completed after a days work or is suspended for more than 30 minutes. These joints shall be provided at the regular location of contraction joints using dowel bars. The joint shall be made butt type. At all construction joints, steel bulk heads shall be used to retain the concrete while the surface is finished. The surface of the concrete laid subsequently shall conform to the grade and cross sections of the previously laid pavement. When positioning of bulk heaW stop-end is not possible, concreting to an additional 1 or 2 m length may be carried out to enable the movement of joint cutting machine so that joint grooves may be formed and the extra 1 or 2 rn length is cut out and removed subsequently after concrete has hardened. 602.6.4. Longitudinal joint 602.6.4.1. The longitudinal joints shall be saw cut as per details of the joints shown in the drawing. The groove may be cut after the final set of the concrete. Joints should be sawn to at least 1/3 the depth of the slab mm as indicated in the drawing. 5 602.6.4.2. Tie bars shall be provided at the longitudtnai joints as per dimensions and spacing shown in the drawing and in accordance with Clause 602.6.6. 602.6.5. Dowel bars 602.6.5.1. Dowel bars shall be mild steel rounds in accordance with Clause 602.2.6 with details/dimensions as indicated in the drawing and free from oil, dirt, loose rust or scale. They shall be straight, free of irregularities and burring restricting slippage in the concrete. The sliding ends shall be sawn or cropped cleanly with no protrusions outside the normal diameter of the bar. The dowel bar shall be supported on cradles/dowel chairs in pie-fabricated joint assemblies positioned prior to the construction of the slabs or mechanically inserted with vibration into the plastic concrete by a method which ensures correct placement of the bars besides full re-compaction of the concrete around the dowel bars.
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Section 600
Concrete Pavement
602.6.5.2. Unless shown otherwise on the drawings, dowel bars shall, be positioned at mid depth of the slab within a tolerance of 20 mm, and centered equally about intended lines of the joint within a tolerance of mm. Tey shall be aligned parallel to the finished 25 surface of the slab and to the centre line of the carriageway and to each other within tolerances given hereunder, the compliance of which shall be checked as per Clause 602.10.7.
(i) For bars supported on cradles prior to the laying of the slab: (a) (b) (c) (d) (ii) All bars in ajount shall be within 3mm per 300mm length of bar 2/3rd of the bars shall be within mm per 300 mm length of bar 2 No bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm length of bar in either the horizontal or vertical plane Cradles supporting dowel bar shall not extend across the line of joint i.e. no steel bar of the cradle assembly shaH be continuous across the joint.
For all bars inseried after laying of the slab: (a) Twice the tolerance for alignment as indicated in (I) above
602.6.5.3. Dowel bars, supported on cradles in assemblies, when subject to a load of 110 N applied at either end and in either the vertical or horizontal direction (upwards and downwards and both directions horizontally) shall conform to be within the following limits:
(i) (ii) Two-thirds of the number of bars of any assembly tested shall not deflect more than 2 mm per 300 mm length of bar The remainder of the bars per 300 mm length of bar.
in
that assembly shall not deflect more than 3 mm
602.6.5.4. The assembly of dowel bars and supporting cradles, including the joint filler board in the case of expansion joints, shall have the following degree of rigidity when fixed in position:(i) For expansion joints, the deflection of the top edge of the fillet board shall be not greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical face of the joint filler board and disuibuted over a length of 600mm by means of a bar or timber packing, at mid depth and midway bet wean individual fixings, or 300 mm from either end of any length of filler board, if a continuous fixing is used. The residual deflection after removal of the load shall be not more than 3 mm. The joint assembly fixings to sub-base shall not fail under the l.3kN load applied for testing the rigidity of the assembly but shall failbe~orethe load reaches 2.6 kN.
(ii)
(iii) The fixings for contraction joint shall not fail under 1.3 kN load and shall fail before the load readies 2~6 kN when applied over a length of 600 mm means of a bar or limber packing placed as near to the level of the line of fixings as practicable.
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Concrete Pavement
Section 600
(iv) Fixings shall be deemed to fail when there is displacement of the assemblies by more than 3 mm with any foms of fixing, under the test load. The displacement shall be measured at the nearest part of the assembly to the centre of the bar or timber packing.
602.6.5.5. Dowel bars shall be covered by a thin plastic sheath for at least two-thirds of the length from one end for dowel bars in contraction joinLs or half the length plus 50 mm for expansion joints. The sheath shall be tough, durable and of an average thickness not greater than 1.25 mm. The sheathed bar shall comply with the following pull-out tests:
(i) Four bars shall be taken at random from stock and without any special preparation shall be covered by sheaths as required in this Clause. The ends of the dowel bars which have been sheathed shall be cast centrally into concrete specimens 150 x 150 a 600 mm, made of the same mix proportions to be used in the pavement, but with a maximum nominal aggregate size of 20 mm and cured in accordance with IS: 516. At 7 days a tensile load shall be applied to achieve a movement of the bar of at least 0,25 trim. The average bond stress to achieve this movement shall not be greater than 014 MPa.
602.6.5.6. For expansion joints, a closely fitting cap 100 mm long consisting of waterproofed cardboard or an approved synthetic material like PVC or (31 pipe shall be placed over the sheathed end of each dowel bar. An expansion space at least equal in length to the thickness of the joint filler board shall be formed between the end of the cap and the end of the dowel bar by using compressible sponge. To block the entry of cement slurry between dowel and cap it may be taped. 602.6.6. Tie bars 602.6.6.1. Tie bars in longitudinal joints shall be deformed steel bars of strength 415 MPa complying with IS:1786 and in accordance with the requirements given below. The bars shall be free from oil, dirt,loose rust and scale. 602.6.6.2. Tie bars projecting across the longitudinal joint shall be protected from corrosion for 75mm on each side of the joint by a protective coating of bituminous paint with the approval of the Engineer. The coating shall be dry when the tie bars are used. 602.6.6.3. Tie bars in longitudinal joints shall be made up into rigid assemblies with adequate supports and fixings to remain firmly in position during the construction of the slab. Alternatively, tie bars at longitudinal joints may be mechanically or manually inserted into the plastic concrete from above by vibration using a method which ensures correct placement of the bars and recompaction of the concrete around the tie bars.
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Section 600
Cemcrete
Pavement
602.6.6.4. Tie bars shall be positioned to remain within the middle third of the slab depth as indicated in the drawings and approximately parallel to the surface and approximately perpendicular to the line of the joint, with the centre of each baron the intended line of the joints within a tolerance of 50mm, and with a minimum cover of 30 mm below the joint groove. 602.7. Weather and Seasonal Limitations 602.7.1. Concreting during monsoon months: When concrete is being placed during monsoon months and when it may be expected to rain, sufficient supply of tarpaulin or other water proof cloth shall be provided along the line of the work, Any time when it rains, all freshly laid concrete which had not been covered for curing purposes shall be adequately protected. Any concrete damaged by rain snail be removed and replaced. If the damage is limited to texture, it shall be retextured in accordance with the directives of the Engineer. 602.7.2. Concreting in hot weather: No concreting shall be done when the concrete temperature is above 30 degree Centigrade. Besides, in adverse conditions like high temperature, low relative humidity, excessive wind velocity, imminence of rains etc., if so desired by the Engineer, tents on mobile trusses may be provided over the freshly laid concrete for a minimum period of 3 hours as directed by the Engineer. The temperature of the concrete mix on reaching the paving site shall not be more than 30C. To bring down the temperature, if necessary, chilled water or ice flakes should be made use of. No concreting shall be done when the concrete temperature is below 5 degree Centigrade and the temperature is descending. 602.8. Side Forms, Rails and Guidewires 602.8.1. Side forms and rails: All side forms shall be of mild steel of depth equal to the thickness of pavement or slightly less to accommo~ date the surface regularity of the sub-base. The forms can be placed on series of steel packing plates or shims to take care of irregularity of subbase. They shall be sufficiently robust and rigid to support the weight and pressure caused by a paving equipment. Sideforms for use with wheeled paving machines shall incorporate metal rails firmly fixed at a constant height below the top of the forms. The forms and rails shall be firmly secured in position by not less than 3 stakes/pins per each 3 m length so as to prevent movement in any direction. Forms and rails shall be straight within a tolerance of 3 mm in 3 m and when in place shall
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Concrete Pavement
Section 600
not settle in excess of 1.5 mm in 3 m while paving is being done. Forms shall be cleaned and oiled immediately before each use. The forms shall be bedded on a continuous bed of low moisture content lean cement mortar or concrete and set to the line and levels shown on the drawings within tolerances ~ mm and 3 mm respectively. The 10 bedding shall not extend under the slab and there shall be no vertical step between adjacent forms of more than 3 mm. The forms shall be got inspected from the Engineer for his approval before 12 hours on the day before the construction of the slab and shall not be removed until at least 12 hours afterwards. 602.8.2. At all times sufficient forms shall be used and set to the required alignment for at least 200 m length of pavement immediately in advance of the paving operations, or the anticipated length of pavement to be laid within the next 24 hrs whichever is more. 602.83. Use of guidewires 602.8.3.1. Where slip form paving is proposed, a guidewire shall be provided along both sides of the slab. Each guidewire shall be at a constant height above and parallel to the required edges of the slab as described in the contract/drawing within a vertical tolerance of 3mm. Additionally, one of the wires shall be kept at a constant horizontal distance from the required edge of the pavement as indicated in the contract/drawing within a lateral tolerance of 10 mm. 602.8.3.2. The guidewires shall be supported on stakes not more than 8 m apart by connectors capable of fine horizontal and vertical adjust.. ment. The guidewire shall be tensioned on the stakes so that a 500 gram weight shall produce a deflection of not more than 20 mm when suspended at the mid point between any pair of stakes. The ends of the guidewires shall be anchored to fixing point or winch and not on the stakes. 602.8.3.3. The stakes shall be positioned and the connectors maintained at their correct height and alignment from 12 hours on the day before concreting takes place until 12 hours after finishing of the concrete. The guidewire shall be erected and tensioned on the connectors at any section for at least 2 hours before concreting that section. 602.8.3.4. The Contractor shall submit to the Engineer for his approval of line and level, the stakes and connectors which are ready for use in the length of road to be constructed by 12 hours on the working
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Section 600
Concrete Pavement
day before the day of construction of slab. Any deficiencies noted by the Engineer shall be rectified by the Contractor who shall then re-apply for approval of the affected stakes. Work shall not proceed until the Engineer has given his approval. It shall be ensured that the stakes and guidewires are not affected by the construction equipment when concreting is in progress. 602.9. Construction 602.9.1. General: A systems approach may be adopted for construction of the pavement, and the Method Statement for carrying out the work, detailing all the activities including indication of time-cycle, equipment, personnel etc., shall be got approved from the Engineer before the commencement of the work. The above shall include the type, capacity and make of the batching and mixing plant besides the hauling arrangement and paving equipment. The capacity of paving equipment, batching plant as well as all the ancillary equipment shall be adequate for a paving rate of atleast 300 m in one day. 602.9.2. Batching and mixing: Batching and mixing of the concrete shall be done at a central batching and mixing plant with automatic controls, located at a suitable place which takes into account sufficient space for stockpiling of cement, aggregates and stationary water tanks. This shall be, however, situtated at an approved distance, duly considering the properties of the mix and the transporting arrangements available with the Contractor. 602.9.3. Equipment for proportioning of materials and paving 602.9.3.1. Proportioning of materials shall be done in the batching plant by weight, each type of material being weighed separately. The cement from the bulk stock may be weighed separately from the aggregates and water shall be measured by volume. Wherever properly graded aggregate of uniform quality cannot be maintained as envisaged in the mix design, the grading of aggregates shall be controlled by appropriate blending techniques. The capacity of batching and mixing plant shall be at least 25 per cent higher than the proposed capacity of the laying/paving equipment. 602.9.3.2. Batching plant and equipment: (1) General- The batching plant shall include minimum four bins, weighing hoppers, and scales for the fine aggregate and for each size of coarse aggregate. If cement is used in bulk, a separate scale for cement shall be included. The weighing hoppers shall
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oncrete Pavement
Section 600
be properly sealed and vented to preclude dust during operation. Approved safety devices shall be provided and maintained for the protection of all personnel engaged in plant operation, inspection and testing. The batch plant shall be equipped with a suitable non-resettable batch counter which will correctly indicate the number of batches proportioned. (2) Bins and hoppers- Bins with minimum number of four adequate separate compartments shall be provided in the batching plant. (3) Automatic weighing devices-Batching plant shall be equipped to proportion aggregates and bulk cement by means of automatic weighing devices using load cells. (4) Mixers- Mixers shall be pan type, reversible type or any other mixer capable of combining the aggregates, cement, and water into a thoroughly mixed and uniform mass within the specific mixing period, and of discharging the mixture, without segregation. Each stationary mixer shall be equipped with an approved timing device which will automatically lock the discharge lever when the drum has been charged and release it at the end of the mixing period. The device shall be equipped with a bell or other suitable warning device adjusted to give a clearly audible signal each time the lock is released. In case of failure of the timing device, the mixer may be used for the balance of the day while it is being repaired, provided that each batch is mixed 90 seconds or as per the manufacturers recommendation. The mixer shall be equipped with a suitable non-resettable batch counter which shall correctly indicate the number of batches mixed. The mixers shall be cleaned at suitable intervals. The pickup and throw-over blades in the drum or drums shall be repaired or replaced when they are worn down 20 mm or more. The Contractor shall (1) have available at thejob site a copy of the manufacturers design, showing dimensions and arrangements of blades in reference to original height and depth, or (2) provide permanent marks on blade to show points of 20 mm wear from new conditions. Drilled holes of 5 mm diameter near each end and at midpoint of each blade are recommended. Batching Plant shall be calibrated in the beginning and thereafter at suitable interval not exceeding I month.
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Section 600
-
Concrete Pavement
(5) Control cabin An air-conditioned centralised control cabin shall be provided for automatic operation of the equipment. 602.9.33. Paving equipment : The concrete shall be placed with an approved fixed form or slip from paver with independent units designed to (i) spread,(ii) consolidate, screed and float-finish, (iii) texture and cure the freshly placed concrete in one complete pass of the machine in such a manner that a minimum of hand finishing will be necessary and so as to provide a dense and homogeneous pavement in conformity with the plans and Specifications.The paver shall be equipped with electronic controls to control/sensor line and grade from either or both sides of the machine, Vibrators shall operate at a frequency of 8300 to 9600 impulses per minute under load at a maximum spacing of 60 cm. The variable vibration setting shall be provided in the machine. 602.9.3.4. Concrete saw : The Contractor shall provide adequate number of concrete saws with sufficient number of diamond-edge saw blades. The saw machine shall be either electric or petrol/diesel driven type. A water tank with flexible hoses and pump shall be made available in this activity on priority basis. The Contractor shall have at least one standby saw in good working condition. The concreting work shall not commence if the saws are not in working condition. 602.9.4. Hauling and placing of concrete 602.9.4.1. Freshly mixed concrete from the central batching and mixing plant shall be transported to the paver site by means of trucks/tippers of sufficient capacity and approved design in sufficient numbers to ensure a constant supply of concrete. Covers shall be used for protection of concrete against the weather. The trucks/tippers shall be capable of maintaining the mixed concrete in a homogeneous state and discharging the same without segregation and loss of cement slurry. The feeding to the paver is to be regulated in such a way that the paving is done in an uninterrupted manner with a uniform speed throughout the days work. 602.9.4.2. Placing of concrete Concrete mixed in central mixing plant shall be transported to the Site without delay and the concrete which, in the opinion of the Engineer, has been mixed too long before laying will be rejected and shall be removed from the site. The total time taken from the addition of the water to, the mix, until the completion of the surface finishing and texturing
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23.4
Concrete Pavement
Section 600
shall not exceed 120 minutes when concrete temperature is less than 25C and 90 minutes when the concrete temperature is between 25Cto 30C. Truck~ltippersdelivering concrete shall not run on plastic sheeting nor shall they run on completed slabs until after 28 days of placing the concrete. The Paver shall be capable of paving the carriageway as shown in the drawings, in a single pass and lift. 602.9.4.3. Where fixed form payers are to be used, forms shall be fixed in advance as per Clause 602.8. of the Specifications. Before any paving is done, the site shall be shown to the Engineer, in order to verify the arrangement for paving besides placing of dowels, tie-bars etc., as per the relevant Clauses of this Specification. The mixing and placing of concrete shall progress only at such a rate as to permit proper finishing, protecting and curing of the pavement. 602.9.4.4. En all cases, the temperature of the concrete shall be measured at the point of discharge from the delivery vehicle. 602.9.4.5. The addition of water to the surface of the concrete to facilitate the finishing operations will not be permitted except with the approval of the Engineer when it shall be applied as a mist by means of approved equipment. 602.9.4.6. If considered necessary by the Engineer, the paving machines shall be provided with approved covers to protect the surface of the slab under construction from direct sunlight and rain or hot wind. 602.9.4.7. While the concrete is still plastic, its surface shall be brush textured in compliance with Clause 602.9.8 and the surface and edges of the slab cured by the application of a sprayed liquid curing membrane in compliance with Clause 602.9.9. After the surface texturing, but before the curing compound is applied, the concrete slab shall be marked with the chainage at every 100 m interval. 602.9.4.8. As soon as the side forms are removed, edges of the slabs shall be corrected wherever irregularities have occurred by using fine concrete composed of one part of cement to 3 parts of fine chips and fine aggregate under the supervision of the Engineer. 602.9.4.9. If the requirement of Clause 902.4. for surface regularity fails to be achieved on two consecutive working days, then normal working shall cease until the cause of the excessive irregularity has been identified and remedied. 602.9.5, Construction by fixed form paver 602.9.5.1. The fixed form paving train shall consist of separate
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Section 600
Concrete Pavement
powered machines which spread, compact and finish the concrete in a continuous operation. 602.9.5.2. The concrete shall be discharged without segregation into a hopper spreader which is equipped with means for controlling its rate of deposition on to the subbase. The spreader shall be operated to strike off concrete uptq a level requiring a small amount of cutting down by the distributor of the spreader. The distributor of spreader shall strike off the concrete to the surcharge adequate to ensure that the vibratory compactor thoroughly compacts the layer. If necessary, poker vibrators shall be used adjacent to the side forms and edges of the previously constructed slab. The vibratory compactor shall be set to strike off the surface slightly high so that it is cut down to the required level by the oscillating beam. The machine shall be capable of being rapidly adjusted for changes in average and differential surcharge necessitated by changes in slab thickness or cross fall, The final finisher shall be able to finish the surface to the required level and smoothness as specified, care being taken to avoid bringing up of excessive mortar to the surface by overworking. 602.9.6. Construction by slip form paver 602.9.6.1. The slip form paving train shall consist of power machine which spreads, compacts and finishes the concrete in a continuous operation. The slip form paving machine shall compact the concrete by internal vibration and shape it between the side forms with either a conforming plate or by vibrating and oscillating finishing beams. The concrete shall be deposited without segregation in front of slip form paver across the whole width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be struck off to the necessary average and differential surcharge by means of the strike off plate or a screw auger device extending across the whole width of the slab. The equipment for striking-olf the concrete shall be capable of being rapidly adjusted far changes of the average and differential surcharge necessitated b change in slab thickness or crossfall. 602.9.6.2. The level of the conforming plate and finishing beams shall be controlled automatically from the guide wires installed as per Clause 602.8 by sensors attached at the four corners of the slip form paving machine. The alignment of the paver shall be controlled automatically from the guide wire by at least one set of sensors attached to the paver. The alignment and level of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlled relative
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Concrete Pavement to the guide wire or to the surface and edge of the slab.
Section 600
602.9.6.3. Slip-form paving machines shall have vibrators of variable output, with a maximum energy output of not less than 2.5 KW per metre width of slab per 300 mm depth of slab for a la~ ~ngspeed upto 1.5 m per minute or pro-rata for higher speeds. The machines shall be of sufficient mass to provide adequate reaction during spreading and paving operations on the traction units to maintain forward movements during the placing of concrete in all situations. 602.9.6.4. If the edges of the slip formed slab slump to the extent that the surface of the top edge of the slab does not comply with the requirements of Clause 602.14, then special measures approved by the Engineer shall be taken to support the edges to the required levels and work shall be stopped until such time as the Contractor can demonstrate his ability to slip form the edges to the required levels. 602.9.7. Construction by hand-guided method: Areas in which hand-guided methods of construction become indispensable shall be got approved by the Engineer in writing in advance. Such work may be permitted only in restricted areas in small lengths. Work shall be carried out by skilled personnel as per methods approved by the Engineer. The acceptance criteria regarding level, thickness, surface regularity, texture, finish, strength of concrete and all other quality control measures shall be the same as in the case of machine laid work. 602.9,8. Surface texture 602.9.8.1. After the final regulation of the slab and before the application of the curing membrane, the surface of concrete slab shall be brush-textured in a direction at right angles to the longitudinal axis of the carriageway. 602.9.8.2. The brushed surface texture shall be applied evenly across the slab in one direction by the use of a wire brush not less than 450 mm wide but longer brushes are preferred. The brush shall be made of 32 gauge tape wires grouped together in tufts spaced at 10 mm centres. The tufts shall contain an average of 14 wires and initially be 100 mm long. The brush shall have two rows of tufts. The rows shall be 20 mm apart and the tufts in one row shall be opposite the centre of the gap between tufts in the. other row. The brush shall be replaced when the shortest tuft wears down to 90 mm long. 602.9.8.3. The texture depth shall be determined by the Sand Patch Test as described in Clause 602.12. This test Shall be performed at least
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Section 600
Concrete
Pavement
once for each days paving and wherever the Engineer considers it necessary at times after construction as under: Five individual measurements of the texture depth shall be taken at least 2 m apart anywhere along a diagonal line across a lane width between points 50 m apart along the pavement. No measurement shall be taken within 300 mm of the longitudinal edges of a concrete slab constructed in one pass. 602.9.8.4. Texture depths shall not be less than the minimum required when measurements are taken as given in Table 600-2 nor greater than a maximum average of 1.25 mm.
TABLE 600.2. Texture Depth Number of Measurements Required Texture Depth (mm) Specified Tolerance Value 1.00 025
Time of Test
I Between 24 hours and 7 days after the constn., of the slab or until ilie stab is first used by vehicles. 2. Not later than 6 weekt before the road is opened to public traffic. ,
An average of 5 measurements An average of 5 measurements
1.00
0.25 -035
602.9.8.5. After the application of the brushed texture, the surface of the slab shall have a uniform appearance. 602.9.8.6. Where the texture depth requirements are found to be deficient, the Contractor shall make good the texture across the full lane width over length directed by the Engineer, by retexturing the hardened concrete surface in an approved manner. 602.9.9. Curing 602.9.9.1. Immediately after the surface texturing, the surface and sides of the slab shall be cured by the application of approved resin- based aluminised reflective curing compound which hardens into an impervious film or membrane with the help of a mechanical sprayer. Curing compounds shall contain sufficient flake aluminium in finely divided dispersion to produce a complete coverage of the sprayed surface with a metallic finish. The compound shall become stable and imperviotis to evaporation of water from the surface of the concrete within 60 rninutes of application a~dshall be of approved type. The curing compot~~ds have a water relention efficiency index of 90 per cent in acstall cordaive with BS Specification No. 7542. 238 <<
Concrete Pavement
Section 600
602.9.9.2. The curing compound shall not react chemically with the concrete and the film or membrane shall not crack, peel or disintegrate within three weeks after application. Immediately prior to use, the curing compound shall be thoroughly agitated in its containers. The rate of spread shall be in accordance with the manufacturers instructions checked during the construction of the trial length and subsequently whenever required by the Engineer. The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and mixing of the compound during spraying. 602.9.9.3. In addition to spraying of curing compound, the fresh concrete surface shall be protected for at least 3 hours by covering the finished concrete pavement with tents as described in Clause 602.7.2, during adverse weather conditions as directed by the Engineer. After three hours, the pavement shall be covered by moist hessian and the same shall then be kept damp for a minimum period of 14 days after which time the hessian may be removed. The hessian shall be kept continuously moist. All damaged/tom hessian shall be removed and replaced by new hessian on a regular basis. 602.9.9.4. The Contractor shall be liable at his expense to replace any concrete damaged as a result of incomplete curing or cracked on a line other than that of a joint. 602.10. Trial Length 602.10.1. The trial length shall be constructed at least one month in advance of the proposed start of concrete paving work. At least one month prior to the construction of the trial length, the Contractor shall submit for the Engineers approval a detailed method statement giving description of the proposed materials, plant, equipment and construction methods. All the major equipments like paving train, batching plant, tippers etc., proposed in the construction are to be approved by the Engineer before their procurement. No trials of new materials, plant, equipment or construction methods, nor any development of them shall be permitted either during the construction of trial length or in any subsequent paving work, unless they form part of further, approved trials. These trial lengths shall be constructed away from the carriageway but with at least a subbase layer below it. 602.10.2. The Contractor shall demonstrate the materials, plant, equipment and methods of construction that are proposed for concrete paving, by first constructing a trial length of slab, at least 60 m but not more than 300 m long for mechanised construction and at least 30 m long
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for hand guided methods. If the first trial is unsatisfactory, the Contractor shall have to demonstrate his capability to satisfactorily construct the pavement in subsequent trials. 602.10.3 The trial length shall be constructed in two parts over a period comprising at least part of two separate working days, with a minimum of 30 m constructed each day for mechanised construction and a minimum of 15 m on each day for hand guided construction. The trial length shall be constructed at a similar rate (speed, around lm/hr) to that which is proposed for the main work. 602.10.4. Transverse joints and longitudinal joints of each type that are proposed for dowel-jointed unreinforced concrete slabs in the main work shall be constructed and assessed in the trial length. If in the trial length the construction of expansion joint and longitudinal joint is not demonstrated, the first 2 expansion joints and at least the first 150 m of longitudinal construction joint for mechanised paving in the main work, shall be considered as the trial length for these joints. 602.10.5. The trial length shall comply with the Specification in all respects, with the following additions and exceptions: 602.10.5.1. Surface levels and regularity
(i) In checking for compliance with Clause 903.5 the levels shall be taken at intervals at the locations specified in this Clause along any line or lines parallel to the longitudinal centre line of the trial length. The maximum number ofpermitted irregularities of pavement surface shall comply with the requiresents of Clause 902.4. Shorier trial lengths shall be assessed pro. rats based on values for a 300 m length.
(ii)
602.10.5.2. Joints
(iii) Alignment, of dowel bars shall be inspected as described in Clause 602.10.7 in any two consecutive transverse joints. If the position or alignment of the dowel bars at one of these joints does not comply with Clause 602.6.5, ii that joint remains the only one that does not comply after the next 3 consecutive joints of the same type have been inspected, then the method of placing dowels shall be deemed to be satisfactory. In order to check sufficient joints for dowel bar alignment without extending the trial length unduly, the Contractor may, by agreement with the Engineer, construct joints at more frequent joint intervals than the normal spacing required in the Contract. (iv) If there are deficiencies in the first expansion joint that is constructed as a trial, the next expansion joint shall be a trial joint. Should this also be deficient, further tziai expansion joints shall be made as pars of the trial length which shall not form part of the permanent works, unless agreed by the Engineer.
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602.10.53. Density
(v) Density shall be assessed as described in Clause 602.3.3, from a! least 3 cores drilled from each part of the trial length.
602.10.5.4. Position of tie bars

(vi) Compliance with Clause 602,6,6 for the position and alignment of tie bars shall be checked by drilling additional cores from the slab unless they can be determined from cores taken for density.
602.10.6. Approval and acceptance 602.10.6.1 Approval of the materials, plant, equipment and construction methods shall be given when a trial length complies with the Specification. The Contractor shall not proceed with normal working until the trial length has been approved and any earlier defective trial lengths have fren removed, unless that can be remedied to the satisfaction of the Engineer, If the Engineer does not notify the Contractor of any deficiencies in any trial length within 10 days after the completion of that trial length, the Contractor may assume that the trial length, and the materials, plant, equipment and construction methods adopted are acceptable. 602.10.6.2. When approval has been given, the materials, plant, equipment and construction methods shall not thereafter be changed, except for normal adjustments and maintenance of plant, without the approval of the Engineer. Any changes in materials, plant, equipment, and construction methods shall entitle the Engineer to require ,the Contractor to lay a further trial length as described in this Clause to demonstrate that the changes will not adversely affect the permanent works. 602.10.6.3. Trial lengths which do not comply with the Specification, with the exception of areas which are deficient only in surface texture and which can be remedied in accordance with Clau~e602.9.8.6 shall be removed immediately upon notification of deficiencies ~y the Engineer and the Contractor shall construct a further trial length. 602.10.7. Inspection of dowel bars 602.10.7.1. Compliance with Clause 602.6.5. for the position and alignment of dowel bars at construction and expansion joints shall be checked by measurements relative to the side forms or guide wires. 602.10.7.2. When the slab has been constructed, the position and alignment of dowel bars and any filler board shalT be measured after carefully exposing them in the plastic concrete across the whole width of the slab. When the joint is an expansion joint, the top of the filler board
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shall first be exposed sufficiently in the plastic concrete to permit measurement of any lateral or vertical displacement of the board. During the course of normal working, these measurements shall be carried out in the pavement section at the end of days work by extending slab length by 2 m. Alter sawing the transverse joint groove, the extended 2 m slab shall be removed carefully soon after concrete has set to expose dowels over half the length. These dowels can be tested for tolerances. 64)2.10.7.3. If the position and alignment of the bars in a single joint in the slab is unsatisfactory then the next two joints shall be inspected. If only one joint of the three is defective, the rate Of checking shall be increased to one joint per day until the Engineer is satisfied that compliance is being achieved. In the event of non-compliance in two or more successive joints, the Contractor shall revert to the construction of fresh trial lengths and make any necessary alteration to concrete mix, paving plant or methods until the dowel bar position and alignment are satisfactory. 602.10.7.4. After the dowel bars have been examined, the remainder of the concrete shall be removed over a width of 500 mm on each side of the line of the joint and reinstated to the satisfaction of the Engineer. The dowels shall be inserted on both sides of the 1 m wide slab by drilling holes and grouting with epoxy mortar. Plastic sheath as per Clause 602.6.5.5 shall be provided on dowels on one of the joints. The joint groove shall be widened and sealed as per Clause 602.11. 602.11. Preparation and Sealing of Joint Grooves 602.11.1, General All transverse joints in surface slabs shall be sealed using sealants ~.lescrihedin Clause 602.2.8. Joints shall not be sealed before 14 days after construction. 602.11.2. Preparation of joint grooves for sealing 602.11.2.1. Joint grooves usually are not constructed to provide the minimum width specified in the drawings when saw cut joints are adopted. They shall be widened subsequently by sawing before sealing. iicpth/w idth gauges shall be used to control the dimension of the groove. 602.11.2.2. If rough arrises develop when grooves are made, they shall be ground to provide a chamfer approximately 5 mm wide. If the groove is at an angle upto 10 degree from the perpendicular to the surface, the overhanging edge of the sealing groove shall be sawn
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or ground perpendicular. If spalling occurs or the angle of the former is greater than 10 degrees, the joint sealing groove shalt be sawn wider and perpendicular to the surface to encompass the defects upto a maximum widl.h, including any chamfer, of 35 mm for transverse joints and 20 mm for longitudinal joints. If the spalling cannot be so eliminated then the arrises shalt be repaired by an approved thin bonded arris repair using cementitious materials. 602.11.2.3. All grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil-free compressed air. If need arises the Engineer may instruct cleaning by pressurised water jets, Depending upon the requirement of the sealant manufacturer, the sides of the grooves may have to be sand blasted to increase the bondage between sealant and concrete. 602.11.2.4. The groove shall be cleaned and dried at the time of priming and sealing. 602.11.2.5. Before seating the temporary seal provided for btocking the ingress of dirt, soil etc., shall be removed. A highly compressible heat resistant paper-backed debonding strip as per drawing shall be inserted in the groove to serve the purpose of breaking the bond between sealant and the bottom of the groove and to plug the joint groove so that the sealant may not leak through the cracks. The width of debonding strip shalt be more than the joint groove width so that it is held tightly in the groove. In the case of longitudinal joints, heat resistant tapes may he inserted to block the leakage through bottom of the joint. 602.11.3. Sealing with sealanis 602.11.3.1. When sealants are applied, an appropriate primer shall also be used if recommended by the manufacturer and it shall be applied in accordance with their recommendation. The sealant shall be applied within the minimum and maximum drying times of the primer recommended by the manufacturer. Priming and sealing with applied sealants shall not be carried out when the naturally occurring temperature in the joint groove to be sealed is below 7C. 602.11.3.2. If hot applied sealant is used it shall be heated and applied from a thermostatically controlled, indirectly heated preferably with oil jacketed melter and pourer having recirculating pump and extruder. For large road projects, sealant shall be applied with extruder having flexible hose and nozzle. The sealant shall not be heated to a temperature higher than the safe heating temperature and not for a period
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longer than the safe heating period, as specified by the manufacturer. The dispenser shall he cleaned out at the end of each day in accordance with the manufacturers recommendations and reheated m4terial shall not be used. 602.11.3.3. Cold applied sealants with chemical formulation like polysulphide may be used. These shall be mixed and applied within the time limit specified by the manufacturer. If primers are recommended they shall be appLied neatly with an appropriate brush. The Movement Accommodation Factor (MAF) shall be more than 10 per cent. 602.11.3.4. The sealants applied at contraction phase of the slabs would result in bulging of the sealant over and above the slab. Therefore, the Contractor in consultation with the Engineer, shall establish the right temperature and time for applying the sealant. Thermometer shall be hung on a pole in the site for facilitating control during the sealing operation. 602.11.3.5. Sealant shall be applied, slightly to a lower level than the slab with a tolerance of 5 mm. 2 602.11.3.6. During sealing operation, it shall be seen that no air bubbles are introduced in the sealant either by vapours or by the sealing process. 602.11.4. Testing of applied sea lants: Manufacturers certificate shall be produced by the Contractor for establishing that the sealant is not more than six months old and stating that the sealant complies with the relevant standard as in Clause 602.2.8. The samples shall meet the requirement of AASHTO M 282 for hot applied sealant or BS 5212: (Part2) for cold applied sealant. 602.12. Measurement of Texture Depth Sand Patch Method 602.12.!. The following apparatus shall be used:
-
(i) (ii) (iii)
A cylindrical container of 25 ml internal capacity A nat wooden disc 64 mm diameter with a hard rubber disc, 1.5 mm thick, stuck to one face, the reverae face being provided with a handle Dry natural sand with a rounded particle shape passing a 300 micmn 15 sieve and nctained on a 150 micron 15 sieve.
602.12.2. Method: The surface to be measured shall be dried, any extraneous mortar and loose material removed and the surface swept clean using a wire brush both at right angles and parallel to the carriageway. The cylindrical container shall be filled with the sand, tapping the base 3 times on the surface to ensure compaction, and
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Section 600
striking off the sand level with the top of the cylinder. The sand shall be poured into a heap on the surface to be treated. The sand shall be spread over the surface, working the disc with its face kept flat in a circular motion so that the sand is spread into a circular patch with the surface depressions filled with sand to the level of peaks. 602.12.3. The diameter of the patch shall be measured to the nearest 5 mm. The texture depth of concrete surface shall be calculated from 3l000/(DxD) mm where D is the diameter of the patch in mm. 602.13. Opening to Traffic No vehicular traffic shall be allowed to run on the finished surface of a concrete pavement within a period of 28 days of its construction and until the joints are permanently sealed. The road may be opened to regular traffic after completion of the curing period of 2~ days and after scaling of joints is completed including the construction of shoulder, with the written permission of the Engineer. 602.14. Tolerances for Surface Regularity, Level, Thickness and Strength The tolerances for surface regularity, level, thickness and strength shall conform to the requirements given in Clause 903.5. Control of quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 602.15. Measurements for Payment 602.15.1. Cement Concrete pavement shall be measured as a finished work in square metres with specified thickness. The volume to be paid for will be calculated on the basis of thickness and plans shown on the project drawings and adjusted for the deficiency in thickness. No additional payment shall be made for extra thickness of the slab. The full payment will be made to this item after 28 days strength of the concrete is found to be satisfactory. The unit for measurement for concrete pavement shall be the cubic metre of concrete placed, based on the net plan areas for the specified thickness shown on the Drawings or directed by the Engineer. The rate shall include all provisions of this Specification and shall include the provision of all materials including polythene film, concrete, stock piling, mixing, transport, placing, compacting, finishing, curing together with all formwork, and including testing and submission of test certificates and records. No deduction shall be made in measurement for openings provided that the area of each is less than 0.5 sq. m. The unit rate
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Section &00
Concrete Pavement
as entered in the Bill of Quantities shall also include the full costs of contraction, expansion, construction, and longitudinal joints, It shall also incLude joint filler, keys, caulking rod, deboding strip, sealant primer, joint sealant, dowel bar and tie rod. 602.15.2, Pavement thickness All precautions and care shall he taken to construct pavement having uniform thickness as called for on the plans. Thickness of the cement concrete pavement shall be calculated on the basis of level data of the cement concrete pavement and the underlying sub-base taken on a grid of 5 m x 3.5 m or 6.25 m x 3.5 m, the former measurement being in longitudinal direction. A days work is considered as a ~lot for calculating the average thickness of the slab. In calculating the average thickness, individual measurements which are in excess of the specified thickness by more than 10 mm shall be considered as the specified thickness plus 10 mm. Individual areas deficient by more than 25 mm shall be verified by the Engineer by ordering core cutting and if in his opinion the deficient areas warrant removal, they shall be removed and replaced with concrete of the thickness shown on the plans. When the average thickness for the lot is deficient by the extent shown in Table 600.3, the Contract unit price will be adjusted as per this TabLe,
TAIILE 600.3. PAYMENT ADJUSTMENT FOR DEFICIENCY IN THICKNFSS Deficiency in the average thickness of days work Upto5mm 6.10mm 11-15mm 16.20mm 21-25mm Per cent of Contract unit price payable 100 87 81 75 70
In the stretch where deficiency of average thickness is more than 25 mm, the section whose thickness is deficient by 26 mm or more is identified with the help of cores. Such slabs shall be removed and reconstructed at the cost of the Contractor. During such rectification work, care shall be taken to replace full slab and to the full depth.
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Seaion 600
602.16. Rate The Contract unit rate for the construction of the cement concrete shall be payment in fuLl for carrying out the operations required for the different items of the work as per these Specifications including full compensation for all labour, tools, plant, equipments, testing and incidentals to complete the work as per Specifications, providing all materials to be incorporated in the work including all royalties, fees, storage, rents where necessary and all leads and lifts. 603. ROLLED CEMENT CONCRETE BASE 603.1. Scope 603.1.1. The work shall consist of construction of rolled concrete base course for cement concrete pavement in accordance with the requirements of these Specifications and in conformity with the lines, grades and cross sections shown on the drawings or as directed by the Engineer. The work shall incLude furnishing of all plant and equipment, material and Labour and performing all operations in connection with the work, as approved by the Engineer. 603.1.2. The design parameters of rolled cement concrete base course viz,, width, thickness, grade of concrete, details of joints, if any, etc. shall be as stipulated in the contract drawings. 603.2. Materials 603.2.1. Source of materials: The Contractor shall indicate to the Engineer the source of all materials to be used in the lean concrete work with relevant test data sufficiently in advance and the approval of the Engineer for the same shall be obtained at least 60 days before the scheduled commencement of the work. If the Contractor later proposes to obtain the materials from a different source, he shall notify the Engineer for his approval at least 60 days before such materials are to be used. t~03.2.2.Cement: Any of the following types of cement may be used with prior approval of the Engineer.
(i) (ii) Ordinary Portland Cement Portland Slag Cement IS 269, 8112 or 12269 455 1489
IS
IS
(iii) Portland Pozzolana Cement
If the subgrade is found to consist of soltible sulphates in a concentration more than 0.5 per cent, cement used shall be sulphate resistant and shall conform to IS 12230. Cement to be used may
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Section 600
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preferably be obtained in bulk form. It shall be stored in accordance with stipulations contained in Clause 1014 and shaLl be subjected to acceptance test prior to its immediate use. 603.2.3. Aggregates 603.2.3.1. Aggregates for lean concrete shall be natural material complying with IS: 383. The aggregates shall not be alkali reactive. The limits of deleterious materials shall not exceed the requirements set out in IS: 383. In case the Engineer considers that the aggregates are not free from dirt, the same may be washed and drained for at least 72 hours before batching as directed by the Engineer. 603.2.3.2. Coarse aggregate : Coarse aggregates shall consist ol clean, hard, strong, dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces. The maximum size of the coarse aggregate shall be 25 mm. The coarse aggregate shall comply with the Clause 602.2.4.2. 603.2.3.3. Fine aggregate : The fine aggregate shall consist of clean natural sand or crushed stone sand or a combination of the two and shalL conform to IS:383. Fine aggregate shall be free from soft particles, clay, shale, Loam, cemented particles, mica, organic and other foreign matter. The fine aggregate shall comply with the Clause 602.2.4.3. 603.2.3.4. The coarse and fine aggregates may be obtained in either of the following manner:(1) (ii) In separate nominal sizes of coarse and fine aggregates and intimately before use. mixed together
Separately as 25 mm nominal single size, 12.5 mm nominal size graded aggregate and fine aggregate of crushed stone dust or sand or a combination of these two.
The material after blending shall conform to the grading as indicated in Table 600-4 below:
TABLE 600.4. AGGREGATE GRADATION FOR DRY LEAN CONCRETE Sieve Designation Percentage Passing the sieve by weight 100 80.100 55-80 35-60 10-35 0-8
37.5 mm 19.0 mm 9.5 mm 4.75 mm 600 micron 75 micron
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603.2.4. Water: Water used for mixing and curing of concrete shall be clean and free from injurious amount of oil, salt, acid, vegetable matter or other substances harmful to the finished concrete. It shall meet the requirements stipulated in IS: 456. 603.2.5. Storage of materials: All materials shall be stored in accordance with the provisions of Clause 1014 of these Specifications, and other relevant IS Specifications. All efforts must be made to store the materials in proper places so as to prevent their deterioration or contamination by foreign matter and to ensure their satisfactory quality and fitness for the work. The storage place must also permit easy inspection, removal and storage of materials. All such materials even though stored in approved godowns must be subjected to acceptance test immediately prior to their use. The requirement of storage yard specified in lause 602.2.9 shall be applicable. 603.3, Proportioning of Materials for the Mix 603.3.1. The mix shall be proportioned with a maximum aggregate: cement ratio of 15.1. After the approval of all the materials to be used in the concrete, the Contractor shall submit the mix design based on weighed proportion of all ingredients for the approval of the Engineer. The mix design shall be submitted at least 30 days prior to the paving of trial length and design shall be done based on the laboratory trials using approved materials and methods. The water content shall be adjusted to the optimum as per Clause 603.3.2. for facilitating compaction by rolling. The target mean strength for the design mix as well as acceptance Speciflcation of concrete shall be in accordance with Clause 903.5.2. The mix design shall be based on the flexural strength of concrete. 603.3.2. Moisture content: The right amount of water for the rolled concrete in the main work shall be decided for ensuring full compaction under rolLing and shall be assessed at the time of rolling the trial length. Too much water will cause the concrete to be picked up on the wheels of the roller and too little will lead to inadequate compaction, a low in-situ strength and an open textured surface. The optimum water content shall be determined in accordance with Clause 603.7. and demonstrated by rolling during trial length construction; and the optimum moisture content and degree of compaction shall be got approved by the Engineer. While laying, in the main work, the rolled concrete shall have a moisture content between the optimum and optimum + 2 per cent,
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keeping in view the effectiveness of compaction achieved and to compensate for evaporation losses. 603.3.3. Cement content: The minimum cement content in the rolled concrete shall not be less than 150 kg/cuff. of concrete. If this mininium cement content is not suflicient to produce concrete of the specified strength, it shall be increased as necessary without additional compensation under the Contract. 603.3.4. Concrete strength: The flexural strength as specified shall be the governing criteria for approval of the mix, While designing the mix in the laboratory, correlation between flexura! and compressive strengths of concrete shall be established on the basis of tests on samples for use at a later date to verify the in situ flexural strength of rolled concrete through testing of cores. At least a batch of two beam and cube specimens, one each for 3 day and 7 day strength testing shall be cast for every 100 cum or part thereof of concrete placed during construction. On each days work not Less than four beams and four cubes shall be made. A ratio between the 3 and 7 day strengths shall be established for the mix to be used. This will help in assessing the fall in strength, if any in advance so that corrective action can be taken for the future work. 603.4. Subgrade The subgrade shall conform to the grades and cross sections shown on the drawings and shall be uniformly compacted to the design strength in accordance with these Specifications and the Specification stipulated in the Contract. The rolled concrete base shall not be laid on a subgrade softened by rain after its final preparation; any surface trenches, soft spots etc., must be properly back-filled and compacted to avoid any weak or soft spot. As far as possible, the construction traffic shall be avoided on the prepared subgrade. A day before placing of the sub-base, the subgrade surface shall be given a fine spray of water and rolled with one or two passes of a smooth wheeled roller after a lapse of 2-3 hours in order to stabilise the loose surface. If the Engineer feels it necessary, another fine spray of water may be applied just before placing the base course. 603.5. Construction Clause 601.5 shaLl apply.
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Section 600
603.6. Trial Mix Using the specified cement content arid proportioned aggregates, the Contractor shall make trial mixes at water contents ranging from 5 per cent to 7 per cent by weight of dry materials at 0.5 per cent intervals using an aggregate /cement ratio of not greater than 15.0. Optimum moisture and density shall be established by preparing cubes with varying moisture contents. The compaction of mould shall be done in three layers as explained in Clause 903.5.2.1. The optimum moisture content determined normally gives an indication about the moisture content which after minor adjustment may provide satisfactory mix which could be rolled. After determining the moisture content from the above trial mix, a set of six beams and cubes shall be prepared for testing them on 3rd and 7th day. if the flexural strength achieved is lower than the desired strength, the above trial shall be repeated after increasing the cement content and adjusting the mix appropriately. During the construction of trial length as per Clause 603.7 minor modifications may have to be carried Out to the moisture content of the mix, But such modified mix shall have to satisfy the flexural strength requirement. Flexural strength to be achieved shall be the governing criteria for the design .of mix. 603.7. Trial Length Clause 601.7 shall apply. 603.8. Traffic No heavy commercial vehicles like trucks and buses shall be permitted on the rolled concrete base after its construction. Light vehicles may be, however, allowed after 7 days of its construction with prior approval of the Engineer. 603.9. Tolerances for Surface ReguIarity~ Level, Thickness and Strength The tolerances for surface regularity, level, thickness and strength shall conform to the requirements given in Clause 903.5. Control of quality of materials and works shall be exercised by the Engineer in accordance with Section 900. 603.10. Measurements for Payment The unit of measurement for concrete and rolled concrete pavement shall be the cubic metre of concrete placed, based on the net plan areas
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for the specified thickness shown on the drawings as directed by the Engineer. 603.11. Rate The Contract unit rate payable for rolled cement concrete for base course shall be payment in full for carrying out the required operations including full compensation for all Labour, materials and equipment, mixing, transport, placing, compacting, finishing, curing, testing and incidentals to complete the work as per Specifications, all royalties, fees, storage and rents where necessary and all leads and lifts.
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Geosynthetics
700 Geosynthetics
<<
Geosynthetics Section 700 701. GEOSYNTHETICS IN ROAD AND BRIDGE WORKS 701.1 Scope This specification covers the various applications of Geosynthetic materials in road and bridge works including supplying and laying as per special provisions. Geosynthetic is a general classification for all synthetic materials used in geotechnical engineering application. It includes geotextiles, geogrids, geonets, geomembranes and geocomposites.
(1)
Geotextile : Any permeable textile natural or Synthetic, used with fotmdation, soil, rock, earth, or any other geoteclasical engineering related material. In the present chapter, ii is related to synthetic material only. Geogrid: A deformed or non-deformed grid of polymeric material used primarily for reinforcement purposes with foundation, soil, suck, earth, or any other geotechnical engineering related material.
(ii)
(iii) Geonets : These are net made of polymeric material used for drainage of foundation, soil, rock, earth or any other geotechnical engineering related material. (iv) Geomembrane : An essentially impermeable membrane of polymeric material used with foundation, soil, rock, earth or any other geotechnical engineering related material, to control fluid migration. (v) Geocomposite A manufactured material using geotextiles. geognds, geonets ancil or geomembrane in laminated or composite form.
701.2 Material Testing and Acceptance Unless otherwise stated, these Geosynthetic materials shall conform to the requirements as under: 701.2.1. Geotextile : Geotextile shall be made of polyethylene or polypropylene or polyester or similar fibres, either woven or nonwoven in variety, through machine made process of heatbonding or needle punching or weaving techniques. These fabrics are required to pass water through but retain the soil particles, which require specific cross-plane permeability or permittivity and apparant opening size or equivalent opening size or 095. The above two requirements alongwith the requirement of strength and durability denote general characteristics of geotextiles to be used. The type of geotextile to be used in a particuLar application shall be decided on the basis of design. 701.2.2. Geogrid : Geogrid shall be made from integralLy jointed, mono or bi-directionally orientated or stretched meshes made from polyethylene or polypropylene or polyester or similar polymer, with high
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secant modulus, in square, rectangular, hexagonal or oval mesh form. Their junction strength shall be high with high creep resistance, and dimensional stability. Their open structure shall permit effective interlocking with soil, aggregates, rock etc., they shall be used as a tensile member or reinforcement. Characteristics strength of such Geogrids vanes from 40 kN/m to 200 kN/m peak strength at a maximum elongation of 15 per cent in the direction of the length of the roll. 701.2.3. Geonet : Geonet shall be made from a single extruded unoriented process from polyethylene or polypropylene or similar polymer. It shall have square or rectangular net shape aperture when used for protective works like gabions and mattresses. While in polygonal aperture it shall be used as a separator. It shall not be used as soil reinforcement due to its high creep characteristics, neither as a slope reinforcement or soil retaining wall or asphaltic reinforcement. Geonets used in protective works for highway structures shall be atleast 650 gm/ sq.m. in unit weight. It shall be black in colour, available in roll form in suitable width. 701.2.4. Geomembrane : Geomembrane shall be made from PVC or polyethelene sheets of atleast 0.8 mm thickness, duly protected from ultraviolet exposure with 2.5 per cent carbon black, in black colour, supplied in roll form with 3 m or above width. The joints of these sheets shall be heatbonded or seamed for effective permeation cut off, at site using standard equipment as part of the laying process. While fixing on to a slope, they shall not be punctured or stappled to impair their use. 701.2.5. Geocomposite : (leocomposites shall be made from combination of geonets, geogrids or geomembranes of above description using heat bonded, seamed stitched or wrap techniques. Their principal use shall be to regulate drainage in cross-plane or in-plane directions. Minimum unit weight of such material shall conform to the special provisions or as per Contract drawing. 701.2.6. Testing and acceptance : Geosynthetics shall be tested in accordance with tests prescribed by BIS. In absence of IS Codes, tests prescribed either by ASTM or British Standards or International Standards Organisation, shall be conducted. 701.3 Application Areas Some of the application areas for geotextiles and related materials and
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their functions are given below in table 700-1.

Table 700-1. ApplIcations and Functions of Geosynthetics 5. No. Application Area ~ I. 2. 3. 4. 5. 6. 7. Embankments on soft soils Retaining walls Drainage and Filtration Drainage-prefab, composite ErosionControlriprap Sediment control-silt fence Asphalt overlay Note GT GG GC ON
= = = =
Geosynthetlcs Involved GT, GO, GT GC, CIT GT GT, S R F D B GO GT ON
Functions for Performance
KS
R F, S D, F, 5, B F,S B, It, S B, R, 5
GC separation reinforcement filtration drainage barrier
geotextile geogrid geocomposite geonet
= = = = =
702. GEOTEXTILES IN SUB-SURFACE DRAINS 702.1. Scope The work covers the use of geotextiles in subsurface drains, such as fin drains or narrow. filter drains. The fin drain shall mean a planar geocomposite structure designed to perform the same function as a narrow filter drain. The work shall be carried out as per design drawings. 702.2. Materials 702.2.1. The geotextile fabric shall be a woven or non-woven fabric consisting of long-chain polymeric filaments or yarns such as polypropylene, polyethylene or polyester or any combination thereof, formed into a stable network such that the filaments or yarns retain their relative position to each other. 702.2.2. The geosynthetic material of which the drain is made shall be treated with carbon black so that they are protected from the deleterious effects of short term exposure to ultraviolet light, and shall be resistant to degradation by acid, alkalis, common chemicals, bacteria, fungi and moulds occurring in soils and highway construction materials. In case of exposure to ultraviolet light, the Engineer may require evidence that the geosynthetic material still complies with the requirements of this Clause. Where necessary, the side intended for entry of water and direction of inplane flow shall be identified. 702.2.3. The geotextile shall
(a) Sustain a load of not less than 10 kN/m at break and have a minimum failure strain 257
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of 10 per cent when determined in accordance with BS:6906 (Part 1) or shall have a grab tensile strength more than 0.4 kN/m and grab elongation corresponding to this limit in accordance with ASTM D 4632. (b) The Apparent opening size, shall satisfy the following (i) Soil with 50 per cent or less particles by weight passing IS sieve 75 microns, apparent opening size less than 0.6 mm.
(ii) Soil more than 50 per cent particles by weight passing IS sieve 75 microns, apparent opening size less than 0.927 mm. The test should be as per TF 25 # 6 (c) allow water to flow through it at right angles to its principal plane, in either direction at a rate of not less than 10 litres/m2/sec. under a constant head of water of 100 mm, determined in accordance with BS:6906 (Part 3) or ASTM D 4491 or as stated in the design drawing. The flow rate determined in the test shall be corrected to that applicable to a temperature of 15Cusing published data on variation in viscosity of water with temperawre. have a minimum puncture resistance of 200 N when determined in accordance with BS:6906 (Part 4) or ASTM D 4833. have a minimum tear resistance of ISO N when determined in accordance with ASTM Standard D 4533.
(d) (e)
702.2.4. The composite drain shall have a flow rate through each face of the drain of more than 75 per cent of the value specified in sub-Clause 702.2.3 (c), determined by direct measurement of the cOmposite drain using BS:6906 (Part 3). The composite drain shall have values of longterm in-plane flow rates as stated in the design drawing. 702.3. InstaHation 702.3.1. The installation of fin drains shall be as per the design drawings. Where fin drains are assembled on site, the assembly area shall be clean and dry and free of any wind-borne pollutants. No geotextile or core material shall be exposed to daylight (or any source of ultraviolet radiation) for a period exceeding a cumulative total of 50 hours. Whei~e fin drains are laid in trench, the bottom of the trench shall be free of irregularities and shall be brought to the required level. Rock and other hard protrusions shall be removed and any excess cut in the trench bottom filled and compacted back to the required grade with suitable excavated or imported material as directed by the Engineer. Fin drains shall be capable of being jointed longitudinally or laterally into pipe~systeinsor chambers for inflow and outflow purposes. Joints parallel to the direction of flow and any exposed edged shall be protected from the ingress of soil by a geotextile wrapping with a minimum overlap of 150 mm or other measures as agreed by the Engineer. 702.4. Narrow filter drains consisting of a porous or perforated pipe
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Section 700
laid in a narrow trench surrounded by a layer of geotext.ile filter shall have the same properties of geotextile as specified in Clause 702.2. The spicing of lengths of geotextile and minimum overlap shall be as per the design drawing or as approved by the Engineer. Such drains shall be installed as per the design drawing to Clauses 702.3 and 309.3.5. 702.5. Measurements for Payment Measurement for fin drain/narrow filter drains shall be per running metre length of the drain. Disposal of surplus material beyond 1000 m shall be measured in cu.m. 702.6, Rates The Contract unit rates for subsurface drains shall be payment in full for all items such as excavation, dressing the sides and bottom, providing geotextile composites, laying and jointing pipes etc. including full compensation for all materials, labour, tools, equipment incidental to complete the work as shown on drawings with all leads and lifts except for removal of unsuitable material for which the lead shall be 1000 m. Provision of inlets, outlet pipes, bedding etc., wherever required shall be incidental to construction of drain. The Contract unit for disposal of surplus and unsuitable material beyond the initial 1000 m lead shall be in accordance with Clause 301.3.11. 703. REINFORCED EARTH 703.1. Scope The work covers the construction of reinforced earth structures, together with the construction of earthwork in layers, assembly and erection of reinforcing elements and placement of facing panels and all associated components. 703.2. Reinforcing Element 703.2.1. The reinforcing element shall be of Oeotextile, aluminium alloy strip, copper strip, carbon steel strip, mats of metal or synthetic grids, or any other proprietary material which may be approved by the Engineer and indicated on the drawings. 703.2.2. Geotextile The material shall conform to Clause 701.2.6. 703.2.3. Aluminium ahoy strip shall comply with BS:1470 quality 5454 in the H 24 condition. 703.2.4. Copper strip shall comply with BS:2870 quality C 101 or C 102 in the 1f2 H condition and shall have 0.2 per cent proof stress of not less than 180 N/mm2.
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703.2.5. Carbon steel strip which shall be galvanized shall comply with BS:l449 (Part 1), either quality KHR 34/20 P or quality 50/35 P, each having a silicon content of not less than 0.25 per cent and not more than 0.40 per cent. The fabricated element shall be galvanized in accordance with BS:729, and the average zinc coating weight for any individual test area shall not be less than 1000 gm/sq.m. 703.2.6. Stainless steel strip shall comply with BS:1449 (Part 2) quality 316 S 31 or 3/6 S 33 except~thatthe material shall be cold rolled to provide a 0.2 per cent proof stress of not less than 400 N/sq. mm and the tensile strength shall not be less than 540 N/sq. m. 703.2.7, All metallic components buried in soil shall be of electrolytically compatible materials. 703.2.8. Geogrids : The supply of geogrids shall carry a certification of BIS or ISO 9002 for all works. While the reinforcing element for wall or slope portion shall be with mono oriented Geogrid, the reinforcement for the foundation of a reinforced earth wall or slope shall be with bidirectionally oriented Geogrid. For mono oriented Geogrid, the characteristic design tensile strength at a strain not exceeding 10 per cent in 100 years shall be at least 40 kM/rn when measured as per GR1:GG3. The strengt~.for bi-directionafly oriented Geogrid in the longitudinal direction shall be at least 40 kN/m at a maximum elongation of 15 per cent. The Geogrid shall be inert to all naturally occurring chemicals, minerals and salts found in soil. 703.3. Earth Fill The fill material for reinforced earth structures shall have an angle of interface friction between the compacted fill and the reinforcing element of not less than 25C,measured in accordance with IS : 13326 (Part 1). The soil should be predominantly coarse grained; not more than 10 per cent of the particles shall pass 75 micron sieve. The soil should have properties such that the salts in the soil should not react chemically or electrically with the reinforcing elements in an adverse manner. 703.4. Facia Material 703.4.1. The facing shall comprise of one of following
(1) Reinforced concrete (Cast in situ or precast) stabs (ii) Plain cement concrete form fill hollow block (Precast) (iii) Masonry constn1ction, Rubble facia (iv) Other proprietary and patented proven system
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Section 700
The facing shall be sufficiently flexible to withstand any deformation of the fill. 703.4.2. Facia unit joint filler should be durable, resistant to the effect of air pollution and water/saline water. 703.4.3. Bedding material shall consist of either cement mortar or a durable gasket seating such as resin bonded cork strip. 703.4.4. Connection between the facia and the reinforcing element shall be by using polyethylene strips/rods, fibre glass dowels or any other material shown in the drawing. Any other material used shall be tested to provide 100 per cent joint strength as of parent element in continuity. Overlapping in principal reinforcement or in the joint shall ensure load transfer through joints, perpendicular to the direction of laying. 703.5. Construction Details 703.5.1. The plan area of the reinforced earth structure shall be excavated to provide a nominally level base which may be stepped at the back as required to receive the horizontal reinforcing element grid. The depth of the foundation below the finished ground level at the foot of the slope or wall shall not be less than 1000 mm. Additional strip footing, trough guide made of concrete or anchor key pad shall be provided at founding level to receive the facia or the bottom most reinforcement connection. This shall have adequate soil cover against erosion and scour in particular cases. 703.5.2. Orientation : The reinforcing elements shall be placed at right angles to the face of the wall, with greater cross sectional dimension in the horizontal plane. The placement of the elements including their vertical/horizontal spacing and length shall be as in the drawing. 703.5.3. Facing batter: It may be necessary to set facing unit at an additional batter than as provided in the drawing as there is a tendency for initially positioned units of facia to lean outward as the fill material is placed and compacted. Care and caution shall be taken to rectify this phenomenon. 703.5.4. Drainage : Drainage shall be provided as per drawing given in detail. The retained fill shall have a suitably designed drainage bay to allow free draining of the reinforced fill.
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703.5$, Laying and compacting : The reinforcing elements shall be laid free from all kinks, damage and displacement during deposition, speading, levelling and compaction of the fill. The programme of filling shall be such that no construction plant runs directly on the reinforcement. All construction plant having a mass exceeding 1000 Kg shall be kept at least 1 .5 m away from the face of slope or wall. In this area (upto 1.5 m from the face of slope or wall), following compaction plant shall be used
(I) (ii) Vibratory roller having a weight per metre width of roll not exceeding 13(X) kg. with total weight not exceeding 10,000 kg. Vibratory plate compactor of maximum weight 1000 kg.
(iii) Vibro tamper having a weight not exceeding 75 kg.
Compaction by any other method like using dozer or back blade compaction by dozer or excavator bucket shall be permitted with due approval from the Engineer after ascertaining the level of compaction so achieved. During construction of reinforced fill, the retained material beyond the reinforcement at the rear or the structure shall be maintained at the same level as reinforced fill, The compacted layer shall not be more than 200 ram, to achieve compaction of 95 per cent of maximum laboratory density where measured as per IS : 2720 (Part 8). Temporary formwork shall be used to support the construction as per specified details given in the drawing. The forms, scaffolding and props shall be sufficient in numbers to allow taking up of a sectoral construction schedule specified in the design. 703.6. Measurements for Payment Measurement for reinforcing elements shall be in linear metre for anchor strips or in sq.m. for geogrid/geotextile etc. The measurement for facia shall be in sq. metres. The measurement for foundation for facia and capping beam shall be in linear metres. Measurement for compacted earthfill shall be in cubic metres for compacted soil. 703.7. Rates Rate shall include cost of labour, plant hire, material storage and handling expenses, for completing the works. Rate for providing reinforcing elements shall include material cost, all 262
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transportation costs and storage of the same as per special provisions. The rate shall also include cost of laying of the reinforcing elements including all overlaps, jointing or stitching, heat bonding or extension. Rate for facia fixing shall include cost of joints, all necessary temporary formwork, scaffolding and all lifts and leads, if any, as shown in the drawing, unless otherwise specified to the treated separately along with foundation or slope/wall kerb at the top of slope or wall. Rate for bed block and capping beam shall include all items of excavation, concrete, reinforcing steel, formwork, labour and equipment. Rate for soil fill shall include compaction as desired in requisite layers through mechanical means, cost of hire or labour for plant operations, dressing and levelling slopes, including special measures for edge reinforcements as shown in the drawing. 704. GEOSYNTHETICS FOR HIGHWAY PAVEMENTS 704.1. Scope This work shall consist of laying geosynthetic materials over existing biuturninous surface, including preparation of surface and joining, stitching or overlapping of geosynthetic fabric etc., as part of highway pavement strengthening in layers as shown on drawings. 704.2. Paving Fabrics 704.2.1. Description : This work shall consist of furnishing and placing as asphalt/bitumen overlay textile (paving fabric) beneath a pavement overlay or between pavement layers to provide a water resistant membrane and crack retarding layer. 704.3. Material Requirements 704.3.1. Paving rabric: The paving fabric will be a nonwoven heat set material consisting of at least 85 per cent by weight polyolefins, polyesters or polyarnides. The paving fabric shall be resistant to chemical attack, rot and mildew and shall have no tears or defects which will adversely alter its physical properties. The fabric shall be specifically designed for pavement applications and be heat bonded only on one side to reduce bleed-through of tack coat during installation. The fabric shall meet the physical requirements of Table 704-2. Heavy duty paving fabrics should be used in areas experiencing unusually high impact forces or heavy loads such as airport runways and taxiways:
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Section 700 Table 704.2. PhysIcal Requirements.Pavlng Fabrics
Geosynthetics
Tensile Strength Elongation Asphalt Retention Melting Point Surface Texture
36.3 50 10 150 I-lest bonded on one side only
ASTM D 4632 ASTM D 4632 Texas DOT 3099 ASTM D 276 Visual Inspection
Notes 1. 2. Certification of conformance from paving fabric manufacturer may be required. All numerical values represent minimum average roll values (average of test results from any sampled roll in a lot shall meet or exceed the minimum values) in weaker principal direction, Lot shall be sampled according to ASTM D 4354, Practice for Sampling of Geosynthetics for Testing. Conformance of paving fabrics to specification property requirements shall be determined as per ASTM 1) 4759, Practice for Determining the Specification Conformance of Geosynthetics.
3.
704.3.2. Tack Coat: The tack coat used to impregnate the fabric and bond the fabric to the pavement shall be a paving grade Bitumen of 80100 penetration. A cationic or anionic emulsion may be used as approved by the engineer. The use of cutbacks or emulsions which contain solvents shall not be used. 704.4. Construction and Installation Requirements 704.4.1. Shipment and storage: The paving fabric shall be kept dry and wrapped such that it is protected from the elements during shipping and storage. At no time shall the paving fabric be exposed to ultraviolet light for a period exceeding fourteen days. Paving fabric rolls shall be stored in a manner which protects them from the elements. If stored outdoors, they shall be elevated and protected with a waterproof cover~. The paving fabric shall be labeled as per ASTM D 4873, Guide for identification, storage, and handling of geotextiles. 704.4.2. Weather limitations: Minimum air and pavement temperature shall be at least 10Cand rising for placement of bitumen and shall be at least 15C and rising for placement bitumen emulsion. Neither bitumen tack coat nor paving fabric shall be placed when weather conditions, in the opinion of the engineer, are not suitable.
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704.43. Surface preparation : The pavement surface shall be thoroughly cleaned of all dirt, water, and oil to the satisfaction of the engineer. Cracks 3 mm wide or greater shall be cleaned and filled with suitable bituminous material or by a method approved by the engineer. Crack filling material shall be allowed to cure prior to paving fabric placement. Potholes and other pavement distress shall be repaired. Repairs shall be performed as directed by the engineer. 704.4.4. Tack coat application : The tack coat shall be spread by means of a calibrated distributor spray bar. Hand spraying and brush application may be used ir~ !ocatiOns of fabric overlap. Every effort shall be made to keep hand spraying to a minimum. The tack coat shall be applied, uniformly to the prepared dry pavement surface at the rate of 1 kg/sq.m. or as recommended by the paving fabric manufacturer and approved by the engineer. When using emulsions, the application rate must be increased as directed by the engineer to offset the water content of the emulsion. Within street intersections, on steep grades, or in other zones where vehicle speed changes are common place, the normal application rate shall be reduced by a~out 0 per cent as directed by the 2 engineer. The tack coat application rate must be sufficient to saturate the fabric and to bond the fabric to the existing pavement surface. The temperature of the tack coat shall be sufficiently high to permit a uniform spray pattern. For bitumen, the minimum temperature shall be 140C. o avoid damage to the fabric, distributor tank temperatures shalt T not exceed 160C.For bitumen emulsions, the distributor tank temperatures shall be maintained between 55Cand 70C. The target width of tack coat application shall be equal to the paving fabric width plus 150 mm. The tack coat shall be applied only as far in advance of paving fabric installation as is appropriate to ensure a tacky surface at the time of paving fabric placement. Traffic shall not be allowed on the tack coat. Excess tack coat shall be cleaned from the pavement. 704.4.5. Paving fabric placement : The paving fabric shall be placed onto the tack coat using mechanical or manual laydown equipment capable of providing a smooth installation with a minimum amount of wrinkling or folding. The paving fabric shall be placed prior to the tack coat cooling and losing tackiness. Paving fabric shall not be installed in areas where the overlay asphalt tapers to a thickness of less than 40 mm. Excess paving fabric which extends beyond the edge of existing pavement or areas of tack coat application shall be trimmed and removed. When bitumen emulsions are used, the emulsion shalt be allowed to cure
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properly such that essentially no water moisture remains prior to placing the paving fabric. Wrinkles or folds in excess of 25 mm shall be slit and laid flat. All transverse joints and slit folds or wrinkLes shall be shingle. lapped in the direction of the paving operation, Brooming and/or pneumatic rolling will be required to maximize paving fabric, contact with the pavement surface. Additional hand-placed tack coat may be required at laps and repairs as detcrm~n~d the engineer to satisfy bitumen by retention of the lapped paving fabric. Alt areas with paving fabrics placed will be ~pavedthe same day. No traffic except necessary construction equipment will be allowed to drive on the paving fabric. Turning of the paver and other vehicles shall be done gradually and kept to a minimum to avoid movement and damage to the paving fabric. Abrupt starts and stops shall also be avoided. Damaged fabric shall be removed and replaced with the same type of fabric. Overlaps shall be shingled-lapped in the direction of paving. Additional tack coat shall be placed between the overlap to satisfy saturation requirements of the fabric. Overlap shall be sufficient to ensure full closure of the joint but not exceed 150 mm. 704.4.6. Overlay placement: Bituminous overlay construction shall closely follow fabric placement. All areas in which paving fabric has been placed will be paved during the same day. Excess tack coat which bleeds through the paving fabric shall be removed. Excess tack coat can be removed by broadcasting hot mix or sand on the paving fabric. 705. PROTECTION WORKS WITH GEOSYNTHETICS 705.1. Scope This work shall consist of laying boulder Gabions/Mattresses in wraps of Geosynthetics in the form of bolsters, on slopes of embankments or in apron. Gabions or Mattresses are also used for stone spurs. Geotextiles are used for prevention of migration of fine soil particles. 705.2. Gabions/Mattresses with Geogrids and Geonets Mattresses constructed with Geogrids or Geonets shall be used for thickness of 300 mm or above as shown in the drawings. While adopting a particular size for gabions or mattresses width of the roll of geogrid/ geonet may be kept in view to minimise wastage of the geosynthetic in cutting off pieces. The mesh opening may very depending on functional requirement but shalt have aperture between 35 mm and tOO mm. The
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Section 700
mesh/net shall have following characteristics

Aperture Colour Mechanical Properties Stands/Fabric Form Life : : Rectangular, square or oval shaped (and not in diamond, round or. polygonal shape). BLack 1~akstrength ia~iless than 10 kN/m at maximum elongation of 15 per cent. Notmore than 5 per cent elongation at half peak load. Integral joints with junction strength of 100 per cent of plain strands as measured by GRI-003 standards. Material shall have ISO 9002 ce~1ification. Aileast B years in case of continuous exposure and 5 years for burned ~plications (drflned as capable of retaining atleast75 per cent of its original strength after the life span awed.
7053. Construction 705,3.1. Assembly: Gabion and mattress boxes shall be assembled in situ, on a level surface. After fabrication is done in situ they shall be correctly filled in layers in dense packed state. The bottom, sides and end panels shall be erected after removal of all kinks, kept in an upright position to form rectangular boxes by joining the sides with connectors of 40 mm x 6 mm size, or by ring staples. The top corners shall be tie tensioned from sides to keep it erect for filling. For gabions of 600 mm or more height, suitable cross internal ties shall be placed in layers of 300 mm connecting opposite sides in lateral braces tied with polymer braids of ultra-violet stabilised variety so as to ensure protection against bulging of the gabions during filling with stones. 705.3.2. Construction and installation : The filling of the gabion/ mattress shalt be done by hand in layers so as to minimise viods and achieve specified density. The stones in contact with the surface of the geogrids/geonets shall be placed in such a way that their sharp edges are kept turned inside so that they do not damage the material of the geogrids/ geonets. The opposite panels of the boxes shall be firmly secured with lateral ties to withstand the design forces. The bottom of the gabion mesh shall be secured in a key type excavation for preventing slide. The space between the gabion and earthen sides shall be filled with sand and the filling compacted, In most of the cases design shall be supplemented with a Layer of geotextile under the gabion/mattress to prevent migration of fines. 705.3.3. Laying boulder apron in crates : Mattresses of minimum height 300 mm shalt be used. The typical size of a single continuous unit shall be I m x 5 m size with baffles at 1 m centres. The size of boulders shall be at least 100 mm or double the size of the aperture whichever is
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larger. The density of boulder filling shall be as stated in the drawing and the specific gravity of stones not less than 2.65. Methodology of laying boulders shall be as peg Clause 2503.3. Gabions if placed in the apron shall be of size 1 m x 5 m in plan with height at least 600 mm, with baffles in 1 m centres. Gabions or mattresses made with polymer geogrids/geonets shall always be laid in situ and shall not be performed, filled and transported to be dropped in deep waters. Where depth of water is low or dry bed is available, the boxes shall be filled in situ. In streams or water body having running boulders in the bed, the gsbions/mattresses shall be armoured with placement of loose large boulders alongside the gabion wall to protect against impact hit of stray boulders. Stakes or keying shall always be provided in the founding recess, where the gabion be located, especially in case the ground is assessed to be sloping or yielding type. 705,3.4. Groynes or spurs with crates : Groynes or spurs of gravity retaining variety shall be constructed using geogrid/geonet gabions placed in a stable configuration one over the other to form a well. They shall be filled in situ on a shallow depth of water or dry bed with firm founding and level strata. The provision of a layer of geotextile/geocomposite shall be made while placing the structure if resting over a bed of fine soil to prevent passage of fines and sinking. 705.3.5. Measurements for payment : The fabric of geotextile/ geocomposite shall be measured in sq. metres,, of plan area of actual use (as per drawing). The connecting rods or polymer braids shall be measured in metres. Ring staples shall be measured in number provided per linear metre. The boulder fill shall be measured in cubic metres. The excavation for keying of gabions in the ground trenches shall be measured in cubic metres. The backfilling in side trenches shall be deemed part of the excavation work. 705.3.6. Rate : The cost of Geosynthetic material for fabrication of (iabions(Mattresses shall be all inclusive of supply, transportation and storage. The contract rate per cubic metre of crate fill shall Consist of cost of boulders and their transportation.
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Section 700
The contract rate for excavation and backfilling of trenches, seating trench upto 15 cm (included in rate), shall include cost of labour, tools and plant for completion of the work. The cost of making a crate shall include preparation of box of geogrid/geonet, tensioning and staking arrangements, tying, internal crossbraids, etc., for foiming of the crates in an engineered manner arid filling the crate by laying boulders. The east shall include transportation of material from store to site. Wherever composite system using Geosynthetics with natural materrial like stone revetrnent etc. shall be used, the provision of measurement and rate as per Clauses 2509 and 2510 are applicable.
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Traffic Signs, Markings and Other Road Appurtenances
800 Traffic Signs, Markings and Other Road Appurtenances
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Traffic Signs, Markings and Other Road Appurtenances 801. TRAFFIC SIGNS
Section 800
801.1. General 801.1.1. The colour, configuration, size and location of all traffic signs for highways other than Expressways shall be in accordance with the Code of Practice for Road Signs, IRC: 67 or as shown on the drawings. For Expressways, the size of the signs, letters and their placement shall be as specified in the Contract drawings and relevant Specifications. In the absence of any details or for any missing details, the signs shall be provided as directed by the Engineer, 801.1.2. The signs shall be either reflectorised or non-refiectorised as shown on the drawings or as directed by the Engineer. When they are of reflectorised type, they shall be of retro-reflectorised type and made of encapsulated lens type reflective sheeting vide Clause 801.3, fixed over aluminium sheeting as per these Specifications. 801.1.3. In general, cautionary and mandatory signs shall be fabricated through process of screen printing. In regard to informatory signs with inscriptions, either the message could be printed over the reflective sheeting, or cut letters of non-reflective black sheeting used for the purpose which must be bonded well on the base sheeting as directed by the Engineer. 801.2. Materials The various materials and fabrication of the traffic signs shall conform to the following requirements: 801.2.1, Concrete : Concrete shall be of the grade shown on the Contract drawings or otherwise as directed by the Engineer. 801.2.2, Reinforcing steel : Reinforcing steel shall conform to the requirement of IS:l786 unless otherwise shown on the drawing. 801.23. Bolts, nuts, washers: High strength bolts shall conform to IS : 1367 whereas precision bolts, nuts, etc., shah conform to IS: 1364. 801.2.4. Plates and supports: Plates and support sections for the sign posts shall conform to IS: 226 and IS: 2062 or any ot!~errelevant IS Specifications. 80 1.2.5. Aluminium: Aluminium sheets used for sign boards shall be of smooth, hard and corrosion resistant aluminium alloy conforming to IS 736-Material designation 24345 or 1900.
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Section 800
Traffic Signs and Appurtenances
801.2.6. Signs with, a maximum side dimension not exceeding 600 mm shall not be less than 1.5 mm thick, All others shall be at least 2 mm thick. The thickness of the sheet shall be related to the size of the sign and its support and shall be such that it does not bend or deform under the prevailing wind and other loads. 801.2.7. In respect of sign sizes not covered by IRC:67, the structural details (thickness, etc.) shall be as per the approved drawings. 801.3. Traffic Signs Having Retro-reflective Sheeting 801.3.1. General requirements: The retro-reflective sheeting used on the sign shall consist of the white or coloured sheeting having a smooth outer surface which has the property of retro-reflection over its entire surface. It shall be weather-resistant and show colour fastness. It shall be new and unused and shall show no evidence of cracking, scaling, pitting, blistering, edge lifting or curling and shall have negligible shrinkage or expansion. A certificate of having tested the sheeting for these properties in an unprotected outdoor exposure facing the sun for two years and its having passed these tests shall be obtained from a reputed laboratory, by the manufacturer of the sheeting. The reflective sheeting shall be either of Engineering Grade material with enclosed lens or of High Intensity Grade with encapsulated lens. The type of the sheeting to be used would depend upon the type, functional hierarchy and importance of the road. 801.3.2. High intensity grade sheeting: This sheeting shall be of encapsulated lens type consisting of spherical glass lens, elements adhered to a synthetic resin and encapsulated by a flexible, transparent water-proof plastic having a smooth surfacer The retro-reflective surface after cleaning with soap and water and in dry condition shall have the minimum co-efficient of retro-reflection (determined in accordance with ASTM Standard E : 810) as indicated in Table 800-1.
TABLE KOO-1. ACCEPTABLE MiNIMUM COEFFICIENT OF RETRO. REFLECTION FOR HIGH INTENSITY GRADE SHEETING (CANDELAS PER LUX PER SQUARE METRE)
Observation angle (in degrees) 0.2 0.2 0.5 0.5 Entrance Angle (In degrees) -4 30 -4 White Yellow Orange
Green/
Red
Blue
+30
250 150 95 65
170 100 62 45
100
60 30 25
45 25 15 10
20 11 7.5 5,0
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Section 800
When totally wet, the sheeting shall not show less than 90 per cent of the values of retro-reflectance indicated in Table 800.-I. At the end of 7 years, the sheeting shall retain at least 75 per cent of its original retro-reftectance. 801.3.3. Engineering grade sheeting: This sheeting shall be of enclosed lens type consisting of microscOpic lens elements embedded beneath the surface of a smooth, flexible, transparent, water-proof plastic, resulting in a non-exposed lens optical reflecting system. The retroreflective surface after cleaning with soap and water and in dry condition shall have the minimum coefficient of retro-reflection (determined in accordance with ASTM Standard: E-810) as indicated in Table 800-2.
TABLE 800-2. ACCEPTABLE MINIMUM COEFFICIENT OF RETROREFLECTION FOR ENGINEERING GRADE SHEETING (CANDELAS PER LUX PER SQUARE METRE) Observation angle In degree 0.2 O~2 0.5 0.5 Entrance angle In degree -4 +30 .4 30 White
Yellow
Orange
Green
Red
Blue
70 31) 30 15
50 22 25 13
25 7.0 13.5
9.0
3.5 4.5 2.2
14.5
6.0 7.5 3.0
4.0
1.7 2.0 0.8
4.0
When totally wet, the sheeting shall not show less than 90 per cent of the values, of retro-reflection indicated in Table 800-2. At the end of 5 years, the sheeting shall retain at least 50 per cent of its original retro-reflectance. 801.3.4. Messages/borders: The messages (legends, letters, numerals etc.) and borders shall either be screen-printed or of cut-outs. Screen printing shall be processed and finished with materials and in a manner specified by the sheeting manufacturer. Cut-outs shall be of materials as specified by the sheeting manufacturer and shall be bonded with the sheeting in the manner specified by the manufacturer. 801.3.S. For screen-printed transparent coloured areas on white sheeting, the co-efficient of retro-reflection shall not be less than 50 per cent of the values of corresponding colour in Tables 800-I and 800-2, as applicable. 801.3.6. Cut-out messages and borders, wherever used, shall be made out of retro-reflective sheeting (as per Clause 801.3.2 or 801.3.3 as applicable), except those in black which shall be of non-reflective sheeting.
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Section 800
801.3,7. Colour: Unless otherwise specified, the general colour scheme shall be as stipulated in IS : 5 Colour for Ready Mixed Paints, viz. Blue IS Colour No. 166: French Blue
-
Red Green Orange
IS IS IS
Colour Colour Colour
No. 537: Signal Red No. 284: India Green No. 591: Deep Orange.
The Colours shall be durable and uniform in acceptable hue when
viewed in day light or under normal headlights at night. 801.3.8. Adhesives : The sheeting shall either have a pressuresensitive adhesive of the aggressive-tack type requiring no heat, solvent or other preparation for adhesion to a smooth clean surface, or a tack free adhesive activated by heat, applied in a heat-vacuum applicator, in a manner recommended by the sheeting manufacturer. The adhesive shall be protected by an easily removable liner (removable by peeling Without soaking in water or other solvent) and shall be suitable for the type of material of the base plate used for the sign. The adhesive shall form a durable bond to smooth, corrosion and weather resistant surface of the base plate such that it shall not be possible to remove the sheeting from the sign base in one piece by use of sharp instrument. In case of pressure-sensitive adhesive sheeting, the sheeting shall be applied in accordance with the manufacturers Specifications, Sheeting with adhesives requiring use of solvents or other preparation for adhesive shall be applied strictly in accordance with the manufacturers instructions. 801.3.9. Refurbishment: Where existing signs are specified for refurbishment, the sheeting shall have a semi-rigid aluminium backing pre-coated with aggressive-tack type pressure sensitive adhesive. The adhesive shall be suitable for the type of material used for the sign and should thoroughly bond with that material.
801,3.10. Fabrication
801.3.10.1. Surface to be reflectorised shall be effectively prepared to receive the retro-refleetive sheeting. The aluminium sheeting shall be de-greased either by acid or hot alkaline etching and all scale/dust removed to obtain a smooth plain surface before the application of retroreflective sheeting. If the surface is rough, approved surface primer may be used. After cleaning, metal shall not be handled, except by suitable de~ice or clean canvas gloves, between all cleaning and preparation
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operation and application of reflective sheeting/primer. There shall be no opportunity for metal to come in contact with grease, oil or other contaminants prior to the application of retro-reflective sheeting. 801.3.10.2. Complete sheets of the material shall be used on the signs except where it is unavoidable; at splices, sheeting with pressure sensitive adhesives shall be overlappednot less than 5 mm. Sheeting with heat-activated adhesives may be spliced with an overlap not less than 5 mm or butted with a gap not exceeding 0.75 mm. Where screen printing with transparent colours is proposed, only butt jointing shall be used. The material shall cover the sign surface evenly and shall be free from twists, cracks and folds. Cut-outs to produce legends and borders shall be bonded with the sheeting in the manner sjecified by the manufacturer. 801.3.11. Warranty and durability The Contractor shall obtain from the manufacturer a seven-year warranty for satisfactory field performance including stipulated retro-reflectance of the retro-reflective sheeting of high intensity grade and a five year warranty for the adhesive sheeting of engineering grade and submit the same to the Engineer. In addition, a seven year and a five year warranty for satisfactory in-field performance of the fmished sign with retro-reflective sheeting of high intensity grade and engineering grade respectively, inclusive of the screen printed or cut out Ieuer~legends their bonding to the retro.-reflective and sheeting shall be obtained from the Contractor/supplier and passed on to the Engineer. The Contractor/supplier shall also furnish a certification that the signs and materials supplied against the assigned work meets all the stipulated requirements and carry the stipulated warranty. Processed and applied in accordance with recommended procedures, the reflective material shall be weather resistant and, following cleaning, shall show no appreciable discolouration, cracking, blistering or dimen. sional change and shall not have less than 50 per cent of the specified minimum reflective intensity values (Tables 800-I and 800-2) when subjected to accelerated weathering for 1000 hours, using type E or Eli Watherometer (AASI3TO Designation M 268). 801.4. Installation 801.4.1. Sign posts, their foundations and sign mountings shall be so constructed as to hold these in a proper and permanent position against the normal storm wind loads or displacement by vandalism. Normally, signs with an area upto 0.9 sq. m. shall be mounted on a single post, and for greater area two or more supports shall be provided. Sign supports may be of mild steel, reinforced concrete or galvanised iron (0.1). Post-
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end(s) shall be firmly fixed to the ground by means of properly designed foundation. The work of foundation shall conform to relevant Specifications as specified, 801.4.2. All components of signs and supports, other than the reflective portion and 0.1. posts shall be thoroughly descaled, cleaned, primed and painted with two coats of epoxy paint. Any part of mild steel (M.S.) post below ground shall be painted with three coats of red lead paint. 801.4.3. The signs shall be fixed to the posts by welding in the case of steel posts and by bolts and washers suitable size in the case of reinforced concrete or 0.1. posts. After the nuts have been tightened, the tails of the bolts shall be furred over with a hammer to prevent removal. 801.5. Measurements for Payment The measurement of standard cautionary, mandatory and information signs shall be in numbers of different types of signs supplied and fixed, while~for direction and place identification signs, these shall be measured by area in square metres, 801.6. Rate The Contract unit rate shall be payment in full for the cost of making the road sign, including all materials, installing it at the site and incidentals to complete the work in accordance with the Specifications.
802. OVERHEAD SIGNS

802,1. General 802.1.1. Overhead signs may be used in lieu of, or as an adjunct to, ground signs where the situation so warrants for proper information and guidance of the road user.The following conditions may be considered while deciding about the provision of overhead signs:
(1) Traffic vohame at or near capacity Complex interchange design Three or more lanes in each direction
(2)
(3) (4) (5)
Restricted sight distance Closely spaced interchanges (6) Multi-Sic exits (7) Large percentage of commercial vehicles
(8)
High
speed traffic
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Section 800 of interchanges
(11) Background of street lighting (12) Distances of important places enroute highways at suitable intervals,
802.1.2. From safety and aesthetic standpoints, overhead signs shall be mounted on overhead bridge structures wherever possible. Where these are required to be provided at some other locations, the support system should be properly designed based on sound engineering principles, to safely sustain the dead load, live load and wind load on the completed sign system. For this purpose, the overhead signs shall be designed to withstand a wind loading of 150 kg/rn2 normal to the face of the sign and 30 kg/rn2 transverse to the face of the sign. In addition to the dead load of the structure, walkway loading of 250 kg concentrated live load shall also be considered for the design of the overhead sign structure. 802.2. Height Overhead signs shall provide a vertical clearance of not less than 5.5 m over the entire width of the pavement and shoulders except where a lesser vertical clearance is used for the design of other structures. The vertical clearance to overhead sign structures or supports need not be greater than 300 mm in excess of the minimum design clearance of other structures. 802.3. Lateral Clearance 802.3.1. The minimum clearance outside the usable roadway shoulder for expressway signs mounted at the road side or for overhead sign supports either to the right or left side of the roadway shall be 1.80 m. This minimum clearance of 1.80 m shall also apply outside of an unmountable kerb. Where practicable, a sign should not be less than 3 m from the edge of the nearest traffic lane. Large guide signs should be farther removed preferably 9 m or more from the nearest traffic lane, unless otherwise specified. Lesser clearances, but not generally less than 1.80 m, may be used on connecting roadways or ramps at inter-changes. 802.3.2. Where a median is 3.6 m or less in width, considerLzion should be given to spanning over both roadways without a central support. Where overhead sign supports cannot be placed at a safe distance away from the line of traffic or in an otherwise protected site, they should either be so designed as to minimise the impact forces or protect motorists adequately by a physical barrier or guard rail of suitable
design.
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802.4. Number of Signs at an Overhead Installation In no case should there be more than three signs displayed at any one Location, including regulatory or warning signs, either on the overhead structure or on its support. 802.5. Materials for Overhead Sign and Support Structures 802.5.1. Aluminium alloy or galvanized steel to be used as truss design supports shall conform to relevant IS. These shall be of sectins and type as per structural design requirements as shown on the plans. 802.5.2. After steel trusses have been fabricated and all required holes punched or drilled on both the horizontal truss units and the vertical and support units, they shall be galvanized in accordance with IS Specifications. 802.5.3. Where aluminium sheets are used for road signs, they shall be of smooth, hard and corrosion resistant aluminium alloy conforming to IS 736- Material Designation 24345 or 1900. Tbe thickness of sheet shall be related to the size of the sign with minimum thickness of sheet as 1.5 mm. 802.5,4. High strength bolts shall conform to IS: 1367 whereas precision bolts, nuts etc. shall conform to IS: 1364. 802.5.5. Plates and support sections for sign posts shall conform to IS: 226 and IS: 2062, 802.5.6. The overhead signs shall be reflectorised with high intensity retro-reflective sheeting preferably of encapsulated lens type. 802.6. Size, Locations, etc. of Signs 802.6.1. The size of the signs, letters and their placement shall be as specified in the Contract drawings and Specifications. 802.6.2. In the absence of details or for any missing details in the Contract documents, the signs shall be provided as directed by the Engineer. 802.7. Installation 802.7.1. The supporting structure and signs shall be fabricated and erected as per details given in the plans. 802.7.2. Sign posts, their foundations and sign mountings shall be so constructed as to hold signs in a proper and permanent position to adequately resist swaying in the wind or displacement by vandalism.
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802.7.3. The work of construction of foundation for sign supports including excavation and backfill, forms, steel reinforcement, concrete and its placement shall conform to the relevant Specifications given in these Specifications. 802.7.4. The structures shall be erected with the specified camber and in such a manner as to prevent excessive stresses, injury and defacement. 802.7.5. Brackets shall be provided for mounting signs of the type to be supported by the structure. For better visibility, they shall be adjustable to permit mounting the sign faces at any angle between a truly vertical position and three degree from vertical. This angle shall be obtained by rotating the front lower edge of the sign forward. All brackets shall be of a length equal to the heights of the signs being supported. 802.7.6. Before erecting support structures, the bottom of each base plate shall be protected with an approved material which will adequately prevent any harmful reaction between the plate and the concrete. 802.7.7. The end supports shall be plumbed by the use of levelling nuts and the space between the foundation and base plate shall be completely filled with an anti-shrink grout. 802.7.8. Anchor bolts for sign supports shall be set to proper locations and elevation with templates and carefully checked after construction of the sign foundation and before the concrete has set. 802.7.9. Al! nuts on aluminium trusses, except those used on the flanges, shall be tightened only until they are snug. This includes the nuts on the anchor bolts. A thread lubricant shall be used with each aluminium nut. 802.7.10. All nuts on galvanized steel trusses, with the exception of high strength bolt connections, shall be tightened only to a snug condition. 802.7.11. Field welding sh~1lnot be permitted. 802.7.12. After installation of signs is complete, the sign shall be inspected by the Engineer. If specular reflection is apparent on any sign, its positioning shall be adjusted by the Contractor to eliminate or minimize this condition. 802.8. Measurements for Payment 802.8.!. Aluminium or steel overhead sign structure will be measured for payment by the specific unit (each) complete in place or for each
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component of the overhead sign structure as indicated in the Bill of Quantities and the detailed drawing(s). 802.8.2. Flat sheet aluminium signs with retro-reflective sheeting thereon shall be measured for payment by the square metre for each thickness, cqmplete in place. 802.9. Rate 802.9.1. The structural steel part of the overhead sign shall be measured in tonnes while the sign hoard shall be measured in sq. in. Other items like excavation for foundation and concrete in foundation to be measured and paid in Cu. m. separately. The Contract unit rate for overhead sign structure shall be payment in full compensation for furnishing all labour, materials, tools, equipment, excavation, fabrication and installation and all other incidental costs necessary to complete the work to the Specifications. 802.9.2. The Contract unit rate for aluminium sheet signs shall include the cost of making the sign including all materials and fixing the same in position and all other incidental costs necessary to complete the work to the Specifications. 803. ROAD MARKINGS 803.1. General The colour, width and layout of road markings shall be in accordance with the Code of Practice for Road Markings with paints, IRC : 35, and as specified in the drawings or as directed by the Engineer. 803.2. Materials Road markings shall be of ordinary road marking paint, hot applied thermoplastic compound, or reflectorisedpaint as specified in the item and the material shall meet the requirements as specified below. 803.3. Ordinary Road Marking Paint 803.3.1. Ordinary paint used for road marking shall conform to Grade I as per IS: 164. 803.3.2. The road marking shall preferably be laid with appropriate road marking machinery. 803.3.3. Laying thickness of road marking paint shall be as specified by the Engineer.
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803.4. Hot Applied Thermoplastic Road Marking 803.4.1. General

(i) The work under this section consists of marking traffic stripes using a thennopi attic compound meeting the requirements specified herein. (ii) The thermoplastic compound shall be screeded/extnided on to the pavement surface in a molten state by suitable machine capable of controlled preparation and laying with surface application of glass beads at a specific rate. Upon cooling to ambient pavement temperature, it ~hatlproduce an adherent pavement marking of specified thickness and width and capable of resisting deformation by traffic. (iii) The colour of the compound shall be white or yellow (IS colour No, 356) as specified in the drawings or as directed by the Engineer (iv) Where the compound is to be applied to cement concrete pavement, a sealing primer as recommended by the manufacturer, shall be applied to the pavement in advance of placing of the stripes to ensure proper bonding of the compound. On new concrete surface any laitance and/or curing compound shall be removed before the markings are applied.
893.4.2. Thermoplastic Material, 803.4.2.1. General : The thermoplastic material shall be homogeneously composed of aggregate, pigment, resins and glass reflectorizing beads, 803.4.2.2. Requirements
(i) CompositIon : The pigment, beads, and aggregate shall be uniformly dispersed in the resin, The material shall be free from all skins, dirt and foreign objects and shall comply with requirements indicated in Table 800-3. 800.3.
TABLE
PROPORTIONS OF CONSTITUENTS OP MARKING MATERIAL

(Percentage by weight) White 18.0 mm. 30-40 10.0 miii. 42.0 max.
Component Binder Glass Beads Titanium Dioxide Calcium Carbonate and Inert Fillers Yellow Pigments Note :
Yellow 1811 mm. 30-40
See Note
Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of the manufacturer, provided all other requirements of this Specification are met. Propertles The properties of thermoplastic material, when tested in accordance with ASTM D36iBS.3262.(Part I), shall be as below: (a) Luminance White : Daylight luminance at 45 degrees-65 per cent miii, as per AASHTO M 249
(ii)
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Traffic Signs and Appurtenances Yellow : Daylight luminance at 45 degrees-45 per cent mm. as per AASHTO M 249
(b)
Drying tIme : When applied at a temperature specified by the manufacturer and so the required thickness, the material shall set to bear traffic in not more than 15 minutes. Skid resistance : not less than 45 as per BS 6044. Cracking resistance at low temperature: The material shall show no cracks on application to concrete blocks. Softening point: 102.5 9.5
(c) (d) (e) (f) (g)
C as pet ASTM
D 36.
Flow resistance: Not more than 25 per cent as per AASIITO M 249. Yellowness Index (for white thermoplastic paint): not more than 0.12 as per AASHTO M 249
(iii) Storage life : The material shall meet the requirements of these Specifications for a period of one year. The themsoplastic material must also melt uniformly with no evidence of skins or unmelted particles for the one year storage period. Any material not meeting the above requirements shall be replaced by the manufac~ turer/ supplier/Contraiior, (Iv) Reflectorlsation : Shall be achieved by incorporation of beads, the grading and other properties of the beads shall be as specified ~un Clause 803.4.3. (v) Marking : Each container of the thermoplastic material shall indelibly marked with the following information: 1. 2. 3. 4. The be clearly and
name, trade mark or oilier means of identification of manufacturer
Batch number Date of manufacture Colour (white or yellow)
S. Maximum application temperature and maximum safe heating temperature. (vi) Sampling and testIng: The thermoplastic material shall be sampled and tested in accordance with the appropriate ASTM/BS method. The Contractor shall furnish to the Employer a copy of certified test reports from the manufacturers of the thermoplastic material showing results of all tests specified herein and shall certify that the material meets all requirements of this Specification.
803.4.3. Reflectorising glass beads 803.4.3.1. General : This Specification covers two types of glass beads to be used for the production of reflectorised pavement markings. Type 1 beads are those which are a constituent of the basic thermoplastic compound vide Table 800-3 and Type 2 beads are those which are to be sprayed on the surface vide Clause 803.6.3. 803.4.3.2. The glass beads shall be transparent, colourless and free from milkiness, dark particles and excessive air inclusions.
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These shall conform to the requirements spelt out in Clause 803.4.3.3. 803.4.3.3. Specific requirements A. Gradation: The glass beads shall meet the gradation requirements for the two types as given in Table 800-4.
TABLE 800.4. GRADATION REQUIREMENTS FOR GLASS BEADS Per can t retaIned Sieve size Type 1 1.18mm 850 micron 600 -do425 -do300 -do180 -dobelow 180 micron Oto3 5 to 20
-
Type 2
-
Oto5 5to20
-
65 to 95
-
0 to 10
-
30 to 75 10 to 30 0 to 15
B. Roundness: The glass beads shall have a minimum of 70 per cent true spheres. C. Refractive index: The glass beads shall have a minimum refractive index of 1.50. D. Free flowing properties : The glass beads shall be free of hard lumps and clusters and shall dispense readily under any conditions suitable for paint striping. They shall pass the free flow-test. 803.4.3.4. Test methods: The specific requirements shall be tested with the following methods:
(i) Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter glass dish. Place the dish in a 250mm inside diameter desiccator which is filled within 25 mm of the top of a desiccator plate with sulphuric acid water solution specific gravity L10). Cover the desiccator and let it stand for 4 hours at 2Oto 29 degree C. Remove sample from desiccator, transfer beads to a pan and inspect for lumps or clusters, Then pour beads into a clean, dry glass funnel having a 100 mm stem and 6 mm orifice. If necessary, initiate flow by lightly tapping the funnel. The glass spheres shall be essentially free of lumps and clusters and shall flow freely through the funnel. The requirements of gradation, roundness and refractive index of glass beads and the amount of glass beads in the compound shall be tested as per BS 6088 and BS 3262 (Part I).
(ii)
(iii) The Contractor shall furnish to the Employer a copy of certified test reports from the manufacturer of glass beads obtained from a reputed laboratory showing 285
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results of all tests specified herein and shall certify that the material meets all requirements of this Specification. Flowever, if so required, these tests may be carried out as directed by the Engineer.
803.4.4. Application properties of thermoplastic material 803.4.4.1. The thermoplastic material shall readily get screeded/ extruded a1 temperatures specified by the manufxturers for respective method of application to produce a line of specified thickness which shall be continuous and uniform in shape having clear and sharp edges. 803.4.4.2. The material upon heating to application temperatures, shall not exude fumes, which are toxic, obnoxious or injurious to persons or property. 803.4.5. Preparation:
~i) The material shall be melted in accordance with the manufacturers instructions in a heater fitted with a mechanical stirrer to give a smooth consistency to the thermoplastic material to avoid local overheating. The temperature of the mass shall be within the range specified by the manufacturer, and shall on no account be allowed to exceed the maximum temperature stated by the manufacturer. The molten material should be used as expeditiously as possible and for thermoplastic material which has natural binders or is otherwise sensitive to prolonged healing, the material thall not be maintained t:n a molten condition for more than 4 hours. After transfer to the laying equipment, the material shall be maintained within the temperature range specified by the manufacturer for achieving the desired consistency for laying.
(ii)
803.4.6. Properties of finished road marking

(a) (b) (c) Ihe stripe shall not be slippery when wet. The marking shall not lift from the pavement in freezing weather. After application and proper drying, the stripe shall show no appreciable deformation or discolouration under traffic and under road temperatures upto 60~C. The marking shall not deteriorate by contact with sodium chloride, calcium chloride or oil drippings from traffic. lhe stripe or marking shalt maintain its original dimensions and position, Cold ductility of the material shall be such as to permit normal movement with the road surface without chopping or cracking. Ihe colour of yellow marking shall conform to IS Colour No. 356 as given in lS: 164.
(d) (e)
(I)
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803.5. Reflectorised Paint Reflectorised paint, if used, shall conform to the Specification by the manufacturers and approved by the Engineer. Reflectorising glass beads for reflectorising paints where used shall conform to the requirement of Clause 803.4.3. 286
Section 800
803.6. Application 803.6.1. Marking shall be done by machine. For locations where painting cannot be done by machine, approved manual methods shall be used with prior approval of the Engineer. The Contractor shall maintain control over traffic while painting operations are in progress so as to cause minimum inconvenience to traffic compatible with protecting the workmen. 803.6.2. The thermoplastic material shall be applied hot either by screeding or extrusion process. After transfer to the laying apparatus, the material shall be laid at a temperature within the range specified by the manufacturer for the particular method of laying being used. The paint shall he applied using a screed or extrusion machine. 803.6.3. The pavement temperature shall not be less than 10C during application. All surfaces to be marked shall be thoroughly cleaned of all dust, dirt, grease, oil and all other foreign matter before application of the paint. The material, when formed into traffic stripes, must be readily renewable by placing an overlay of new material directly over an old line of compatible material. Such new material shall so bond itself to the old line that no splitting or separation takes place. Thermoplastic paint shall be applied in intermittent or continuous lines of uniform thickness of at least 2.5 mm unless specified otherwise. Where arrows or letters are to be provided, thermoplastic compound may be hand~sprayed. In addition to the beads included in the material, a further quatnity of glass beads of Type 2, conforming to the above noted Specification shall be sprayed uniformly into a mono-layer on to the hot paint line in quick succession of the paint spraying operation. The glass beads shall be applied at the rate of 250 grams per square metre area. 803.6.4. The minimum thickness specified is exclusive of surface applied glass beads, The method of thickness measurement shall be in accordance with Appendices B and C of BS 3262 (Part 3). 803.6.5. The finished lines shall be free from ruggedness on sides and ends and be parallel to the general alignment of the carriageway. The upper surface of the lines shall be level, uniform and free from streaks.
-
803.7. Measurements fof Payment 803.7.1. The painted markings shall be measured in sq. metres of actual area marked (excluding the gaps, if any).
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803.8. Rate The Contract unit rate for road markings shall be payment in full compensation for furnishing all labour, materials, tools, equipment, including all incidental costs necessary for carrying out the work at the site conforming to these Specifications complete as per the approved drawing(s) or as directed by the Engineer and all other incidental costs necessary to complete the work to these Specifications. 804. HECTOMETRE/KILOMETRE STONES 804.1. General The work covers the supply, painting, lettering and fixing of distance measurement stones and shall include:
(i) (ii) Flectometre stones Kilometre stones
(iii) 5th Kilometre stones
804.2. The dimengions of the stones and the size, colour, arrange~ ment of letters and script shall be as per IRC : 26 Type Designs for 200 Metre Stones and 1RC: 8 Type Designs for Highway Kilometre Stones. 804.3. The hectometre/kilometre stones may be made of local stones, concrete or any other material available locally and approved by the Engineer. The stones shall be bedded into the ground with adequate foundations as indicated in the drawings or in the relevant I.R.C. Specifications or as directed by the Engineer. The orientation and location of the stones shall be as indicated in the drawings or in the relevant I .R.C. Specifications or as directed by the Engineer. 804.4. Measurements for Payment The measurement will be in numbers of 200 metre, kilometre and 5th kilometre stones fixed at site. 804.5. Rate The Contract unit rate for hectometre/kilometre/5th kilometre stones shall be payment in full compensation for furnishing all labour, materials, tools, equipment and making the stones, painting and lettering and fixing at site and all other incidental costs necessary to complete the work to these Specifications.
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805. ROAD DELINEATORS 805.1. General The work covers supplying and fixing roadway indicators, hazard markers and object markers. 805.2. The design, materials to be used and the location of the road delineators shall conform to Recommended Practice for Road Delineators, IRC: 79, and to relevant drawings or as otherwise directed by the Engineer. 805.3. Measurements for Payment The measurement shall be made in numbers of delineators fixed at site. 805.4. Rate The Contract unit rate for Road Delineators shall be payment in full compensation for furnishing all labour, materials, tools, equipment for preparing, supplying and fixing at site and all other incidental costs necessary to complete the work to these Specifications. 806. BOUNDARY STONES 806.1. General The work comprises of supplying and fixing boundary stonr~as per designs and Specifications given in IRC: 25 Type Designs fo Bdtrndary Stones and at locations indicated. iii the drawings or~asdirec~&i the by Engineer. 806.2. Measi~rernentsfor Payment The measurement shall be made in numbers of bouridary,stones fixed at site. 806.3. Rate The Contract unit rate for boundary stones shall be paymnt in full compensation for furnishing all labour, materials, tools, equipment for preparing, supplying and fixing and all other incidental costs necessary to complete the work to these Specifications. 807. FENCING 807.1. General The work comprises of fixing Mild Steel (M.S.) pusts and providing barbed wire fencing including necess~ry stays and entry gates as shown in the drawing (s) and as directed by the Engineer.
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807.2. The M.S. posts shall conform to IS :226 and shall be of angle iron of size indicated in the drawings. The angle iron shall be embedded in concrete to a sufficient depth below ground as indicated in the drawings. The steel shall be fabricated and painted to conform to Section 1900 of these Specifications. 807.3. to IS:278. 807.4, the design 807.5. The barbed wire shall be of galvanised iron and shall conform Entry gate(s) shall be made of M.S. rods or other metal as per shown in the drawing(s). Measurements for Payment
The measurement shall be in running metre of fencing including the entry gates. 807.6, Rate The Contract unit rate for fencing shall be payment in full compensation for furnishing all labour, materials, tools, equipment for fabrication and fixing at site and all other incidental costs necessary to complete the work to these Specifications. 808. TUBULAR STEEL RAILING 808.1. General The work shall consist of supplying, fixing and erecting tubular steel railings as shown on the drawings and as directed by the Engineer. 808.2. The railings shall be of tubular steel in conformance to IS:1239. The fabrication and painting except for the final coat shall be completed before despatch to the site. Prior to the painting, all surfaces shall be grit blasted to the satisfaction of the Engineer and pickled. The priming coat of paint shall be applied as soon as the steel has dried. 808.3. The posts shall be vertical and of the type as shown in the drawing with a tolerance not exceeding 6mm in a length of 3 m. The railing shall be erected true to line and grade. 808.4. Measurements for Payment The railing shall be measured in linear metre from end to end along the face of the railing, including end and intermediate posts, with no deductions for gaps as shown on the drawings. 808.5. Rate The Contract unit rate for Tubular Steel Railing shall be payment
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in full compensation for furnishing all labour; materials, tools, equipment and plant required for fabrication, connection, oiling, painting, temporary erection, inspection, test and final erection at site and all other incidental costs necessary to complete the work to these Specifications. 809. CONCRETE CRASH BARRIER 809.1, General 809.1.1. This work shall consist of construction, provision and installation of concrete crash barrier at the edges of the road and median at locations and of dimensions as shown on the drawings or as directed by the Engineer. 809.1.2. Concrete barrier shall generally be located on approaches to bridge structures, at locations where the embankment height is more than 3 metres and at horizontal curves. 809.2. Materials 809.2.1. All materials shall conform to Section lOGO-Materials for Structures as applicable, and relevant Clauses in Section 1600 shall govern the steel reinforcement. The concrete barriers shall be constructed either by the cast-in-place with fixed forms method or the extrusion or slip form method or a combination thereof at the Contractors option with the approval of the Engineer. Where extrusion or slip form method is adopted, full details of the method and literature shall be furnished. 809.2.2. Concrete barriers shall be constructed with M 20 grade concrete and with High Yield Strength deformed reinforcement conforming to IRC: 21. 809.23. An expansion joint with pre-moulded asphalt filler board shall be provided at the junction of crash bather on structure and crash barrier on the fill. The crash barrier on the fill shall be constructed in pieces of length not exceeding 20 m, with pre-moulded asphth filler board joints. 8093. Construction Operations 809.3.1. The location of crash barrier shall be strictly adhered to as shown on the drawing and as directed by the Engineer. Concrete crash bathers shall present a smooth, uniform appearance in their final position, conforming to the horizontal and vertical lines shown on the plans or .as ordered by the Engineer and shall be free o1f lumps, sags or other irregularities. The top and exposed faces of the bathers shall conform to the specified tolerances, as defined in Clause R()9.4, when t~sted with 3 m straight edge, laid on the surface.
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809.3.2. When concrete barriers are to be constructed on recently completed bridges, the height of the barriers shall be adjusted to compensate for the camber and dead load deflection of the superstructure. The amount of adjustment shall be determined by the Engineer and shall be ordered before the concrete is placed. Such barriers shall be placed after form work has been released and as long after the superstructure construction as possible without hampering the progress of the work. 809.3.3. Backfilling to the concrete barriers shall be compacted in layers to the compaction of the surrounding earthwork. 809.4. Tolerance The overall horizontal alignment of rails shall not depart from the road alignment by more than mm, nor deviate in 30 any two successive lengths from straight by more than 6 mm and the fices shall not vary more than 12 mm from the edge ot~a rn straight 3 edge. Rarriers shall be at the specified height as shown in the plans above the edge of the nearest adjacent carriageway or shoulder, within a tolerance of mm. 30 8093. Measurements for Payment All barriers will be measured by linear metres of completed and accepted length in place, corresponding end to end along the face of concrete barriers including approach and departure ends. 809.6. Rate The Contract unit rate shall include full compensation for furnishing all labour, materials, tools, equipment and incidental costs necessary for doing all the work involved in constructing the concrete barrier complete in place in all respects as per these Specifications. 810. METAL BEAM CRASH BARRIER 810.1. General 810.1.1. This work shall consist of furnishing and erection of metal beam crash barrier of dimensions and at locations as shown on the drawing (s) or as directed by the Engineer. 810.1.2. Metal beam crash barrier shall generally be located on approaches to bridge structures, at locations where the embankment height is more than 3 metres and at horizontal curves. 810.2. Materials 810.2.1. Metal beam rail shall be corrugated sheet steel beams of
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the class, type, section and thickness indicated on the plans. Railing posts shall be made of steel of the section, weight and length as shown on the plans. All complete steel rail elements, terminal sections, posts, bolts, nuts, hardware and other steel fittings shall be galvanised. All elements of the railing shall be free from abrasions, rough or sharp edges and shall not be kinked, twisted or bent. 810.2.2. Steel beam elements and terminal sections shall be galvanised (zinc coated, O.55 kg per square metre, minimum single spot) unless otherwise specified. The galvanising on all other steel parts shall conform to the relevant IS Specifications. All fittings (bolts, nuts, washers) shall conform to the IS 1367 and IS 1364. All galvanizing shall be done after fabrication. 810.2.3. Concrete for bedding and anchor assembly shall conform to Section 1700 of these Specifications. 810.3. Construction Operations 810.3.!. The line and grade of railing shall be true to that shown on the plans. The railing shall be carefully adjusted prior to fixing in place, to ensure proper matching at abutting joints and correct alignment and camber throughout their length. Holes for field connections shall be drilled with the railing in place in the structure at proper grade and alignment. 810.3,2. Unless otherwise specified on the drawing, railing steel posts shall be given one shop coat of paint (primer) and three coats of paint on structural steel after erection, if the sections are not galvanised. Any part of assembly below ground shall be painted with three coats of red lead paint. 810.3,3. Splices and end connections shall be of the type and designs specified or shown on the plans and shall be of such strength as to develop full design strength of the rail elements. 810,4. Installation of Posts 810.4.1. Holes shall be dug or drilled to the depth indicated on the plans or posts may be driven by approved methods and equipment, provided these are erected in proper position and are free trom distortion and burring or any other damage. 810.4.2. All post holes that are dug or drilled shall be of such size as will permit proper setting of the posts and allow sufficient room for backfilling and tapping. 810.4.3. Holes shall be backfilled with selected earth or stable 293
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materials in layers not exceeding 100 mm thickness and each layer shall be thoroughly tamped and rammed. When backfihling and tamping are completed, the posts or anchors~ shall be held securely in place. 810.4,4. Post holes that are drilled in rock and holes for anchor posts shall be backfilled with concrete. 810.4.5. Posts for metal beam guardrails on bridges shall be bolted to the structure as detailed on the plans. The anchor bolts shall be set to proper location and elevation with templates and carefully checked. 810.5. Erection 810.5.1. All guardrail anchors shall be set and attachments made and placed as indicated on the plans or as directed by the Engineer. 810.5.2. All bolts or clips used for fastening the guardrail or fittings to the posts shall be drawn up tightly. Each bolt shall have sufficient length to extend atleast 6 mm through and beyond the full nut, except where such extensions might interfere with or endanger traffic in which case the bolts shall be cul off flush with the nut. 810.5.3. All railings shall be erected, drawn and adjusted so that the longitudinal tension will be uniform throughout the entire length of the rail. 810.6. Tolerance The posts shall be vertical with a tolerance not exceeding 6 mm in a length of 3 metre. The railing barrier shall be erected true to line and grade. 810.?. Measurements for Payment 810.7.1. Metal beam railing barriers will be measured by linear metre of completed length as per plans and accepted in place. Terminalsf anchors of various types shall be paid for by numbers. 810.7.2. No measurement for payment shall be made for projections or anchors beyond the end posts except as noted above, Furnishing and placing anchor bolts and/or devices for guard rail posts on bridges shall be considered incidental to the construction and the costs thereof shall be included in the price for other items of construction. 810.7.3. No measurement for payment will be made for excavation or backlilhing performed in connection with this construction. 810.8. Rate The Contract unit rate shall include full compensation for furnishing
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of labour, materials, tools, equipments and incidental costs necessary for doing all the work involved in constructing the metal beam railing barrier complete in place in all respects as per these Specifications. 811. ROAD TRAFFIC SIGNALS 811.1. General The traffic signal, its configuration, size and location shall be in accordance with IRC: 93 and IS: 7537 and as shown in the drawings or as directed by the Engineer. Prior to installation of signals, the Contractor shall submit to the Engineer, for approval, detailed proposals showing the signal type, sizes, paint and structural details of the signal posts including control system. 811.2. The tralfic signals shall have a complete electronic mechanism for controlling the operation of traffic with an auxiliary manual controller. The time plan of signals shall be as per drawing and shall be modified as directed by the Engineer. 811.3. Materials The various materials and fabrication thereof shall conform to the following: 8113.1. Signal foundation: The signal foundations shall be constructed as per Specifications given in Clause 13 of IRC: 93 or as shown in the drawings. 811.3.2. Constructional requirements: The constructional requirements for post, signal head assembly, signal head, optical system, lamp and holder, visor, post, supports for overhead mounted signals, equipment housing, locks, inter-connecting cables, earthing, mains termination, controller electrical components, etc., shall conform to IS: 7537 unless otherwise stated in IRC: 93. The post shall be painted and protected as per Clause 3.7. of IS: 7537. 8113.3. Optical requirements: The shape of all signal lenses shall be circular and shall be of specified colour and size and as shown in the drawing. Quality of lenses, arrangement of lenses, illuminations, visibility and shielding of signals shall be as per relevant Clauses of IRC : 93 and IS:7537. 811.4. Tests Tests shall be carried out on all components of traffic signal including tests on complete system for its performance as per relevant Clauses of IRC : 93 and IS: 7537.
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811.5. Maintenance of Traffic Signals It shall be the responsibility of the Contractor to provide for maintenance of the signal section system throughout the warranty period for at least five (5) years after installation and as per Clause 18 of IRC : 93. 811.6. Measurements for Payment The measurement for traffic signalisation system shall be by unit for complete work as specified and as per drawing for complete road junction. 811.7. Rate The Contract unit rate for the traffic signalisation system as a whole shall be payment in full compensation for furnishing all labour, materials, toots, equipment for preparing, supplying, fixing at site, testing and maintenance throughout ~warrantyperiod and all other incidental costs necessary to complete and maintain the work to these Specifications.
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Quality Control for Road Works
900 Quality Control for Road Works
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Section 900
901. GENERAL 901.1. All materials to be used, all methods adopted and all works performed shall be strictly in accordance with the requirements of these Specifications. The Contractor shall set up a field laboratory at locations approvedby the Engineer and equip the same with adequate equipment and personnel in order to carry out all required tests and Quality Control work as per Specifications and/or as directed by the Engineer. The internal layout of the laboratory shall be asper Clause 121 and/or asdirected by the Engineer. The list of equipment and the facilities to be provided shall be got approved from the Engineer in advance. 901.2. The Contractors laboratory should be manned by a qualified Materials Engineer/Civil Engineer assisted by experienced technicians, and the set-up should be got approved by the Engineer. 901.3. The Contractor shall carry out quality control tests on the materials and work to the frequency stipulated in subsequent paragraphs. In the absence of clear indications about method and or frequency of tests for any item, the instructions of the Engineer shall be followed. 901.4. For satisfyinghimselfaboutthe quality ofthe materials and work, quality control tests will also be conducted by the Engineer (by himself,by his Quality Control Units or by any other agencies deemed fit by him), generally to the frequency set forth herein under. Additional tests may also be conducted where,in the opinion of the Engineer,need forsuch tests exists. 901.5. The Contractor shall provide necessary co-operation and assistance in obtaining the samples for tests and carrying out the field tests as requiredby the Engineer from time to time. This may include provision of labour, attendants, assistance in packing and despatching and any other assistance considered necessary in connection with the tests. 901.6. For the work of embankment, subgrade an&pavement, construction ofsubsequent layerofsame or othermaterial over thefinished layer shall be done after obtaiiiing permission from the Engineer. Similar permission from the Engineer shall be obtained in respect of all other items of works prior to proceeding with the next stage of construction. 901.7. The Contractor shall carry out modifications in the procedure of work, if found necessary, as directed by the Engineer during inspection, Works falling short of quality shall be rectified/redone by the Contractor at his own cost, and defective work shall also be removedfrom the site ofworks by the Contractor at his own cost.
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901.8. The cost of laboratory building including services, essential supplies like water, electricity, sanitary services and their maintenance and cost of all equipment, tools, materials, labour and incidentals to perform tests and other operations of quality control according to the Specification requirements shall be deemed to be incidental to the work and no extra payment shall be made for the same. If, however, there is a separate item in the Bill of Quantities for setting up of a laboratory and installing testing equipment, such work shall be paid for separately. 901.9: For testing of samples of soils/soil mixes, granular materials, and mixes, bituminous materials and mixes, aggregates, cores etc., samples in the required quantity and form shall be supplied to the Engineer by the Contractor at his own cost. 901.10. For cement, bitumen, mild steel, and similar other materials where essential tests are to be carried out at the manufacturers plants or atlaboratories other than the site laboratory, the cost of samples, sampling, testing and furnishing of test certificates shall be borne by the Contractor. He shall also furnish the test certificates to the Engineer. 901.11. For testing of cement concrete at site during construction, arrangements for supply of samples, sampling, testing and supply of test results shall be made by ttte Contractor as per the frequency and number of tests specified in the Handbook of Quality Control for Construction of Roads and Runways (IRC: SP: 11) and relevant IS Codes or relevant clauses of these Specifications, the cost of which shall be borne by the Contractor. 901.12, The method of sampling and testing of materials shall be as required by the Handbook ofQuality Control for Construction of Roads and Runways (IRC SP: 11), and these MOST Specifitations. Where they are contradicting, the provision in these Specifications shall be followed. Where they are silent, sound engineering practices shall be adopted. The sampling and testing procedure to be used shall be aS approved by the Engineer and his decision shall be final and binding on the Contractor. 901.13. The materials for embankment construction shall be got approved from the Engineer. The responsibility for arranging and obtaining the land for borrowing or exploitation in any other way shall rest with the Contractor who shall ensure smooth and uninterrupted supply ofmaterials in the required quantity during the construction period. Similarly, the supply of aggregates for.construction of mad pavement shall be from quarries approved by the Engineer. Responsibility for arranging uniterrupted supply of materials from the source shall be that of the Contractor. 300
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Quality Control for Road Works 901.14. Defective Materials
Section 900
All materials which the Engineer/his representative has determined as not conforming to the requirements of the Contract shall be rejected whether in place or not; they shall be removed immediately from the site as directed. Materials, which have been subsequently corrected, shall not be used in the work unless approval is accorded in writing by the Engineer. Upon failure of the Contractor to comply with any order of the Engineer/his representative, given under this Clause, theEngineer/his representative shall have authority to cause the removal of rejected material and to deduct the removal cost thereof from any payments due to the Contractor, 901.15. Imported Materials At the time of submission of tenders, the Contractor shall furnish a list of materials/finished products manufactured, produced or fabricated outside India which he proposes to use in the work. The Contractor shall not be entitled to extension of time for acts or events occurring outside India and it shall be the Contractorsresponsibility to make timely delivery to the job site of all such materials obtained from outside India. The materials imported from outside India shall conform to the relevant Specifications of the Contract. In case where materials!finished products are not covered by the Specifications in the Contract, the details of Specifications proposed to be followed and the testing procedure as well as laboratories! establishments where tests are to be carried out shall be specifically brought out and agreed to in the Contract. The Contractor shall furnish to the Engineer a certificate of compliance ofthe tests carried out. Inaddition, certified mill test reports clearly identified to the lot ofmaterials shall be furnished at the Contractors cost. 902. CONTROL OF ALIGNMENT, LEVEL AND SURFACE REGULARITY 9011. General All works performed shall conform to the lines, grades, cross sections and dimensions shown on the drawings or as directed by the Engineer, subject to the permitted tolerances described herein-after. 902.2. Horizontal Alignment Horizontal alignments shallbe reckoned with respect to the centre line of the carriagewayas shown on the drawings. The edges of the carriageway asconstructed shall be correct within a tolerance of10 mm therefrom. The
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corresponding tolerance for edges of the roadway and lower layers of pavement shall be mm. 25 902.3. Surface Levels The levels of the subgrade and different pavement courses as constructed, shall not vary from those calculated with reference to the longitudinal and cross-profile of the road shown on the drawings or as directed by the Engineer beyond the tolerances mentioned in Table 900-i.
TABLE 900.1. TOLERANCES IN SURFACE LEVELS I. Subgrade +20mm -25 mm
2.
Sub-base + 10mm (a) Flexible pavement (b) Concrete pavement IDry lean concrete or Rolled concretel Base-course for flexible pavement (a) Bituminous course (1,) Other than bituminous (i) Machine laid (ii) Manually laid
+
-
20mm 6 mm 10mm
3.
+6 mm - 6mm + 10mm .10mm + l5rnxn - 15mm
4.
Wearing course for flexible pavement (a) Machine laid (I,) Manually laid
+6mm -6mm + 10mm - 10mm
5.
~
Cement concrete pavement
+5 mm
-6mm ~
Thit may not ex,,ceed -8mm at 0. 30cm from the edges.
Provided, however, that the negative tolerance for wearing course shall not be permitted in conjunction with the positive tolerance forbase course, if the thickness of the former is therebyreduced by more than 6 mm for flexible pavements and 5 mm for concrete pavements. For checking compliance with the above requirement for subgrade, subbase and base courses, measurements of the surface levels shall be taken on a grid of points placed at 6.25 m longitudinally and 3.5 m transversely.For any 10 consecutive measurements taken longitudinally or transversly, not more than one measurement shall be permitted to exceed the tolerance as above, this one measurement being not in excess of 5 mm above the
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permitted tolerance. For checking the compliance with the above requirement for bituminous wearing courses and concrete pavements, measurements of the surface levels shall be taken on a grid of point~ spaced at 6.25 m along the length and at 0.5 m from the edges and atthe ceure of the pavement. In any length of pavement, compliance shall be deemed to be met for the final road surface, only if the tolerance given above is satisfied for any point on the surface. 902.4. Surface Regularity of Pavemer Courses The longitudinal profile shall be checked with a 3 metre long straight edge/moving straight-edge as desired by the Engineer at the middle of each traffic lane along a line parallel to the centre line of the road. The maximum permitted number of surface irregularities shall be as per Table 900-2.
TABLE 900.2. MAXIMUM PERMIITEI) NUMBER OF SURFACE
IRREGULARITIES
Surfaces of carriageways and paved shoulders 1rre~isrity Length(m) National Highways/

Expressways Roads of lower category 20
Surfaces of laybys, service areas and all bitumInous base courses ~ 7mm 4mm 75 1
2
4mm
300
7mm 75
18
75 9
18
300
2
300 40
60
300
75
2
4 6
40
27
Category of each section of road as described in the Contract
The maxirnurn allowable difference between the road surface and underside of a 3 m straight-edge whenplacedparallelwith, or at right angles to the centre line of the road at points decided by the Engineer shall be: for pavement si1tface (bituminous and cement concrete) forbituminous base courses for granular sub-base/base courses for sub-bases under concrete pavements 3 mm 6 mm 8 mm 10 mm
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Quality Control
for Road Works
902.5. Rectification Where the surface regularity of subgrade and the various pavement courses fall outside the specified tolerances, the Contractor shall be liable to rectify these in the manner described below and to the satisfacion of the Engineer.
(I) Subgradet Where the surface is high, it shall be trimmed and suitably compacted. Wherethe same is low, the deficiency shall be corrected by scarifying the lower layer and adding fresh material and recompacsing to the required densityThe degree of compaction and the type of material to be used shall conform to the requirements of Clause 305. Granular Sub-base: Same as at (i)above, except that the degree of compaction and the type ofmaterial to be used shall conform to the requirements of Clause 401.
(ii)
(iii) Lime/Cement Stabilized Soil Subbase: For lime/cement treated materials where the surface is high, the same shall be suitably trimmed while taking care that the material below is notdisturbed due to this operation. However, where the surface is low, the same shall be corrected as described herein below. For cement treated material when the time elapsed between detection of irregularity and the time of mixing of the material is less than 2 hours, the surface shall be scarified to a depth of 50 mm supplemented with freshly mixed materials as necessary and recompacted to the relevant specification. When this time is more than 2 hours, the full depth of the layer shall be removed from the pavement and replaced with fresh material toSpecification This shall alan apply to lime treated material except that the time criterion shall be 3 hours instead of 2 hours. (lv) Water Bound Macadam/Wet MIx Macadam Sub.baseiBase: Where the surface is high or low, the top 75 mm shall be scarified, reshaped with added material as necessary and recompacted to Clause 404. This shall also apply to wet mix macadam to Clause 406. (v) Bituminous Constructions: Forbituminous constructionother than wearing course, where the surface is low, thedeficiency shall be corrected by adding fyesh material over a suitable tack coat if needed and recompacting to specifications. Where the surface ishigh, the full depth of the layer shall be removed and replaced with fresh material and compacted to specifications. For wearing course, where the surface is high or low, the full depth of the layer shall be removed and replaced with fresh material and compacted to specifications. In all cases where the removal and replacementof a bituminous layer is involved, the area treated shall not be less than 5 m in length and not less thari 35 m in width (vi) Dry Lean Concrete Sub.base/Rolled Cement Concrete: The defective length of the course shall be removed to full depth and replaced with material conforming to Clauses 601 or 603, as applicable. the area treated shall be at least 3m long, not less than I lane wide and extend tothe full depth. Beforerelaying the course, the disturbed subgrade or layer below shall be corrected by levelling, watering and compacting. (vll) Cement concrete pavement: The defective areas having surface irregularity exceeding 3 mm but not greater than 6 mm may be. rectified by bump cutting or scrabbling or grinding using approved equipment. When required by the Engineer areas which have been reduced in level by the above operation(s) shall be retextured
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Section 900
in an approved manner either by cutting groove~ 5 mm deep) or roughening the ( surface by hacking the surface. If high areas in excess 6mm or low areas in excess of 3 mm occur, exceeding the permitted numbers and ifthe Contractor carusot rectify, the slab shall be demolished and reconstructed at the Contractors expense and innocasethearearemoved shalibe less than thefullwidthofthe lane in ~iiich the irregularity occurs and full length of the slab If deemed necessary by the Engineer, any section of the slab which deviates from the specified levels asd tolerances shall be demolished and reconstructed ax the Contractors expense,
903, QUALITY CONTROL TESTS DURING CONSTRUCTION 903.1, General The materials supplied and the works carried Out by the Contractor shall conform to the specifications prescribed in the preceding Clauses. For ensuring the requisite quality of construction, the materials and works shall be subjected to quality control tests, as described hereinafter. The testing frequencies set forth are the desirable minimum and the Engineer shall have the full authority to carry out additional tests as frequently as he may deem necessary, to satisfy himself that the materials and works comply with the appropriate specifications. However, the number of tests recommended in Tables 900-3 and 900-4 may be reduced at the discretion of the Engineer if it is felt that consistency in the quality of materials can still be maintained with the reduced number of tests. Test procedures for the various quality control tests are indicated in the respective Sections of these Specifications or for certain tests within this Section. Where no specific testing procedure is mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to the directions of the Engineer. 903.2. Tests on Earthwork for Embankment, Subgrade Construction and Cut Formation 903.2.1, Borrow material Grid the borrow area at 25 m c/c (or closer, if the variability is high) to full depth ofproposed working. These. pits should be logged and plotted for proper identification of suitable sources of material. The following tests on representative samples shall be carried out: (a) Sand Content [IS: 2720 (Part-4)J: 2 tests per 3000 cubic metres of soil.
(b) Plasticity Test uS: 2720 (Part5)J: Each type to be tested,2tests per3000 cub. metres
of soil. (c) (d) Density Test [IS:2720 (Part S)l: Each soil type to be tested, 2 tests per 3000 cubic metres of soil. Deleterious Content Test [IS:2720 (Part27)): As and when Engineer. required by the
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Quality Control for Road
Works
Moisture Content Test (IS :2720 (Pa*2)l: One test for every 250 cubic metres of soil. CBR Teston materials to be incorporated In the sub~radeon soaked/unsoaked samples uS : 2720 (Part.16)]: one CBR test for every 3000 cu. m. atleast or closer as and when required by the Engineer.
(I)
903.2.2. Compaction Control: Control shall be exercisedon each layer by taking at least one measurement ofdensity for each 1000 square metres ofcompacted area, or closeras required to yield the minimum number of test results for evaluating a days work on statistical basis. The determination of density shall be in accordance with IS: 2720 (Part-28). Test locations shall be chosen only through random sampling techniques. Control shall not be based on the result of any one test but on the mean value of a set of 5-10 density determinations. The number oftests in one set of measurements shall be 6 (if non-destructive tests are carried out, the number of tests shall be doubled) as long as it is felt that sufficient control over borrow material and the method of compaction is being exercised. Ifconsiderable variations are observed between individual density results, the minimum number of tests in one set of measurement shall be increased to 10. The acceptance criteria shall be subject to the condition that themean density is not less than the specified density plus:
(No. of samples)~j However, for earthwork in shoulders (earthen) and in the subgrade, at leastone density measuz~ement hall be taken for every 500 square metres s for the compacted area provided further that the number oftests in each set ofmeasurements shall be atleast 10. In other respects, the control shall be similar to that described earlier. 903.2,3. Cut formation : Tests for the density requirements of cut formation shall be carried out in accordance with Clause 903.2.2. 903.3. Tests on Sub-bases and Bases (excluding bitumen bound bases) The tests and their frequencies for the different types ofbases and subbases shall be as given in Table900-3. The evaluation of density results and acceptance criteria for compaction control shall be on lines similar to those set out in Clause 903.2.2. 903.3.1. Acceptance criteria: The acceptance criteriafor tests on the strength of cement/lime stabilised soil and distribution of stabiliser content shall be subject to the condition that the mean value is not less than the
[ 11.65 [
1.65
1 times the standard deviation.
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specified value plus: 1.65 1.65 I times the standard deviation. (No. of samples)~j
TABLE 900.3. CONTROL TESTS AM) THEIR MINIMUM FREQUENCY FOR SUB. BASES AND BASES (EXCLUDING BITUMEN BOUND BASES) SI. Type of No. Construction I Granular (i) (ii) (iii) (iv) (v) (vi) 2. Lime/Cement Stabilised Soil Sub-base (i) Test Frequency (mm.)
Gradation Atterberg limits Moisture content prior to compaction Density of compacted layer Deleterious constituents C.B.R. Quality of Iime/ cement
3 One test per 200 m One test per 200 m One test per 250m2 One test per 500 m2 As required As required One test for each consignment subject to a minimum of one test per 5 sonnes Regularly, through procedural checks Periodically as considered necessarj As required
(ii)
Lime/Cement content Degree of puiverisation CBR or Unconfined Compressive Strength testona setof3 specimens Moisture content prior to compaction Density of compacted layer Deleterious constituents Aggregate Impact Value Grading Flakiness Index and Elongation Index Atterberg limits of binding material
(iii)
(iv)
(v) (vi) (vii) 3. Water Bound Macadam (i) (ii) (iii)
One test per 250 sq. m. One test per 500 in2 As required One test per 200 in1 of aggregate One test per 100 m2 One test per 200m of aggregate One test per 25 in5 of binding material
(iv)
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Section 900 SI. Type of No. Construction (v) Test
Quality Control far Road Works Frequency (miss.)
Auerberglimitsof portion of aggregate passing 425 micron sieve Aggregate impact Value Grading Flakiness and Elongation Index Atterberg limits of portion of aggregate passing 425 micron sieve Dthsity of compacted layer,
Onelesiper 100 cubic metre of aggregate
4.
Wet Mix Macadam
(1)
One test per 200m of aggregate One testper 100 m of aggregate 3 One test per 200 m of aggregate One test per 100 m3 of aggregate
(ii) (iii) (iv)
(v)
One test per 500 m2.
903,4. Tests on Bituminous Constructions 903.4.!. The tests and their minimum frequencies for the differenttypes of bituminous works shall be as given in Table 900-4. 903.4.2. Acceptance criteria : The acceptance criteria for tests on density and Marshall stability shall be subject to the condition that the mean value is not less than the specified value plus:
r1.65
--
1.65 times the standard deviation. (No. of samples)~j

CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR BITUMINOUS WORKS Test Frequency (minimum)
TABLE 900-4.
S. Type of Construction No. I. Prime Coat/Tack Coat
(i) Quality of binder
(ii) Binder temperature for application (iii) Rate of spread of Binder 2. Seal Coat/Surface Dressing
Two samples per lot to be subjected toall or some tests as directed by theEngineer At regular close intervals Two tests per day
(I) Quality of binder
Two samples per lot Dressingto be subjected to all or
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Quality Control for Road Works S. Type ofConstruction No. Test
Section 900 Frequency (Minimum)
(ii) Aggregate Impact Value * (iii) Flakiness Index and Elongation Index (iv) Stripping value of aggregates
some tests as directed by the Engineer 5 of One test per 50 m aggregate -doInitially one set of 3 representative specimens for each source of supply. Subsequently when warranted by changes in the quality of aggregates -doOne testper25moI aggregate As required At regular close intervals One test per 500m2 of work Two samples per lot to be subjected to all or some tealsas directed by Engineer One test perSO m of aggregate -do-
(v) Watcrabsorptionof aggregates (vi) Grading of aggregates (vii) Stone polishing value (viii) Temperatureof binder as application (jx) Rate of spread of materials 3. Open-graded Premix Carpet/Mix-Seal Surfacing (i) Quality of binder
(ii) Aggregate Impact Value (iii) flakiness Index and Elongation Index of aggregates (iv) Stripping value (v) Water absosplion of aggregates (vi) Grading ofaggregates (vii) Stone polishing value (viii) Temperature of binder at application (ix) Binder content (x) Rate of spread of mixed material
Same as mentioned under Serial No.2 Sameas mentioned under Serial No.2 One test per 25 m5 of aggregates As required At regular close intervals Two tests perday Regular control through checks on materials and layer thickness Two samples per lot to be subjectedto all or some tests as directed by the Engineer
Bituminous Macadam
(I) Quality of binder
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Section 900 S. Type of Construction No. Test
Quality Control for Road Works Frespsency (Minimum) 3 of One test per 50 m aggregate -do--
(ii) Aggregate Impact Value (iii) Flakiness index and Elongation index of aggregates (iv) Stripping value (v) Grading of aggregates
(vi) Water absorption of aggregates (vii) Binder content
Same as mentioned under Serial No. 2 teats per day per plant both on the individuai constituents and mixed aggregates from the dryer Same as in Serial No. 2 Periodic, subject to minimum oftwo tests per day per plant At regular close intervals
(viii) Control oftemperature ofbinder and aggregate for mixing and ofthe mix at the time of laying and rolling (ix) Rate of spread of mixed material
Regular control through checks of layerthickness Two samples per lot to be subjectedto all orsome tests as directed by the Engineer. One test per ZOOm of aggregate doSame as mentioned under Serial No 2 Sameas in Serial No.2 Onetestper lOOm ofaggregate At regular close intervals One test per 500 m of area
5.
Bituminous Penetration Macadarn/ Built-up Spray-Grout
(i) Quality ofbinder
(ii) Aggregate Impact Value (iii) Flakiness Index and Elongation Index (iv) Stripping value (v) Water absorption of aggregates (vi) Aggregate grading (vii) Temperature of binder at application (viii) Rateofipreadof binder 6. Dense Bituminous Macadam/Semi Dense Bituminous Concrete! Bituminous Concrete (i) Quality ofbinder
(ii) Aggregate Impact Value
Two samples per lot to be subjected to all or some tests as directed by the Engineer One testper 50 m of aggregate
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Section 900
Test
Frequency (Minimum)
S. Type of Construction No,
(iii) Flakiness Index and Elongation Index of aggregates (iv) Stripping Value (v) Water absorption of
do-
As in Serial No.2 As in Serial No. 2 As required As required, for Semi Dense Bituminous Concrete/Bituminous Concrete One set of tests on individual constituents and mixed aggregate from the dryer for each 400 tonnes of mix subject to a minimum of two tests per plant per day For each 400 tonnes ofmix peoduced,asetof 3 Marshall specimens to be prepared andtessed forstability, flow value, density and void content subject to a minimum oftwo sets beingtested per plant per day As required for Bituminous Concrete do. At regular close intervals
-
aggregates (vi) Sand equivalent test (vii) Stone Polishing Value
(viii) Mix grading
(ix) Stability ofMix
(a) Water sensitivity of mix (i~etention of Marshall Stability) (xi) Swell tell on the mix (xli) Control of temperature of binder in boiler, aggregate in the dryer and mix at the time of laying and rolling (xiii) Control ofbinder content and gradation in the mix (xiv) Rate of spread of
mixed material
One test for each 400 tonnes of mix subject to a minimum of two tests per day perplant Regular control and through checks on the weight of mixed material and layer thickness One test per 250 m~ area
(xv) Density of compacted layer
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311
Section 900
Quality Control
for Road Works
903.5. Quality Control Tests for Concrete Road Construction 903.5.1. Dry lean concrete sub-base: 903.5.1.1. Sampling and testing of cubes: Samples of dry lean concrete for making cubes shall be laken from the uncompacted material from different locations immediately before compaction at the rate of 3 samples for each 1000 sq. m. or part thereof laid each day. The sampling of mix shall be done from the paving site. Test cubes of 150mm size shall be made immediately from each mix sample. Cubes shall be made in accordance with the methods described in 15:516 except that the cubes shall be compacted by means of a vibratory hammer with the motilds placed on a level and rigid base. The vibrating hammer shall be electric or pneumatic type fitted with a square or rectangular foot having an area ofbetween 7500 to 14000 sq.mm. The compaction shall be uniformly applied for 60 seconds with a downward force ofbetween 300 Nand 400 5 N on to each of the three layers of the lean concrete material placed into the mould. The surface of each compacted layer shall be scarifiedbefore the next layer is added to give key for the next layer. The final layer shall be finished flush with the top of the cube mould. The dry lean concrete cubes shall be cured in accordance with IS:5 16. 903.5.1.2. In-situ density: The dry density of the laid material shall be determined from three density holes at locations equally spaced along a diagonal that bisects each 2000 square metre or part thereof laid each day and shall comply with the requirements as per Clause601.5.5.1. This rate of testing may be increased at the discretion of the Engineer in case ofdoubt or to determine the extent of defective area in the event of non-compliance. Density holes at random may be made to check the density at edges. 903.5.13. Thickness: The average thickness of the subbase layer as computed by the level data ofsub-base and subgrade or lower sub-base shall be as per the thickness specified in the contract drawings. The thickness at any single location shall not be 10mm less than the specified thickness. Such areas shall be correctedas stated in Clause 601.5.5.5. Areas which cannot be repaired should be replaced over full width. The extent of deficient area should be decided based on cores. 903.5.1.4. Frequency of quality control tests: The frequency of quality control tests for levels, alignment and materials shall be as in Table 900-6.
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312
Quality Control for
Road Works
Section 900
903.5.2. Pavement concrete 903.5.2.1. Samplingand testing ofbeam and cube specimens: Atleast two beam and two cube specimens, oneeach for7 day and 28 day strength testing shall be cast for ever 150 cu.m (or part thereof) of concrete placed during construction. On each days work, not less than three pairs of beams and cubes shall be made for each type ofmix from the concrete delivered to the paving plant. Each pair shall be from a differentdelivery ofconcrete and tested at a place to he designated by the Engineer in accordance with the testing procedure as outlined in Clause 602.3.3. Groups of four consecutive results from single specimens tested at28 days shall be used for assessing the strength for compliance with the strength requirements. The specimens shall be transported in an approved manner to prevent sudden impact causing fractures or damage to the specimen.The flexural strength testresults shall prevail over compressive strength tests for compliance. A quality control chart indicating the strength values of individual specimens shall be maintained for continuous quality assurance. Where the requirements are not met with, or where the quality of the concrete or its compaction is suspect, the actual strength of the concrete in the slab shall be ascertained by carrying Out tests on cores cut from the hardened concrete at such locations. The cores shall be cut at the rate of 2 cores for every 150 cu. m. of concrete. The results of crushingstrength tests on these cores shall not be less than 0.8 times the corresponding crushing strength of cubes, where the height to diameter ratio of the core is twO. Where height to diameter ratio is varied, then the necessary corrections shall be made in calculating the crushing strength of cubes in the following manner. The crushing strengths of cylinders with height to diameter ratios between 1 and 2 may be corrected to correspond to a standard cylinder of height to diameter ratio of 2 by multiplying with the correction factor obtained from the following equation: f= 0.lln+0.78 where f = correction factor and n = height to diameter ratio The correctedtest results shall be analysed forconformity with the specification requirements for cube samples. Wherethe core tests are satisfactory, they shall have precedence for assessing concrete quality over the results of moulded specimens. The diameter of cores shall not be less than 150 mm. If, however, the tests on cores also confirm that the concrete is not satisfying the strength requirements, then the concrete corresponding to
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313
Section 900
Quality
Control
for Road Works
the area from which the cores were cut should be replaced,i.e., atleast over an area extending between two transverse joints where the defects could be isolated or over larger areas, if necessary, as assessed by additional cores and their test results. The equivalent flexural strength at 28 days shall be estimated in accordance with Clause 602.3.3.2, In order to ensure that the specified minimum strength at 28 days is attained in 99 per cent of all test beams, the mix shall be proportioned to give an average strength at28 days exceeding the specified strength by 2.33 times the standard deviation calculated first from the flexural strengths of test beams made from the trial mix and subsequently from the accumulating result of flexural strengths of job control test beams. The standard deviation shall be re-calculated from the test results obtained after any change in the source or quality of materials and the mix shall be adjusted as necessary to comply with the requirements. An individual 28 day test strength below thespecified strength shall not be evidence for condemnation of the concrete concerned ifthe average 28 day strength of this beam plus the preceding 5 and succeeding 4 beams exceeds the specified strength by 2.33 times the standard deviation and provided that there is no other evidence that the concrete mix concerned is substandard. Beams shalibemade each dayin pairs at intervals, each pairbeing from a different batch of concrete. At the start of the work, and until such time as the Engineer may order a reduction in the number of beams required, at least six pairs of beams and cubes shall be made each day, one of each pair for testing at 28 days for determination of ifle minimum permissible flexural strength and the other for testing at an early age for the Engineer to assess the quality ofthe mix. When the firstthirty numberof28-day results are available, and for so long as the Engineer is satisfied with the quality of the mix, he may reduce the number of beams and cubes required. During the course ~f construction, when the source of any material is to be changed, or if there is any variation in the quality of the materials furnished,additional tests and necessary adjustments in the mix shall be made as required to obtaIn the specified strength. The flexural strengths obtained on beams testedbefore28 days shall be used in conjunction with a correlation between them and th~ day flexural 28 strengths to detect any deterioration in the quality of the concrete being produced. Any such deterioration shall be remedied without awaiting the 28 day strengths but the earlier strengths shailnot constitute sole evidence
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314
Quality Control for Read Works
Section 900
of non-compliance of the concrete from which they were taken. Concrete shall not comply with the Specification when more than one test beam in a batch has a 28 day strength less than the specified strength and the average 28 day flex ural strength of the batch of beams is less than the specified strength plus 2.33 times the standard deviation of the batch. Should the c~ncretefail to pass the Specification for strength as described above, the Contractor may, all at his own expense, elect to cut cores from the suspect concrete as the Engineer shall direct. From the relation between cube strength and flexural strength, the core strength shall be converted to flexural strength. The equivalent flexural strength at 28 days shall be the estimated insitu strength multiplied by 100 and divided by the age-strength relation obtained from Table 900-5. Any concrete that fails to meet the strength specification shall be removed and replaced at Contractors expense.
TABLE 900.5. AGE- STREr~GTHRELATION OF CONCRETE (RELATED TO 100 PER (TENT AT 28 DAYS) DAYS
0 10
0
.
2 41.0
85.0
4
60.0 87.5
6 71.0
90.0
8 77.5
92.0
81.5
20 30 40 50 60 70 80 90 100 110 120 130 140 150

160
94.0 101.0
106.5
96.0
102.0 107.0
97.5
103.5
98.5
1043 1093
100.0
105.5 110.0 113.0
170
180
190 200
110.5 114.0 116.5 119.0 121,0 123.5 125.0 126.0 127.5 129.0 130.5 131.5 1323 1333 135.0 135.5
111.0 1143 117,0 1193

121.5
1233 125.0 1263

128.0
108.0 112.0 115.0 1173 1193 122.0 123.5

1253
1125 115.5 118.0 120.0 122.0 124.0 1253
116.0 118.5 120.5

122.5
127.0
128.5
127.0
1283
1293 1303 1313 132$ 134.0 135.0 1353 315
1293 131.0 132.0 133.0 134.0 135.0 136.0
130.0 131.0 132.0 133.0 1343 135.5 136.0
124.5 126.0 1273 129.0 130.0 131.5 132.5 1333 134.5 135,5 136.5
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Section 900 210 220 230 240 250 260 270 280 290 136.5 137.0 138.0 139.0 139.5 140.5 141.0 142.0 142.5 143.0 143.5 144.0 144.5 145.0 146.0 146.0 136.5 1373 138$ 139.0 140.0 1403 141.0 142.0 142.5 143.0 1433 144.5 145.0 1453 146.0 146.0
Quality Control for Road Works 137.0 137.5 138.5 139.0 140.0 140.5 141.5 142.0 142.5 143.0 144.0 144.5 145.0 145.5 146.0 146.5 137.0 1373 138.5 139.5 140.0 140.5 141$ 142.0 142.5 !43.0 144.0 144.5 145.0 145.5 146.0 146.5 137.0 138.0 138.5 139.5 140.0 141.0 141.5 142.0 142.5 143.5 144.0 144.5 145.0 145.5 146.0 146.5
3(X)
310 320 330 340 350 360
903.5.2.2. In-situ density The density of the compacted concrete shall be such that the total air voids are not more than 3 per cent. The air voids shall be derived from the difference between the theoretical maximum dry density of the concrete calculated from the specific gravities of the constituents ofthe concrete mix and the average value of three direct density measurements made on cores at least 150mm diameter. Three cores shall be taken from trial lengths and in first two km length of the pavement, while the slab isbeing constructed during normal working. The proportions of the mix and the vibratory effortimparted i.e the frequency and magnitude of vibration shall be adjusted to achieve the maximum density. All cores taken for density measurement in the trial section shall also be checked for thickness. The same cores shall be made use of for determining in-situ strength. In case of doubt, ftdditional cores may be ordered by the Engineer and taken at locations decided by him to check the density of concrete slab or the position of doweljtie bars without any compensation being paidfor the same. In calculating the density, allowance shall be made for any steel in cores. Cores removed from the main carriageway shall be reinstated with compacted concrete with mix proportions of 1 partof portland cement: 2 parts of fine aggregate : 2 parts of 10 mm nominal size single sized coarse aggregate by weight. Before filling the fine mix, the sides shall be hacked and cleaned with water. Thereafter cement-sand slurry shall be applied to the sides just prior to filling the concrete mix.
316
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Section 900
903.5.23. Thickness: Thickness shall be controlled by taking levels as indicated in Clause 902.3. Thickness of the slab at any point checked as mentioned above shall be within a tolerance of -5 mm to + 25 mm of the specified thickness as per Drawing. Thickness deficiency more than 5 mm may be accepted and paid for ata reduced rate given in Clause 602,15.2. In no case, however, thicknessdeficiency shall be more than 25 mm. 903.5.2.4. Summary of control tests : Table 900-6 gives a summary of frequency of testing of pavement quality concrete.
TABLE 900.6 . FREQUENCY OF QUALITY CONTROL TESTS FOR PAVING QUALITY CONCRETE 1. Levels, alIgnment and texture (i)
Level tolerance Widthof pavement and position of paving edges (iii) Pavement thickness (iv) Alignment ofjoints, widths, depths of dowel grooves (ii) (v) Surface regularity both transversely and longitudinally Clause 902.3
Clause 902.2. Clauses 902.3 and 903,5.2.3 To be checked c~t Joint one per 400 m length or a days work whichever is more. Once a day orone days work, without disturbing the curing operation. To be checked in trial length as per Clause 64)2.10.5.2 and once on every 2 km.
(vi) Alignment of dowel bars and their accuracy~tie bars
2.
(vii) Texture depth Clause602.9,8 Quality of Materials and Concrete Control tests for materials and concrete shall be as under: Cement Physical and chemical tests
IS: 269 IS: 455 IS : 1489 IS : 8112 IS : 12269
Once for each source of

supply and occasionally when called for in case ~oftongiirnproper storage. B~sides, he Contractor also t will submit daily test data on cement released by the
2.
Coarse and Fine aggregates
(i) Gradation
IS: 2386 (Pt 1)
Manufactwer. One zest for every days work of each fraction of coarse aggregate and fine aggregate. initially; may be relaxed later at the discretion of the engineer.
-do-
(ii) Deleterious
constituents
IS: 2386 (Pt. 2)
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317
Section
900
(iii) Water absoiption
Quality Control for Road Works IS:2386 (Pt. 3) Regularly as required subjectto a minimum of one zest a day for coarse aggre. gale & two tests a day for frne aggregate. This data shall be used for correcting the waterdemand ofthe mix on daily basis. Once foreach source of supply and subsequently on monthly basis. Before approving the aggregates and every month subsequently
3.
Coarse Aggregate
(i) Los Angeles Abrasion value or Aggregate Impact test (ii) Soundness
(iii) Alkali aggregate reactivity Chemical Tests
IS:2 386
(Pt.4)
lS:2386 (Pt5)
IS:2386 (Pt.7) lS:456
-doOnce for approval of source of supply, subsequently only in case of doubt.

2cubes and2beams per 150 in or part thereof (one forlday tnd other for 28 day strength) or minimum 6 cubes and 6 beams per days work whichever is more. As per the requirement of the Engtheer~nly in case of o doubt, One teat per each dumper load at both Batching plant site and paving site initially
4.
Water
5.
Concrete
(i) Strength of concrete
lS:516
(ii) Core strength on hardened concrete (iii) Workability of fresh concrete.Slump Test
IS:5l6
IS:1199
wheat work starts. Subtequendy sampling may be

(iv) Thickness determination done from alternate dumper. From the level data of con~ crete pavement surface and sub-base at grid points of 5/ 6.25mx33m
(v) Thickness measurement for trial length

(vi) Verification of level of string line in the case of slip form paving and steel forms in the case of fixed
form paving
3 cores per trial length. String line or steel forms shall be checked for level at an interval of 5.0 m or 6.25 m. The level tolerance allowed shall be 2~nm. These shallbc got approved 1.2 hours before the cornmeatcement of the concret~ ing activity.
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318
Section 900
903.5.3. Rolled Concrete Base 903.5.3.1. Sampling and testingofbeamsand cubes: Clause9O3.5.2, 1 shall apply 903.5.3.2. Thickness Thickness shall be controlled by taking levels as indicated in Clause 903.5.1.3. 903.5.3.3. In-situ density : The dry density of the laid material shall be determined from three density holes at locations equally spaced along a diagonal that bisects each 2000 square metre or part thereof laid each dayand shall comply with the requirements as per Clause 601.5.5.1. This rate of testing may be increased atthe discretion of the Engineer in case of doubt or to determine the extent of defective area in the event of non compliance. Density holes at random may be made to check the density atedges. 903.5.3.4. Summary of control tests : Table 900-6 gives the summary of tests for levels, alignment and materials. 903.5.4. Summary of rate of sampling and testing:
(i) (ii) Strength 3 beams and 3 cubes for each 100 sq. Density
in. or
pan thereof laid each day.
3 density holes for each 2000 sq.m. or past thereof laid each day.
(iii) Cores : Only when Engineer instructs. They shall not be cut on regular basis.
A, relation between flexural strength and compressive strength may be developed by regression analysis using the available data. This may be updated from time to time.
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319
Materials for Structures
1000 Materials for Structures
<<
Section 1000
100L GENERAL Materials to be used in the work shall conform to the specifications mentioned on the drawings, the requirements laid down in this section and specifications for relevant items of work covered under these specifications. If any material, not covered in these specifications, is required to be used in the work, it shall conform to relevant Indian Standards, if there are any, or to the requirements specified by the Engineer. 1002. SOURCES OF MATERIAL The Contractor shall notify the~ Engineer of his proposed sources of materials prior to delivery. If it is found after trial that sources of supply previously approved do not produce uniform and satisfactory products, or if the product from any other source proves unacceptable at any time, the Contractor shall furnish acceptable material from other sources at his own expense. 1003. BRICKS Burnt clay bricks shall conform to the requirements of IS:l077, except that the minimum compressive strength when tested flat shall not be less than 8.4 MPa for individual bricks and 10.5 MPa for average of 5 specimens. They shall be free from. cracks and flaws and nodules of free lime. The brick shall have smooth rectangular faces with sharp corners and emit a clear ringing sound when struck. The size may be according to local practice with a tolerance of per cent. ~
1004. STONES
Stones shall be of the type specified. It shall be hard, sound, free from cracks, decay and weathering and shall be freshly quarried from an approved quarry. Stone with round surface shall not be used. The stones, when immersed in water for 24 hours, shall not absorb water by more than 5 per cent of their dry weight when tested in accordance with IS:1 124. The length of stones shall not exceed 3 times its height nor shall they be less than twice its height plus one joint. No Stone shall be less in width than the height and width on the base shall not be greater. than three-fourth of the thickness of the wall nor less than 150 mm. 323
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Section 1000
Materials for Stnictures
1005. CAST IRON Cast iron shall conform to IS:210. The grade number of the material shall not be less than 14, 1006. CEMENT Cement to be used in the works shall be any of the following types with the prior approval of the Engineer
a) Ordinary Portland Cement, 33 Grade, conforming to IS~269. Rapid Hardening Portland Cement, confonning to IS:8041. Ordinary Portland Cement, 43 Grade, conforming to lS:81 12. Ordinary Portland Cement, 53 Grade, confonning to IS:12269.
b) c) d) e)
Sulphate Resistant Portland Cerneni, confomting to lS:12330.
Cement conforming to IS:269 shall be used only after ensuring that the minimum required design strength can be achieved without exceeding the maximum permissible cement content of 540 kg/cu.m. of concrete. Cement conforming to IS:8112 and IS:12269 may be used provided the minimum cement content mentioned elsewhere from durability considerations is not reduced. From strength considerations, these cements shall be used with a certain caution as high early strengths of cement in the 1 to 28-day range can be achieved by finer grinding and higher constituent ratio of C3S/C2S, where C3S is Tricalcium Silicate and C2S is Dicalcium Silicate. In such cements, the further growth of strength beyond say 4 weeks may be much lower than that traditionally expected. Therefore, further strength tests shall be carried out for 56 and 90 days to fine tune the mix design from strength considerations. Cement conforming to IS: 12330 shall be used when sodium sulphate and magnesium sulphate are present in large enough concentration to be aggressive to concrete. The recommended threshold values as per IS:456 are sulphate concentration in excess of 0.2 per cent in soil substrata or 300 ppm (0.O3per cent) in ground water. Tests to confirm actual values of sulphate concentration are essential when the structure is located near the sea coast, chemical factories, agricultural land using chemical fertilizers and sites where there are effluent discharges or where soluble sulphate bearing ground water level is high. Cement conforming to IS: 12330 shall be carefully selected from strength considerations to ensure that the minimum required design strength can be achieved without exceeding the maximum permissible cement content of 540 kg/ cu.m. of concrete.
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324
Materials for Stmctures
Section 1000
Cement conforming to IS:8041 shall be used only for precast concrete products after specific approval of the Engineer. Total chloride content in cement shall in no case exceed 0.05 per cent by mass of cement. Also, total sulphur content calculated as sulphuric anhydride (SO3) shall in no case exceed 2.5 per cent and 3.0 per cent when tn-calcium aluminate per cent by mass is upto 5 or greater than 5 respectively. 1007. COARSE AGGREGATES For plain and reinforced cement concrete (PCC and RCC) or prestressed concrete (PSC) works, coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable pieces of crushed stone, crushed gravel, natural gravel or a suitable combination thereof or other approved inert material. They shall not consist pieces of disintegrated stones, soft, flaky, elongated particles, salt, alkali, vegetable matter or other deleterious materials in such quantities as to reduce the strength and durability of the concrete, or to attack the steel reinforcement. Coarse aggregate having positive alkalisilica reaction shall not be used. All coarse aggregates shall conform to IS:383 and tests for conformity shall be carried out as per IS:2386, Parts I to VIII. The contractor shall submit for the approval of the Engineer, the entire information indicated in Appendix A of IS:383. Maximum nominal size of coarse aggregate for various structural components in FCC, RCC or PSC, shall conform to Section 1700. The maximum value for flakiness index for coarse aggregate shall not exceed 35 per cent. The coarse aggregate shall satisfy the following requirements of grading
TABLE 1000-1 REQUIREMENTS OF COARSE AGGREGATE IS Sieve Size
63mm 40mm 20 mm 12.5mm
Per rent by Weight Passing the Steve 40mm

100 95-100 30.70
20mm
12.5mm

100 95.100
100 90-100
10 mm
4.75mm
10-35 0-5
25.55 0-10
40.85
0-10
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325
Section 1000
1008.
SANDIFINE AGGREGATES
For masonry work, sand shall conform to the requirements of IS:21 16. For plain and reinforced cement concrete (FCC and RCC) or prestressed concrete (PSC) works, fine aggregate shall consist of clean, hard, strong and durable pieces of crushed stone, crushed gravel, or a suitable combination of natural sand, crushed stone or gravel. They shall not contain dust, lumps, soft or flaky, materials, mica or other deleterious materials in such quantities as to reduce the strength and durability of the concrete, or to attack the embedded steel. Motorised sand washing machines should be used to remove impurities from sand, Fine aggregate having positive alkali-silica reaction shall not be used. All fine aggregates shall conform to IS:383 and tests for conformity shall be carried out as per IS:2386, (Pans I to VIII). The Contractor shall submit to the Engineer the entire information indicated in Appendix A of lS:383. The fineness modulus of fine aggregate shall neither be less than 2.0 nor greater than 3.5. Sand/fine aggregate for structural cOncrete shall conform to the following grading requirements TABLE 1000-2
IS Sieve Size 10mm 4.75 mm 2.36 mm 1.18 mm 600 uderon 300 micron 150 micron Per cent by Weight Passing the Sieve Zone 100 90-100 60-95 30.70
Zone II Zone Ill
100 90-100 75-100 55-90
100
90-100
15-34
5-20 0-10
35.59
8-30 0-10
85-100 75-100 60.79 12.40

0-10
1009. STEEL
1009.1. Cast Steel The use of cast steel shall be limited to bearings and other similar parts. Steel for castings shall conform to Grade 280-520N of IS: 1030. In case where subsequent welding is unavoidable in the relevant cast steel components, the letter N at the end of the grade designation of the steel casting shall be replaced by letter W. 0.3 per cent to 0.5 per cent copper may be added to increase the corrosion resistance properties.
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326
Materials for Stmctures 1009.2. Steel for Prestressing
Section 1000
The prestressing steel shall conform to either of the following

(a) (b) (c)
Plain hard drawn seel wire conforming to IS:1785 (Part I) and 1S~1785 (Part II).
Cold drawn indented wire conforming to 1S:~O03 High tensile steel bar conforming to lS:2090
(d)
(Jncoated stress relieved strands conforming to 1S:600t
10093. Reinforcement I Untensioned Steel For plain and reinforced cement concrete (FCC and RCC) or prestressed concrete (PSC) works, the reinforcement / untensioned steel as the case may be shall consist of the following grades of reinforcing bars.
Grade
Designation S 240
TABLE 1008-3 Characteristic to governing IS Strength iy MPa

liar Type conforming Specification
Elastic
Modulus GPa
lS:432 Part 1 Mild Steel Bar
240 415 ~
200 200
S 415
IS:1786 High Yield

Strength Deformed Bars (HYSD)
Other grades of bars conforming to IS:432 and IS: 1786 shall not he permitted. All steel shall be procured from original producers, no re-rolled steel shall be incorporated in the worL Only new steel shall be delivered to the site. Every bar shall be inspected before assembling on the work and defective, brittle or burnt bar Shall be discarded. Cracked ends of bars shall be discarded. Fusion-bonded epoxy coated reinforcing bars shall meet the requirements of IS: 13620. Additional requirements for the use of such reinforcement bars have been given below
(a) Patch up materials shall be procured in sealed containers with certi(icates from the agency who has supplied the fusion bonded epoxy bars.
wires of 180 shall catiy be used in conjtutction with fusion bonded epoxy bars. (c) (lairs for supporting the reinforcement shall also be of fusion bonded epoxy coated bars. (d) The cut ends and damaged ponictes shall be touched up with repair patch up material. (b)
PVC costed 0.1. binding
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327
Section 1000 (e) (I) (g) (Ii)
The bars shall be cut by saw-cutting rather than flame cutting. While bending the bars, the pins of work benches shall be provided with PVC or plastic sleeves. The coated steel shall not be directly exposed to sun rays or rains and shall be protected with opaque polyethelene sheets or such other approved materials While concreting, the woTkmen or trolleys shall not directly move on coated bars but can move on wooden planks placed on the bars.
When specified in the contract, protective coating prescribed by CECRI shalt be provided in conformance to specifications given in Appendix /000/!, The CECRI coating process shall be allowed to be implemented at the site of works provided a representative of the Institute is present throughout the duration of the coating process who shall certify that the materials and worimanship are in accordance with prescribed specifications developed by the Institute. 1009.4. Grey Iron Castings Grey Iron castings to be used for bearings shall have the following minimum properties
(i) (ii) (iii) (iv) (v) Minimum ultimate tensile strength Modulus of Elasticity Brinell Hardness Shear Strength Compressive Strength 370 MPa 147000 Mls
230 Mls
370 Mls 1370 Mls
The testing shall be as specified in IS:210. 1009.5. Steel Forgings Forged steel pins shall comply with clause 3, 3A or 4 of IS: 1875 and steel forgings shall comply with clause 3, 3A or 4 of IS:2004. Raw materials of the forging will be taken as per IS:1875 with minimum reduction ratio of 1.8:1. Alter atively, if forging is made from ingot, a minimum reduction ratio between the ingot and forging will be 4:1. Forging shall be normalised. 1009.6. Structural Steel Unless otherwise permitted herein, all structural steel shall before fabrication comply with the requirements of the following Indian Standards: IS:226 Structural Steel (Standard Quality) 1S~961 Structural Steel (High Tensile)
IS:2062
IS:8500 Weldable Structural Steel Weldable Structural Steel (medium & high strength qualities)
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328
Section 1000
(0110
IS
1148
Hot rolled rivet bars
40mm dia) for structural purposes
IS:1 149 IS: 1161 IS:4923 :
High tensile rivet bars for structural purposes Steel tubes for structural purposes
Ilollow Steel sections for structural use

Structural weather resistant steel Specifications, for Rolled Steel Beam, Channel and Angle Sections
lS:1 1587 : IS:808 IS:1239 IS:1730 IS: 1731 IS: 1732 IS:1852 : : : : :
Mild Steel Tubes Dimension for Steel Plate, sheet and strip for structural and general engineering purposes
Dimension for Steel flats for structural andgeneral engineeringpurposes Dimension for round and square steel bars for structural and general
engineering purposes Rolling and cutting tolerances for hot rolled steel products
The use of structural steel not covered by the above standards may be permitted with the specific approval of the authority. Refer to Section 1900 for further details. 1009.7. Stalnless Steel Stainless steel shall be austenitic chromium-nickel steel, possessing rust, acid and heat resistant properties conforming to IS:6603 and IS:6911. Mechanical properties/grade for such stainless steel shall be as specified by the accepting authority, but in no case be inferior to mild steel. Generally, stainless steel is available as per AISI grades. AISI 304 which is equivalent to grade O4Crl8Ni 110 of IS:6911 satisfies the requirements of mechanical properties of structural steel. Other grades of stainless steel for specific purposes may be provided as per specific requirements. For application in adverse/ corrosive environment, stainless steel shall conform to AISI 316L or 02G17 Ni Mo2 of IS:6911. 1010. WATER Water used for mixing and curing shall be clean and free from injurious amounts of oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. Potable water is generally considered satisfactory for mixing concrete. Mixing and curing with sea water shall not be permitted. As a guide, the following concentrations represent the maximum permissible values
(a) (b) To ncualise 200 ml sample of water, using phenolpthalein as an indicator, it should not require more than 2 ml of 0.1 normal NsOH. To neutralise 200 ml sample of water, using methyl orange as art indicator, it should not require more than 10 ml of 0.1 normal H~.
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329
Section 1000 (c)
The permissible limits for solids shall be as follows when tested in accordance with lS:3025 Permissible Limits (max) 200 mg/lit 3000 mg/lit 500 mg/lit 500 mg/lit * 2000 mg/lit
Organic Inorganic Sulphatcs (SO
4) Chlorides (Cl) Suspended matter
~ In case of structures of lengths 30m and below, the permissible limit of chlorides may be increased upto 1000 mg/lit. All samples of water (including potable water) shall be tested and suitable measures taken where necessary to ensure conformity of the water so the requirements stated berein. (d) The pH value shall not be less than 6
1011. TIMBER The timber used for structural purposes shall conform to IS:883, 1012. CONCRETE ADMIXTURES 1012.1. General Admixtures are materials added to the concrete before or during mixing with a view to modify one or more of the properties of concrete in the plastic or hardened state. Concrete admixtures are proprietary items of manufacture and shall bc obtained only from established manufacturers with proven track record, qttality assurance and full fledged laboratory facilities for the manufacture and testing of concrete. The contractor shall provide the following information concerning each admixture after obtaining the same from the manufacturer
(a) (b) (c) (d) (e) Norsnal dosage and detrimental effects, if any, of under dosage and over dosage. The chemical names of the main ingredients in the admixtures. The chloride content, if any, expressed as a percentage by the weight of the adsnixture. Values of dry material content, ash content and relative density of the admixture which can be used for Uniformity Tests. Whether or not the admixture leads to the entertainment of air when used as per the manufacturers recommended dosage, and if so to what extent. Where two or more admixturea are proposed to be used in any one mix, confirmation as to their compatibility. There would be no increase in risk of corrosion of the reinforcement or other embedments as a result of using the admixture.
(Q
(g)
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Section 1000
1012.2. Physical and Chemical Requirements Admixtures shall conform to the requirements of IS:9103. In addition, the following conditions shall be satisfied
(a) (h) Plasticisers and Super-Plasticisers shall meet the requirements indicated for Water reducing Admixture. Except where resistance to freezing and thawing and to disru11ive action of de. icing salts is necessary, the air content of freshly mixed concrete in accordance with the pressure method given in lS:1199 shall not be more than 2 per cent higher than that of the corresponding control mix and in any case not more than 3 per cent of the test mix. The chloride content of the admixture shall not exceed 0.2 per cent when tested in accordance with IS:6925. In addition, the maximum permissible limit of chloride content of all the constituents as indicated in Section 1700 shall also be observed Uniformity tests on the admixtures are essential to compare qualitatively the composition of different samples taken from batch to batch or from the same batch at different times. The tests that shall be performed along with permissible variations in the same are indicated below
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(c)
(d)
Dry Material Content to be within 3 per cent and 5 per cent of liquid and solid admixtures respectively of the value stated by the manufacturer Ash content turer. to be within 1 per cent of the value stated by the manufacto be within 2 per cent of the value
Relative Density (for liquid admixtures) stated by the manufacturer. (e)
All tests relating to the concretes admixtures shall be conducted periodically at an independent laboratory and compared with the data given by the manufacturer
1013, REINFORCED CONCRETE PIPES Reinforced concrete pipes for highway structures shall be of NP4 type conforming to the requirements of IS:458. 1014. STORAGE OF MATERIALS 1014.1. General All materials may be stored at proper places so as to prevent their deterioration or intrusion by foreign matter and to ensure their satisfactory quality and fitness for the work. The storage space must also permit easy inspection, removal and restorage of the materials. All such materials even though stored in approved godawns/places, must be subjected to acceptance test prior to their immediate use. 1014.2. Brick Bricks shall not be dumped at site. They shall be stacked in regular
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Section 1000
tiers as they are unloaded, to minimise breakage and defacement. The supply of bricks shall be available at site at any time. Bricks selected for use in different situations shall be stacked separately. 1014.3. Aggregates Aggregate stockpiles may be made on ground that is denuded of vegetation, is hard and well drained. If necessary, the ground shall be covered with 50 mm plank. Coarse aggregates, unless otherwise agreed by the Engineer in writing, shall be delivered to the site in separate sizes (2 sizes when nominal size is 25 mm or less and 3 sizes when the nominal size is 32 mm or more). Aggregates placed directly on the ground shall not be removed f~omthe stockpile within 30 cm of the ground until the final cleaning up of the work, and then only the clean aggregate will he petmitted to be used. Jn the case of fine aggregates, these shall be deposited at the mixing site not less than 8 hours before use and shall have been tested and approved by the Engineer. 1014.4. Cement Cement shall be transported, handled and stored on the site in such a manner as to avoid deterioration or contamination. Cement shall be stored above ground level in perfectly dry and water.tight sheds and shall be stacked not more than eight bags high. Wherever bulk storage containers are used their capacity should be sufficient to cater to the requirement at site and should be cleaned at least once every 3 to 4 months. Each consignment shall be stored separately so that it may be readily identified and inspected and cement shall be used in the sequence in which it is delivered at site. Any consignment or part of a consignment of cement which had deteriorated in any way, during storage, shall not be used in the works and shall be removed from the site by the Contractor without charge to the Employer. The Contractor shall prepare and maintain proper records on site in respect of delivery, handling, storage and use of cement and these records shall be available for inspection by the Engineer at all times. The Contractor shall make a monthly return to the Engineer on the date corresponding to the interim certificate date, showing the quantities of cement received and issued during the month and in stock at the end of the month. << 332
Section 1000
1014.5. Reinforcement /Untensioned Steel The reinforcement bars, when delivered on the job, shall be stored above the surface of the ground upon platforms, skids, or other supports, and shall be protected from mechanical injury and from deterioration by exposure. 1014.6. Prestressing Materials All prestressing steel, sheathing, anchorages and sleeves or coupling must be protected during transportation, handling and storage. The prestressing steel, sheathing and other accessories must be stored under cover from rain or thmp ground and protected from the ambient atmosphere if it is likely to be aggressive. Storage at site must be kept to the absolute minimum.
(a) Tendon: Wire, strand and bar from which tendons are to be fabricated shall be stored about 300mm above the ground in a suitably covered and closed space so as to avoid direct climatic influences and to protect them from splashes from any other materials and from the cutting operation of an oxy-acetylene torch or arc welding process in the vicinity. Under no circumstances, tendon material shall be subjected td any welding operation or on site heat treatment or metallic coating such as galvanising. Storage facilities and the procedures for transporting material into or out of store, shall be such that the material does not become kinked or notched. Wire or strand shall be stored in large diameter coils which enable the tendons to be laid out straight. As a guide, foe wires above 5mm dia, coils of about 2sn dia without breaks or joints shall be obtained from manufacturer and stored. Protective wrapping for tendons shall be chemically neutral, All prestressing steel must be provided with temporary protection during storage. Anchorage Components : The handling and storing procedures shall maintain the anchorage components in a condition in which they can subsequently perform their function to an adequate degree. Components shall be handled and stored so that mechanical damage and detrimental corrosion are prevented. The corrosion of the gripping and securing system shall be prevented. The use of correctly formulated oils and greases or of other corrosion preventing material is recommended where prolonged storage is required. Such protective material shall be guaranteed by the producer to be non.aggressive and non-degrading.
(5)
Prestressing steel shall be stored in a closed store having single door with double locking arrangements and no windows. Also the air inside the store shall be kept dry as far as possible by using various means to the satisfaction of the Engineer. Also instrument measuring the air humidity shall be installed inside the store. This is with a view to eliminating the possibility of initial rusting of prestressing steel during storage. The prestressing steel shall be coated with water solvabletrease. The prestressing steel should be absolutely clean and without any signs of rust.
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Section 1000
All prestressing steel shall be stored at least 30 cm above ground level and it shall be invariably wrapped by protective cover of tar paper or polythene or any other approved material. The Contractor should see that prestressing steel shall be used within 3 months of its manufacture. He should chalk out his programme in this respect precisely, so as to avoid initial corrosion before placing in position. 1014.7. later Water shall be stored in containers/tanks covered at top and cleaned at regular intervals in order to prevent intrusion by foreign matter or growth of organic matter. Water from shallow, muddy or marshy surface shall not be permitted. The intake pipe shall be enclosed to exclude silt, mud, grass and other solid materials and there shall be a minimum depth of 0.60 m of water below the intake at all times. 1015. TESTS AND STANDARD OF ACCEPTANCE All materials, even though stored in an approved manner shall be subjected to an acceptance test prior to their immediate use. independent testing of cement for every consignment shall be done by the Contractor at Site in the laboratory approved by the Engineer before use. Any cement with lower quality than those shown in manufacturers certificate shall be debarred from use. In case of imported cement, the same series of tests shall be carried out before acceptance. 1015.1. Testing and Approval of Material The Contractor shall furnish test certificates from the manufacturer/ supplier of materials along with each batch of material(s) delivered to site. The Contractor shall set up a field laboratory with necessary equipment for testing of all materials, finished products used in the construction as per requirements of conditions of contract and the relevant specifications. The testing of all the materials shall be carried out by the Engineer or his representative for which the Contractor shall make all the necessary arrangements and bear the entire cost. Tests which cannot be carried out in the field laboratory have to be got done at the Contractors cost at any recognised laboratory / testing establishments approved by the Engineer.
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1015.2. Sampling of Materials Samples provided to the Engineer or his representative for their retention are to be in labelled boxes suitable for storage. Samples required for approval and testing must be supplied well in advance by at least 48 hours or minimum period required for carrying out relevant tests to allow for testing and approval. Delay to works arising from the late submission of samples will not be acceptable as a reason for delay in the completion of the works. If materials are brought from abroad, the cost of sampling/testing whether in India or abroad shall be borne by the Contractor. 1015.3. Rejection of Materials not Conforming to the Specifications Any stack or batch of material(s) of which sample(s) does not conform to the prescribed tests and quality shall be rejected by the Engineer or his representative and such materials shall be removed from site by the Contractor at his own cost. Such rejected materials shall not be made .acceptable by any modifications. 1015,4. Testing and Approval of Plant and Equipment All plants and equipment used for preparing, testing and production of materials for incorporation into the permanent works shall be in accordance with manufacturers specifications and shall be got approved by the Engineer before use.
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Pile Foundations
1100 Pile Foundations
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Pile Foundations 1101. DESCRIPTION
Section 1100
1101,.!. This work shall consist of construction of all types of piles for structures in accordance with the details shown on the drawings and conforming to the requirements of these specifications. 1101.2. The construction of pile foundations requires a careful choice of the piling system depending upon sub-soil conditions and loading characteristics and type of structure. The permissible limits of total and differential settlements, unsupported length of pile under scour, impactl entanglement of floating bodies and any other special requirements of project are also equally important criteria for selection of the piling system. The method of installing the piles, including details of the equipment shall be submitted by the Contractor and got approved from the Engineer.
.
1101.3. The work shall be done as per IS:291l except as modified herein. 1102. SUB-SURFACE INVESTIGATION 1102.1. The complete sub-surface investigation of strata in which pile foundations are proposed shall be carried out in advance and by in-situ pile tests. For details of geotechnical sub-surface explorations reference may be made to Section 2400, At least one bore-hole for every foundation of the bridge shall be executed. Borings should be carried upto sufficient depths so as to ascertain the nature of strata arottnd the pile shaft and below the pile tip. However, depth of boring shall not be less than
i) ii) iii) 1.5 times estimated length of pile in soil but not less than 15 m beyond the probable length of pile 15 times diameter of pile in weak/jointed rock but minimum 15 m in such rock 4 times diameter of pile in sound, hard rock but min[mum 3 m in such rock
1102.2. The sub-surface investigation shall define adequately stratification of sub-strata including the nature and type of strata, its variation and extent and specific properties of the same. The investigation shall be adequate for the purpose of selection of appropriate piling system and for estimating design capacities for different diameters and length of piles.
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1102.3. Pressure meter tests may be used in the case of rock, gravel or soil for direct evaluation of strength and compressibility characteristics. Though these tests are of specialised nature they are most appropriate for difficult/uncertain sub-strata especially for important projects, 1102.4. For piles socketed into rocks, it is necessary to determine the uniaxial compressive strength of the rock and its quality. The investigation shall also include location of ground water table and other parameters including results of chemical tests showing sulphate and chloride content and any other deleterious chemical content in soil and/or ground water, likely to affect durability. 1103. TYPE OF PILES The piles may be of reinforced concrete, prestressed concrete, steel or timber. The piles may be of solid or hollow sections or steel cased piles filled with concrete. Concrete piles may be driven castin-situ or precast or bored cast-in-situ or precast piles. driven into preformed bores. The shape of piles may be circular, square, hexagonal, octagonal, H or I Section. 1104. MATERIALS 1104.1. The basic materials shall conform to the specifications for materials given in Section 1000. The specifications for steel reinforcement, structural concrete, prestressed concrete and structural steel to be used in pile foundations shall be as given in the relevant sections. 1104.2. Concrete in Piles Grade of concrete to be used in cast-in-situ piles shall not be less than M 20 and the cement content shall not be less than 400 kg per cubic meter of concrete. Grades of concrete for precast reinforced and prestressed concrete piles shall not be less than M 25 and M 35 respectively. Maximum water cement ratio shall be 0.5 for cast-in-situ piles and 0.45 for precast piles. The minimum slump of concrete for driven cast-in-situ piles shall be 1,00 mm to 150 mm and that of bored cast-in-situ piles 150 mm to 200 mm. The slump should not exceed 200 mm in any case. Concrete mix should have homogeneous mixture with required workability for the system of piling adopted. Suitable and approved admixtures may be used in concrete mix where necessary. 340
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Where piles are exposed to actin of harmful chemicals or severe conditions of exposure due to presence of sulphate, chloride etc. it may be preferable to opt for higher grades of concrete restricting water cement ratio to 0.45. Special types of cement, such as sulphate resistant cement may be used where considered appropriate. 1105. TEST PILES 1105.1. Test piles which are shown on the drawings or specified in the contract or installed by the Contractor on his own to determine the lengths of piles to be furnished shall conform to the requirements for piling as indicated in these specifications, if they are to be incorporated in the completed structure. Test piles that are to become a part of the completed structure shall be installed with the same type of equipment that is proposed to be used for piling in the actual structure. Test piles which are not to be incorporated in the completed structure shall be removed to at least 600 mm below the proposed soffit level of pile cap and the remaining hole shall be backfilled with earth or other suitable material. The piles shall be load tested in accordance with provisions laid down in this section. 1106. PRECAST\CONCRETE PILES 1106.1. General Precast concrete piles shall be of the size and shape as shown in the approved drawings. if a square section is employed, the corners shall be chamfered at least 25 mm unless otherwise specified on the drawings. The length of pile shall not normally exceed 25 metres. However, where special equipments for handling and installation are available to the satisfaction of the Engineer, longer length could be permitted. Piles shall be cast with a driving point and for hard driving, shall be shod with a metal shoe approved by the Engineer. 1106.2. Stacking, Storing and Handling Care shall be taken that at all stages of transporting, lifting and handling, piles are not damaged or cracked. During transport and stacking of piles, they shall be supported at the same points as those provided for lifting purposes. If the piles are put down temporarily during handling, they shall be placed on trestles or blocks located at the same points.
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Piles shall be stored at least 300 mm above tim level ground which is not liable to ui ~ual subsidence or settlement under the weight of the stack of piles. They shall be placed on timber supports which are level and spaced so as to avoid bending. The supports shall be verti cally one above the other. Spaces shall be left round the piles to enable them to be lifted without difficulty. The order of stacking shall be such that the older piles can be withdrawn without disturbing newer piles. Separate stacks shall be provided for different lengths of piles. Where piles are stacked in layers, the number of layers shall not exceed three. Whanever curing is needed during storage, arrangements shall be made to enable the piles to be watered. For detailed precautions with regard to curing operations specifications for structural concrete given in Section 1700 shall apply. Before the operation of handling and driving the piles, the minimum periods counted from the time of casting shall be allowed for as indicated in Table 1100-1. Prestressed piles shall not be lifted or handled until fully stressed.
TABLE 1100.1 TIME FOR CURING PRECAST PILES Minimum periods from time of casting Type of cement used in casting the pile Ordinary Portland Rapid hardening Portland Strike side. shutters (hours) 24 12 End of wet curing (days) 7 7
*
Lift from castIng bed (days) 10 7

.
Drive (days) 28 10
1106,3. Lengthening of Piles Where a pile is to have another length cast on it during driving, the longitudinal reinforcement shall preferably be joined by full penetration butt welding. The concrete at the top of the original pile shall be cut down to expose not less than 200 mm of the bars to avoid spalling of the concrete by heat. The added bars have to be held accurately and rigidly in position during welding. Where facilities on site are insufficient to make proper butt welding practicable, the joint may be made by lapping. The reinforcement at the head of pile will need to be exposed for full anchorage length or 600 mm whichever is greater and the new bars over-lapped for this distance. Unless otherwise specified, the extension of the pile shall be formed to the same cross-sectional profile and wiLh concrete of at least the same strength as that specified for the original pile. The stirrup spacing shall in no case be greater than
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Pile Foundations
Section 1100
150 mm. Not more than one extension shall be permitted. In case more than one extension is permitted by the Engineer, only approved mechanical couplers shall be used. Driving shall not be resumed until
(i)
The strength of the concrete in the extension is at least equal to the specified characteristic strength of concrete in pile, and The approval of the Engineer has been obtained.
(ii)
1106.4. Removal of Surplus Length Any length of pile surplus to that required for incorporation in the structure shall be cut off neatly and removed. During the process of cutting off, it shall be ensured that projecting reinforcement to be anchored into the pile cap and the prestressing strands/wires are not damaged. When stripping prestressed concrete piles, shock release of tendons shall be avoided. Reference may also be made to clause 7.7.1. of IS:2911 (Part I Section 3) in this connection. 1106.5. Risen Piles Level reading should be taken on each pile after driving and again after all the piles are driven. Piles which are found to have risen due to ground heave or as a result of driving adjacent piles, shall be re-driven to the original depth or resistance unless re-driving tests on adjacent piles have shown this to be unnecessary. 1106.6, Manufacture The pile should be cast in one continuous operation from end to end of each pile. Manufacture of precast concrete piles shall conform to the guidelines contained in clause Nos. 7.1,7.2 and 7.3 of IS:2911 (Part I, Section 3). Pile shall be provided with suitable shoe for protecting the point of the pile during driving in hard ground. Piles shall not be moved from casting bed until the concrete has hardened sufficiently. Piles shall not be driven in less than 28 days after casting or unless their strength at the time of driving is at least that specified for 28 days. 1106.7. Prestressed Concrete Piles Additional specifications for precast prestressed concrete piles shall conform to those contained in clause 8 of IS:2911 (Part I Section 3).
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Section
1100
Pile 1107. CAST-IN-SITU CONCRETE PILES
Foundations
Cast-in-situ concrete piles may be either installed by making a bore into the ground by removal of material or by driving a metal casing with a shoe at the tip and displacing the material laterally. The two types of piles are termed as bored piles and driven piles respectively. Cast-in-situ concrete piles may be cast in metal shells which may remain permanently in place. However, other types of cast-in-situ concrete piles, plain or reinforced, cased or uncased, may be used if in the opinion of the Engineer the soil conditions permit their use and if their design and the methods of placing are satisfactory. The metal casing shall be of sufficient thickness and strength to hold its original form and show no harmful distortion after it and adjacent casings have been driven and the driving core, ~f any, has been withdrawn. Cast-in-situ concrete driven piles shall be installed using a properly designed detachable shoe at the bottom of the casing. Certain specific requirements of cast-in-situ driven piles shall be as per Clauses 1110 and 1111. Any liner or bore-hole which is improperly located or shows partial collapse that would affect the load carrying capacity of the pile, shall be rejected or repaired as directed by the Engineer at the cost of the Contractor. Wherever practicable, concrete should be placed in a clean dry hole. Where concrete is placed in dry and there is casing present, the top 3 m of the pile shall be compacted using internal vibrators. The concrete should invariably be poured through a tremie with a funnel so that the flow is directed and concrete can be deposited in the hole without segregation. Where the casing is withdrawn from cohesive soils for the formation of cast-in-situ pile, the concreting should be done with necessary precautions to minimise the softening of the soil by excess water. Where mud flow conditions exist, the casing of cast-in-situ piles shall not be allowed to be withdrawn. Care shall be taken during concreting to prevent as far as possible the segregation of the ingredients. The displacement or distortion of reinforcement during concreting and also while extracting the tube shall be avoided.
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Pile Foundations
Section
1100
If the concrete is placed inside precast concrete tubes or consists of precast sections, these shall be free from cracks or other damage before being installed. The concrete shall be properly graded, shall be self-compacting and shall not get mixed with soil, excess water, or other extraneous matter. Special care shall be taken in silty clays and other soils with the tendency to squeeze into the newly deposited concrete and cause necking. Sufficient head of green concrete shall be maintained to prevent inflow of soil or water into the concrete. The placing of concrete shall be a continuous process from the toe level to the top of the pile. To prevent segregation, a tube or tremie pipe as appropriate shall be used to place concrete in all piles. To ensure compaction by hydraulic static heads, rate of placing concrete in the pile shaft shall not be less than 6 m (length of pile) per hour. Bored cast-in-situ piles in soils which are stable, may often be installed with only a small casing length at the top. A minimum of 2.0 m length of top of bore shall invariably be provided with casing to ensure against loose soil falling into the bore. In cases in which the side soil can fall into the hole, it is necessary to stabilise the side of the bore hole with drilling mud, or a suitable steel casing. The casing may be left in position permanently specially in cases where~ the aggressive action of the ground water is to be avoided, or in the cases of piles built in water or in cases where significant length of piles coWd be exposed due to scour. For bored cast-in-situ piles, casing/liner shall be driven open ended with a pile driving hammer capable of achieving penetration of the liner to the length shown on the drawing or as approved by the Engineer. Materials inside the casing shall be removed progressively by air lift, grab or percussion equipment or other approved means. Where bored cast-in-situ piles are used in soils liable to flow, the bottom of the casing shall be kept enough in advance of the boring tool to prevent the entry of soil into the casing, thus preventing the formation of cavities and settlements in the adjoining ground. The water level in the casing should generally be maintained at the natural ground water level for the same reasons. The joints of the casing shall be made as tight as possible to minimise inflow of water or leakage of slurry during concreting.
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Section 1100
Pile Foundations
Boring shall be carried out using rotary or percussion type equipment. Unless otherwise approved by the Engineer, the diameter of the bore-holes shall be not more than the inside diameter of the liner. Prior to the lowering of the reinforcement cage into the pile shaft, the shalt shall be cleaned of all loose materials. Cover to reinforcing steel shall be maintained by suitable spacers. The diameter of the finished pile shall not be less than that specified and a continuous record shall be kept by the Engineer as to the volume of concrete placed in relation to the pile length cast. Before concreting under water, the bottom of the hole shall be cleaned of drilling mud and all soft or loose material very carefully. in case a hole is bored with use of drilling mud, concreting should not be taken up when the specific gravity of bouom slurry is more than 1.2. The drilling mud should be maintained at 1.5m above the. ground water level. Concreting under water for cast-in-situ concrete piles may be done either with the use of tremie method or by the use of an approved method specially designed to permit under water placement of concrete. General requirements and precautions for concreting under water are as follows
(a) The concreting of a pile must be completed in one continuous operation. Also, for bored holes, the finishing of the bore, cleaning of the bore, lowering of reinforcement cage and concreting of pile for full height must be accomplished in one continuous operation without any stoppage. should be coherent, rich in cement with high slump and restricted water cement ratio. The tremie pipe wilt have to be large enough with due regard to the size of aggregate. For 20 mm aggregate the tremie pipe should be of diameter not less than 150 mm and for larger aggregate, larger diameter tremie pipes may be necessary. The first charge of concrete should be placed with a sliding plug pushed down the tube ahead of it to prevent mixing of water and concrete. The tremie pipe should always penetrate well into the concrete with an adequate margin of safety against accidental withdrawal if the pipe is surged to discharge the concrete. The pile should be concreted wholly by tremie and the method of depoaitinn should not be changed part way up the pile to prevent the taitance from being entrapped within the pile.
Q,) The concrete

(c)
(11) (e)
(f)
(g)
All
tremie tubes should be scn3pulously cleaned after use.
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Pile
Foundations
Section 1100
The minimum embedment of cast-in-situ concrete piles into pile cap shall be 150 mm. Any defective concrete at the head of the completed pile shall be cut away and made good with new concrete. The clear cover between the bottom reinforcement in pile cap from the top of the pile shall be not less than 25 mm. The reinforcement in the pile shall be exposed for full anchorage length to permit it to be adequately bonded into the pile cap. Exposing such length shall be done carefully to avoid damaging the rest of the pile, in cases where the pile cap is to be laid on ground, a levelling course of M 15 nominal mix concrete 100 mm thick shall be provided. Defective piles shall be removed or left in place as judged convenient without affecting the performance of adjacent piles or pile cap. Additional piles shall be provided to replace the defective piles. 1108. STEEL PILES Steel piles shall be H or I sections as shown on the drawings and shall be of structural steel conforming to the specifications given in Section 1000. Steel piles shall be protected by suitable anti-corrosive painting as specified on the drawing. Piles shall be stored above the ground using protective packing to minimise damage to surface coating. Each pile shall be supplied preferably in one piece without splices. At the option of the Contractor, steel piling consisting of structural steel plates welded together may be substituted for the rolled sections specified, provided that the depth, width and average thicknesses are at least equal to those of the rolled sections, the steel plates conform to specification given in Section 1000, the flanges are welded to the web with continuous fillet welds on either side of the web, and the welding conforms to Clause 1904.8 of these specifications. The length of the steel pile may be built up in sections either before or during driving operations. The sections shall be of identical cross-section. Pile splices shall be made with full penetration butt welds over the whole cross-section. Pile splices shall develop at least the yield strength of pile. The connections shall be made by butt-welding the entire crosssection in accordance with the provisions in Clause 1904.8 of these specifications. Care shall be taken to properly align the sections connected so that the axis of the pile will be straight. The number of welded connections in the length of pile shall be as few as possible.
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Section 1100
Pile Foundations
1109. TIMBER PILES The Engineer shall stamp each pile on the butt with a stamp which shall make an impression that is readily legible. Treated timber piles will be inspected by the Engineer after treatment, Untreated timber may be used as test piles. Untreated timber piles and treated timber piles shall be of approved quality. Treated timber piles shall be driven within 6 months after treatment. Timber piles shall be fumished with tip protection and shall be protected by the use of steel straps as hereinafter specified. Tip protection shall be suitable for use on timber piling of the size to be driven. Details of tip protection shall be furnished to the Engineer for review and approval before driving piles. Not less than 2 separate steel straps shall be placed within 600 mm of the butt of each pile after the pile is square cut, Not less than 2 separate steel straps shall be placed within 300 mm of the tip of each pile. Additional intermediate steel straps shall be placed at not more than 3 metres centre measured along the length of the pile.
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Timber piles which are to be capped shall be separately cut off so that true bearing is obtained on every pile. Piles inaccurately cut off shall be replaced. Splicing of timber piles shall not be permitted except by written permission of the Engineer. 1110. DRIVING EQUIPMENT Piles or their casings may be driven with any type of drop hammer, diesel hammer or single-acting steam or compressed air hammer, provided they penetrate to the prescribed depth or attain the designed resistance without being damaged. The weight or power of the hammer should be sufficient to ensure a penetration of at least 5 mm per blow, unless rock has been reached. It is always preferable to employ the heaviest hammer practicable and to limit the stroke, so as not to damage the pile. The minimum weight of the haniiper shall be 2.5t. In the case of precast concrete piles the mass of the hammer shall be not less than 30 times the mass of 300 mm length of pile. Steam or air hammers shall be furnished along with boiler or air compressor of capacity at least equal to that specified by the manufacturer of the hammers. The boiler or air compressor shall be equipped with
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Section 1100
an accurate pressure gauge at all times. The valve mechanism and other parts of steam, air or diesel hammers shall be maintained in first class condition so that the length of stroke and number of blows per minute for which the hammer is designed, will be obtained. Inefficient steam, air or diesel hammers shall be removed from the work. 1111. DRIVING 1111.1. General Procedure Details of the equipment and the method proposed for driving the piles shall be submitted with the tender for scrutiny and approval of the Engineer. Piles shall be installed from firm ground or from temporary supports or from fixed platform. The arrangement shall provide sufficient rigidity to ensure accuracy of pile driving under all conditions of tide, stream flow or hammer drop. During driving the top of pile shall be protected by a suitable helmet of substantial steel constru~tion. The helmet shall provide uniform bearing across the top of the pile and shall hold the pile centrally under the hammer. No pile shall be driven unless inspected and approved by the Engineer. Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of driving within specified tolerances. Forces producing undue bending or torsional stresses in piles shall not be applied during driving. The force of the hammer shall be directed centrally and axially during driving. The stroke of a single acting or drop hammer shall be limited to 1.2 m unless otherwise permitted by the Engineer. A shorter stroke may be necessary when there is danger of damaging the pile. Piles shall not be bent or sprung into position but shall be effectively guided and held on-line during the initial stages of driving. Attempts to correct any tendency for the pile to run off-line by the application of significant horizontal restraint will not be permitted. Shortly after the commencement of driving and at regular intervals throughout the driving operation, checks shall be made to ensure that the pile frame does not exert any undue lateral force on the pile due to restraint within the helmet.~ If the indications are that a pile will finish outside the specified tolerances, driving operations on that pile will cease. The pile shall be withdrawn, the hole filled and the pile re-driven at no extra cost.
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Section 1100
Pile Foundations
To avoid the possibility of premature set-up pile driving shall be continuous in the later stages, without any deliberate stops. (Delays of an hour or less may lead to significant set-up in piles i.e. resistance to further driving increases after driving is stopped). If any pile is damaged in any way during driving, it shall be repaired or replaced as directed by the Engineer, at no extra cost. If during driving, the head of a pile is damaged to the extent that further driving is not possible, the head shall be cut off and driving continued. The cost of cutting off shall be bome by the Contractor and where, as a result of such cutting off the head, the pile is too short, the Contractor, shall, at his own cost, supply and splice on sufficient length of pile to restore the pile to its correct length. Piles should be driven to the minimum acceptable penetration shown on the drawings. This may require preboring and/or jetting as indicated in these specifications with the full approval of the Engineer. Piles shall be driven to nominal refusal or the required ultimate dynamic capacity nominated on the drawings or until the top of the pile is at the level required and specified on the drawing whichever gives the lowest toe elevation. The Engineers decision in these matters shall be final. Nominal refusal shall be taken as equivalent to 25 mm total penetration for the final 20 blows using a hammer of driving energy as specified and shall be used as the criterion for acceptance for piles founded on rock. Severe driving which results in an average set per blow less than 0.5 mm will not be permitted. Where hard drilling is encountered because of dense strata or obstructions located above the predetermined pile tip level, nominal refusal shall not be considered to have been achieved unless the Engineer is satisfied that the total number of blows, as the average driving resistance specified for nominal refusal, indicates that further driving will not advance the pile through dense strata or obstructions, The pile shall be driven as accurately as possible to the vertical or to specified batter. Straining the pile into position can damage it and the driving equipment should be adjusted as much as possible to follow the position of the pile. Any deviation from the proper alignment shall be noted and promptly reported to the Engineer. If the deviation is to such an extent that the resulting eccentricity cannot be taken care of by strengthening the pile cap or pile ties, such a pile shall, at the discretion of the Engineer, be replaced or supplemented by an additional pile. Unless otherwise specified, the permissible
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1100
positional deviation for piles shall be limited to those indicated in Clause 1116. Care shall be taken not to damage the pile by over-driving. Any sudden change in the rate of penetration which cannot be ascribed to the nature of the ground shall be noted and its cause ascertained, if possible, before driving is continued. When employing a tube which is subsequently withdrawn for the formation of cast-in-situ pile, consideration shall be given to the possibility of doing harm to a pile recently formed by driving the tube nearby before the concrete has sufficiently set. The danger of doing harm is greater in compact soils than loose soils. No pile shall be bored or driven within 3 in of a newly cast pile until at least 24 hours after completion of its installation. Driving piles in loose sand tends to compact the sand which in turn increases the skin friction. Therefore, driving a number of friction piles in a group shall proceed outward from the centre as otherwise it will be difficult to drive the inner piles to the same depth as the others. In the case of stiff clay also, the driving for a group of piles shall proceed outward from the centre. However, in case of very soft soil, the driving may proceed from outside to inside, so that the soil is restrained from flowing out during driving operations. If there is a major variation between the depth at which adjacent foundation piles in a group meet refusal, a boring shall be made nearby to ascertain the cause of this difference. If the boring shows that the soil contains pockets of highly compressive material below the level of the shorter pile, it will be necessary to enforce penetration of all the piles to a level below the bottom of the zone which shows such pockets. 1111.2. Preboring and Jetting Driving of the piles may be assisted by preboring holes or by the use of jets or both subject to the approval of the Engineer. These may be used essentially to achieve the minimum penetration shown on the drawings where such penetration is not reached under normal conditions of driving indicated in Clause 1111.1. The diameter of the hole shall not be greater than the diagonal dimension of the pile less 100 mm. The maximum depth of the preboring shall be such that the
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specified set (or less) is obtained when the toe of the pile is at founding level. Preboring shall be as approved by the Engineer and shall not extend below one metre above the founding level and the pile shall be driven to at least one metre below the prebored hole. To ensure that the pile is properly supported laterally in the hole, any space remaining around the pile at the ground level after driving is finished shall be backfilled with approved granular material. When water jetting is used, at least two jets shall be attached to the pile symmetrically when this type of technique is used. The volume and pressure of water at the outlet nozzles shall be sufficient to freely erode material adjacent to the toe of the pile. The maximum depth of jetting shall be such that the specified set (or less) is obtained when the toe of the pile is at founding level. Jetting shall cease as directed by the Engineer and shall not proceed below one metre above the founding level and the pile shall be driven at least one metre below the pre..bored hole. To avoid very hard driving and vibration in materials such as sand, jetting of piles by means of water may be carried out only by express permission of the Engineer and in such a manneras hot to impair the bearing capacity of piles already in place, the stability of the soil or the safety of any adjoining buildings. Details of the arrangement for jetting shall be got approved from the Engineer in advance. If, for jetting, large quantities of water are used, it may be necessary to make provision for collection of water when it comes to the ground surface, so that the stability of the piling plant is not endangered by the softening of the ground. Jetting shall be stopped before completing the driving which shall always be finished by ordinary methods. Jetting shall be stopped if there is any tendency for the pile tips to be drawn towards the pile already driven owing to the disturbance to the ground. 1112. RAKER (INCLINED) PILES The maximum rake to be permitted in piles shall not exceed the following
I) ii) iii) I m S for large diameter cast-in-situ piles viz 0.75 m diameter and above I in 5 for smaller diameter casI-m-situ piles I in 4 for precast driven piles
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Pile Foundations 1113. PILE TESTS 1113.1. General
Secilon
1100
The bearing capacity of a single pile may be determined from test loading a pile. The load test on a con~rete pile may not be carried out earlier than 28 days from the time of casting of the pile. There shall be two categories of tests on piles, namely, initial tests and routine tests. Initial tests should be carried out on test piles which are not to be incorporated in the work, Routine tests shall be carried Out as a check on working piles. The number of initial and routine tests on piles shall be as determined by the Engineer depending upon the number of foundations, span length, type of superstructure and uncertainties of founding strata. In any case, the initial load tests shall not be less than 2 in number, while the routine load tests shall not be less than 2 per cent of the total number of piles in the structure nor less than 2 in number. The above stipulations hold good for both vertical as well as lateral load tests on pile foundations. However, both initial and routine tests may be suitably increased for important structures or cases with large variation in the subsurface strata. The methodology of carrying out load tests and of arriving at sale load on piles shall conform to IS:2911 (Part IV). In case of any doubt of workmanship or load carrying capacity of working piles not subjected to routine tests, or when ordered. by the Engineer, or when provided in the contract, load tests on working piles may be supplemented by non-destructive testing. Such tests may include integrity Testing of ~oncrete in the installed pile and utitisation of Pile Driving Analyser which gives an indication of pile capacity in end bearing and side friction. 1114. PILE CAP Pile Caps shall be of reinforced concrete. A minimum offset of 150 mm shall be provided beyond the outer faces of the outer most piles in the group. If the pile cap is in contact with earth at the bottom, a levelling course of minimum 100 mm thickness of M 15 nominal mix concrete shall be provided. The attachment of the pile head to the cap shall be adequate for the transmission of loads and forces. A portion of pile top may be
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Section 1100
Pile
Foundations
stripped of concrete and the reinforcement anchored into the cap. Manual chipping may be permitted after three days of pile casting, while pneumatic tools for chipping shall not be used before seven days after pile casting. The top of pile alter stripping shall project at least 150 mm into the pile cap. A layer of surface reinforcement may be provided with a cover of 25 mm to retain the integrity of concrete below the main cap reinforcement which is to be laid 25 mm above the pile top. Concreting of the pile cap shall be carried out in dry conditions. The bottom of the pile cap shall be laid preferably as low as possible taking account of the water level prevalent at the time of casting. The top of concrete in a pile shall be brought above cut-off level to permit removal of all laitance and weak concrete before pile cap is laid. This will ensure good concrete at the cut-off level. 1115. IMPORTANT CONSIDERATIONS, INSPECTION/ PRECAUTIONS FOR DIFFERENT TYPES OF PILES 1115.1. Driven Cast-in-Situ Piles 1115.1.1, Specialist literature and the guidelines from the pile construction industry shall be consulted regarding the method of installation, equipment and accessories for pile driving and recording of data. 1115.1.2. During installation of piles the final set of penetration of pile per blow of hammer shall be checked taking an average of last 10 blows. 1115.1.3. The pile shoes which may be of either cast iron conical type or mild steel flat type shall have double reams for proper seating of the removable casing tube inside the space between the reams. 1115.1.4. Before commencement of pouring of concrete, it shall be ensured that there is no ingress of water in the casing tube from the bottom. Further adequate control during withdrawal of the casing tube is essential so as to maintain sufficient head of concrete inside the casing tube at all stages of withdrawal. 1115.1.5. Concrete in piles shall be cast upto a minimum height of 600 mm above the designed ~top level of pile, which shall be stripped off at the time of construction of pile cap.
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Section 1100
1115.2. Bored Cast-lu-Situ Piles 1115.2.1. While concreting uncased piles, voids in concrete shall be avoided and sufficient head of concrete is to be maintained to prevent inflow of soil or water into the concrete. It is also necessary to take precautions during concreting to minimise the softening of the soil by excess water. Uncased cast-in-situ piles shall not be allowed where mudflow conditions exist. 1115.2.2. The drilling mud such as bentonite suspension shall be maintained at a level sufficiently above the surrounding ground water level to ensure the stability of the strata which is being penetrated throughout the boring process until the pile has been concreted. 1115.2.3. Where bentonite suspension is used to maintain the stability of the bore-hole, it is essential that the properties of the material be carefully controlled at stages of mixing, supply to the bore-hole and immediately before concrete is placed. It is usual to limit i) Tht~density of benton~tesuspension to 1.05 gjcc ii) The marsh cone viscosity between 30 and 40
~i) The p11 value between 9.5 and 12
iv)
The silt content less than I per cent The liquid limit of bentonite not less than 400 per cent
v)
These aspects shall act as controlling factors for preventing contamination of bentonite slurry for clay and silt. 1115.2.4. The bores shall be washed by bentonite flushing to ensure clean bottom at two stages viz, after completion of boring and prior Io concreting alter placing of reinforcement cage. Flushing of bentonite shall be done continuously with fresh bentonite slurry till the consistency of inflowing and out-flowing slurry is similar. 1115.2.5. Tremie of 150 mm to 200 mm diameter shall be used for concreting. The tremie should have uniform and smooth cross-section inside, and shall be withdrawn slowly ensuring adequate height of concrete outside the tremie pipe at all stages of withdrawal. Other recommendations for tremie concreting are
(i) (ii) The sides of the bose-hole have to be stable throughout. The tremie shall be water-tight throughout its length and have a hopper attached at its head by a water-tight connection
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Pile Foundations
(iii) The tremie pipe shalt be large enough in relation to the size of aggregates. For 20 mm aggregate the tremie pipe shall be of diameter not less than 150 mm and for larger size aggregate tremie pipe of larger diameter is required. (iv) The tremie pipe shall be lowered to the bottom of the bore-hole, allowing water or dotting mud to rise inside it before pouring concrete. (v) The tremie pipe shall always be kept full of concrete and shall penetrate well into the concrete in the bore-hole with adequate margin of safety against accidental withdrawal if the pipe is surged to discharge the concrete.
1115.2.6. For very long or large diameter piles, use of retarding plasticiser in concrete is desirable. 1115.2.7. For large diameter piles, it may be essential to conduct non-destructive pile integrity tests to evaluate integrity of the pile. 1115.2.8. Where possible, it may be desirable to grout the base of pile with cement slurry under suitable pressure after concrete in the pile attains the desired strength. For this purpose, conduit pipes with easily removable plugs at the bottom end should be placed in the bore alongwith reinforcement cage before concreting. 1116. TOLERANCES 1116.1. Permissible Tolerances for Pile
i) Precast Concrete Piles a) h) c) d) Variation in cross-sectional dimensions Variation in length Surface irregularities measured with 3 m straight edge Row for length in mm 5 mm 25 mm
5 mm
Pile Length in mm 1000
ii)
Driven Piles a) b) c) d) Variation in cross-sectional dimensions Variation from vertical or specified rake Variation in the final position of the head in plan Variation of level of top of piles 50 mm,
-10 mm
in 50
75 mm
: 25 men
iii)
Bored Piles a) b) c) d) Variation in cross-sectional dimensions Variation from vertical or specified rake Variation in the final position of the head in plan Variation of level of top of piles
+
50
mm,
-10
mm
I in 50 : 50 men 25 mm
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Section 1100
1116.2. Permissible Tolerances for Pile Caps

(a) (b) (c) (d) Variation in dimensions : 50 mm 15 mm
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10 mm
Misplacement from specified position in plan : Surface irregularities measured with 3 m straight edge Variation of levels at the top
mm
: 25 mm
1117. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these SpecificaLions and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 1118. MEASUREMENTS FOR PAYMENT For supply of precast concrete, timber or steel piles of specified cross-section, the measurement shall be in metres of the length of piles ordered in writing by the Engineer measured from the head to the butt of the shoe or the tapered point. Reinforcement in precast concrete piles shall not be measured for payment. For cast-in-situ driven and bored concrete piles of specified crosssection, the measurement shall be the length in metres of the accepted pile that remains in the finished structure complete in place. Reinforcement in cast-in-situ driven and bored concrete piles shall be measured for payment as per Section 1600. Routine and Initial Pile Load Tests shall not be measured for payment. For installation of the pile, i.e. by driving in the case of precast concrete, timber, steel and cast-in.~situ driven piles, and by boring in the case of cast-in-situ bored piles the measurement shall be the length in metres that remains in the finished structure complete in place, limited to that shown on drawings or ordered by the Engineer. No distinction shall be made for penetration through hard strata or rock and socketing into rock. For steel 1iner~fcasingshown on the drawings to be permanently left in place, the measurement shall be by weight in tonnes that remains in the finished structure complete in place, limited to that shown on drawings or ordered by the Engineer. For the pile cap, the quantity of concrete shall be measured in cubic metres as per Section 1700. While reinforcement in pile cap
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Section 1100
Pile Foundations
shall be measured in tonnes as per Section 1600, 1119. RATE The contract unit rate for supplying precast concrete, timber or steel piles shall include cost of all labour, materials, tools and equipment, and other work involved in making or fabricating the pile complete as shown on the drawing, and where required its loading, transport, delivery to site unloading and stacking it at the place indicated by the Engineer. The cost of reinforcement as per Seciton 1600 in precast concrete piles shall be deemed to be included in the quoted rate for supply of piles. The contract unit rate for cast-in-situ driven and bored piles shall include the cost of concrete and all other items as per Section 1700. The contract unit rate shall also include costs of all labour, materials, equipments and all other incidentals involved in conducting routine and initial pile load tests including installation of piles for initial load tests. The contract unit rate for reinforcement in cast-in-situ driven and bored piles shall be as per Section 1600. The contract unit rate for installation of piles shall include full compensation for furnishing all labour, materials, tools and equipment, and incidentals for doing all the works involved in driving timber, precast concrete and steel piles, driving or making bores for cast-in-situ driven and bored concrete piles, cutting off pile heads, all complete in place to the specified penetration of piles. Providing temporary liner/casing and its withdrawal and placing reinforcement in position shall also be deemed to be included in the rate for installation of piles and no additional payment shall be made for the same. The contract unit rate for permanent steel liners shall incude cost of all labour, fabrication and placing the steel liner to the required depth as shown on the drawings and as ordered by the Engineer. The contract unit rate for concrete in pile cap shall cover all costs of labour, materials, tools, plant and equipment, formwork and staging including placing in position, sampling and testing and supervision, all as per Section 1700. Reinforcement in the pile cap shall be paid for separately as per Section 1600.
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Well Foundations
1200 Well Foundations
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Well Foundations
Section 1200.
1201. DESCRIPTION
This work consists of construction of well foundation, taking it down to the founding level through all kinds of ~ub-sLrata, lugging the p bottom, filling the inside of the well, plugging the top and providing a well cap in accordance with the details shown on the drawing -and as per these specifications, or as directed by the Engineer. In case of well foundations of size larger than 12 m diameter, supplemental construction specifications will be necessary.
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1202. GENERAL 1202.1, Wells may have a circular, rectangular, or D-shape in plan and may consist of one, two or more comprirtments in plan. The outer wall of the well is known as -well stein~g which may be cellular. The process of taking down the web the founding level is known as well sinking. Aftu reaching the fot~ndinglevel, the hollow inside the well, (dredge hole) is plugged at the bottom by concrete (bottom plug). The dredge hole is then filled with approved filling upto the level indicated on the drawings and provided with a concrete plug (top plug). To facilitate sinking of well, steel cutting edge is fabricated and connected to a concrete well curb of required shape. On top of the well curb, adequate height of well steining is cast and the process of sinking is carried out. After a portion of the well has been sunk, another height of well staining is cast on top of the previous section and further sinking carried out. This process is continued till the bottom level of the well reaches the founding level. At the top of the well steining, an adequately designed well cap is laid which transmits the loads and forces from the sub-structure (piers or abutments) to the foundations. 1202.2. At least one bore-hole must be available/carried out in accordance with these specifications at each well foundation location, prior to commencement of work, The depth of bore-holes should extend upto a depth equal to one and a half times the outer diameter/least dimension of the well below the anticipated founding level. The results of soil exploration should be presented in accordance with clause 7.4 of IRC:78. In case the well foundation is to rest on a rocky strata, it may be necessary to undertake additional borings /probings prior to commencement of work to ascertain the actual profile and the quality 361
Section 1200
Well Foundations
of the rocky strata, at the level at which the well has to be seated, etc. 12023, Blasting may have to be resorted to in order to facilitate sinking through difficult strata, such as boulders and rocks etc. In case blasting is anticipated, protective/strengthening measures specified in clause 710.6 (IV) of IRC:78 shall be taken. The grade of concrete in bottom 3 metres of steining shall not be leaner than M 20 or as shown on the drawings. 1202.4, In case the bore hole data shows the presence of steeply dipping rock, chiselling may have to be resorted to so as to obtain proper seating of the fouodation. For this purpose, the well may require to be, dewatered completely under high air pressure inside the well. This process is known as pneumatic sinking. Pneumatic sinking may also have to be resorted to in cases where obstacles such as tree trunks, large sized boulders or hard strata etc. cannot be removed by open dredging. The necessity of adop4ng pneumatic sinking shall be decided by the EngineeP. The curb and steining have to be specifically designed for speciai loading* ~Thenpneumatic sinking is adopted. 1203, SETTING OUT AND PREPARATIONS FOR SINKING 120~1.Necessary reference points shall be fixed, away from the zone of blow-ups or possible settlements resulting from well sinking operations. Such reference points shall be connected to the permanent theodolite stations with the base line on the banks. The centre of the individual wells shall be marked with reference to these stations. The distance, wherever practicable, shall be checked with the help of accurate tapes and precision distomat. Reference points shall also be fixed to mark X-X axis (usually traffic direction) and Y-Y axis (normal to X-~Caxis) accurately. A temporary bench mark shall also be established near the well foundation, away from the zones of blow-ups or possible settlement. The bench mark shall be checked regularly with respect to the permanent bench mark established at the bridge site. 1203.2. For wells which are to be pitched in water, an earthen or sand island shall be constructed. Sand islands are practicable for water depths of about 5 metres under stable bed soil conditions. For greater depths or in fast flowing rivers or for locations where soil is too weak to sustain sand island, floating caissons may have to be adopted.
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Well Foundations
Section 1200
The plan dimensions of sand islands shall be such as to have a working space of at least 2 metres all around the steining. The dimension of the sand islands shall however be not less than twice the dimension in plan of the well or caisson. Sand islands shall be maintained to perform their functions, until the well is sunk to a depth below the bed level at least equal to the depth of water. Sand island shall be protected against scour and the top level shall be sufficiently above the prevailing water level to be decided by the Engineer so that it is safe against wave action. While sand islands are constructed at well location, floating caissons are generally fabricated at or near the banks on dry land or dry docks. floating caissons are towed into position in floating condition. Floating caissons may be of steel, reinforced concrete or a combination of the two. They should have at least 1.5 m free board above water level and increased, if considered necessary, in case there is a possibility of caissons sinking suddenly owing to reasons such as scour likely to result from the lowering of caissons, effect of waves, sinking in very soft strata etc. Stability of floating caissons sh~flbe ensured against overturi~ing and capsizing while being towed and during sinking for the action of water current, wave pressure, wind etc. For floating caissons, a detailed method statement for fabrication, floating and sinking of caissons shall be prepared and furnished to the Engineer. Such statement shall include the total tonnage of steel involved, fabrication and welding specifications, list of materials and plant and a description of operations and manpower required for the work. The caisson shall be tested for leakages before being towed to site. 12033. Equipment Equipment shall be deployed for construction of well foundation as required and as directed by the Engineer. Generally, the following equipments may be required for the work: (a) Crane with grab buckets capacity 0.5 to 2.0 cern.
-
(b) (c)
Submersible pimps Air compressors, air locks and other accessories where pneumatic sinking of well is anticipated.
(ci) Chisels of apprepriste sizes
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Section 1200 (e) (I) (g) Aqua-header for cutting rocky strata
Well Foundations
Diving helmets and accessories Equipment for concrete production, transportation planing and compaction.
1204. CUTTING EDGE 1204.1. The mild steel cutting edge shall be made from structural steel sections, The cutting edge shall weigh not less than 40 kg per metre length and be properly anchored into the well curb, as shown in the drawing. When there are two or more compartments in a well, the bottom end of the cutting edge of the inner walls of such wells shall be kept at about 300 mm above that of outer walls. 1204.2. The parts of cutting edge shall be erected on level firm ground. Temporary supports shall be provided to facilitate erection and maintaining the assembly in true shape. The fabrication may be carried out in the shop or at site. Steel sections shall not be heated and forced into shape. However, Vt cuts may be made in the horizontal portion, uniformly throughout the length, to facilitate cold bending. After bending, such V cuts should be closed by welding. Joints in the lengths of structural sections, unless otherwise specified shall be fillet welded using single cover plate to ensure the requisite strength of the original section, 12043. The cutting edge shall be laid about 300 mm above prevalent water level. 1205. WELL CURB 1205.1. The well curb may be precast or cast-in-situ. Steel formwork for well curb shall be fabricated strictly in conformity with the drawing. The outer face of the curb shall be vertical, Steel reinforcements shall be assembled as shown on the drawings. The bottom ends of vertical bond rods of steining shall be fixed securely to thei cutting edge with check nuts or by welds. The formwork on outer face of curb may be removed within 24 hours after concreting. The formwork ott inner face shall be removed after 72 hours. 1205.2. All concreting in the well curb shall be done in one continuous operation.
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1206. WELL STEINING 1206.1. The dimensions, shape, concrete strength and reinforcements of the well shall strictly conform to those shown on the drawings. The fomtwork shall preferably be of M.S. sheets shaped and stiffened suitably. In case timber forms are used, they shall be lined with plywood or M.S. sheets. 1206.2. Steining built in the first lift above the well curb shall not be more than 2 metres and in subsequent lifts it shall not exceed the diameter of the well or the depth of well sunk below the adjoining bed level at arty time. For stability, the first lift of steining shall be cast only after sinking the curb at least partially for stability. ConcNting of steining may be carried out in subsequent lifts of about 2 to 2.5 metres. Attempts should be made to minimise the number of construction joints. The concreting layers shall be limited to about 450 mm restricting the free fall of concrete to not more than 1.5 m. Laitance formed at the top surface of a lift shall be removed to expose coarse aggregates before setting of concrete at the proposed construction joint. As far as possible, construction joints shall not be kept at the location of laps in the vertical steining bars. 1106.3. The steining of the well shall be built in one straight line from bottom to top such that if the well is tilted, the next lift of steining will be aligned in the direction of th~ The work will be tilt. checked carefully with the aid of straight edges of lengths approved by the Engineer. Plumb bob or spirit level shall not be used for alignment. After sinking of a stage is complete, damaged portions if any, of steining at top of the previous stage shall be properly repaired before constructing the next stage. 1206.4. The height of steining shall be calibrated by making at least 4 gauges (preferably in traffic direction and in a direction normal to traffic direction) distributed equally on the outer periphery of the well each in the form of a 100 mm wide strip painted on the well, with every metre mark shown in black paint. The ,,~gaugesshall start with zero at the bottom of the cutting edge. Marking of the gauges shall be done carefully with a steel tape. 1206.5. After reaching the founding level, the well steining shall be inspected to check for any damage or cracks. The Engineer will direct and the Contractor shall execute the remedial measures before acceptance of the well staining. In case the well cannot be~ accepted even with any remedial measures, then the well shall stand rejected.
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Section 1200
Well Foundations
1207. WELL SINKING

1207.1. General The well shall as far as possible be sunk true and vertical through all types of strata. Sinking or loading of the well with kentledge shall be commenced only after the steining has been cured for at least 48 hours or as specified in the drawings. No well shall be permitted to be placed in a pre-dredged hole. The well shall be sunk by excavating material uniformly from inside the dredge hole. Use of water jetting, explosives and divers may be adopted for sinking of wells through difficult strata with prior approval of the Engineer. Normally dewatering of well should not be permitted as a means for sinking the well. It also shall never be resorted to if there is *any danger of sand blowing under the well. Dewatering sl~ailhowever be done when well is to be founded into rock. Pneumatic sinking may have to be resorted to where obstacles such as tree trunks, large size boulders, etc. are met at the bottom or when there is hard strata which cannot be removed by open dredging, The necessity for pneumatic sinking shall be decided by the Engineer. Sinking history of well shall be maintained in the format given in Appendix 1200/I. 1207,2, Use of Kentledge as Sinking Load Kentledge shall be placed in an orderly and safe manner on the loading platform and in such a way that it does not interfere with the excavation of the material from inside the dredge hole and also does not in any way damage the steining of the well. Where tilts are present or there is a danger of well developing a tilt, the position of the load shall be regulated in such a manner as to provide greater sinking effort on the higher side of the well. 1207.3. Use of Water Jetting Water jetting may be employed for well sinking wherever necessary. 1207A, Use of Explosives Mild explosive charges may be used as an aid for sinking of the well only with prior permission of the Engineer. Blasting of any sort 366 <<
Well Foundations
Section 1200
shall only be done in the presence of the Engineer and not before the concrete in the steining has hardened sufficiently and is more than 7 days old. When likelihood of blasting is predicted in advance, protection of the bottom portion of the well shall be done as per these specifications. After blasting operations are completed, the well curb and steining should be examined for any cracks and remedial measures taken. If blasting has been used after the well has reached the design foundation level, normally 24 hours shall be allowed to Lapse before the bottom plug is laid. The charges shall be exploded well below the cutting edge by making a sump so as to avoid chances of any damage to the curb or to the steining of the well. A minimum-sump of I metre depth should be made before resorting to blasting. Use of large charges, 0.7 kg or above, may not be allowed except under expert direction and with the permission from the Engineer. Suitable pattern of charges may be arranged with delay detonators to reduce the number of charges fired at a time. The burden of the charge may be limited to 1 metre and the spacing of holes may normally be kept as 0.5 to 0.6 metres. All prevalent laws concerning handling, storing and using of explosives shall be ~strictlyfollowed. All safety precautions shall be taken as per IS:4081 Safety Code for B lasting and related Drilling Operations, to the extent applicable, whenever blasting is resorted to. There shoull be no equipment inside the well nor shall there be any labour in the close vicinity of the well at the time of exploding the charges. If rock blasting is to be done for seating of the well, the damage caused by flying debris should be minimised by covering blasting holes by nibber mats before blasting. 1207.5, Use of Divers Use of divers may be made both for sinking purpose like removal of obstructions, rock blasting and for inspection. All safety precautions shall be taken as per any acceptable safety code for sii~kingwith divers or any statutory regulations in force. Only persons trained for the diving operation shall be employed and shall be certified to be fit for diving by an approved doctor. They shall work under expert supervision. The diving and other
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Section 1200
Well Foundations
equipments shall be of acceptable standard and certified to this effect by an approved independent agency. It shall be well maintained for safe use. Arrangement for ample supply of low pressure clean cool air shall be ensured through an armoured flexible hose pipe. Standby compressor plant shall be provided in case of breakdown. Separate high pressure connection for use of pneumatic tools shall be made. Electric lights where provided shall be at 50 volts (maximum). The raising of the diver from the bottom of wells shall be controlled so that decompression rate conforms to the rate as laid down in appropriate regulations. 1207.6. Use of Pneumatic Sinking 1207.6.1. General The Engineer shall familiarise himself with particular reference to caisson diseases and working of the medical air-lock. A doctor competent to deal with cases of Caisson Diseases or other complications arising as a result of working under high pressure, shall be stationed at the construction site when pneumatic sinking is under progress. The contractor shall provide complete facilities including the issuing of orders to ensure strict enforcement of the requirements outlined in these specifications. Safety provisions as contained in IS:4138 and in these speci. fications shall be strictly followed. Pneumatic sinking shall be restricted to a depth of 30.0 m. 1207.6.2. Man-Locks and Shafts Locks, reducers, and shaft used in connection with caissons shall be of riveted construction throughout. The material used in their manufacture shall be steel plate with thickness not less than 6 mm. Shafts shall be subjected to hydrostatic or air pressure test of at least 0.5 MPa, at which pressure they shall be tight. The pressure at which testing has been done shall be clearly and visibly displayed. Shafts shall be provided, with a safe, proper and suitable staircase for its entire length including landing platforms which are not more than 6 metres apart. Where this is impracticable due to space constraint, suitable ladders along with landing platforms shall be installed. These
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shall be kept clear and in good condition at all times and shall be constructed, inspected and maintained to the entire satisfaction of the Engineer. A 1.0 m wide platform with 1.0 m high railing shall be provided all round the caisson air locks. Where 15 or more men are employed, caissons shall have two locks, one of which shall be used as a man lock. Locks shall be located so that the lowest part of the bottom door shall not be less than 1 metre above high water level. The supply of fresh air to the working chamber shall at all times be sufficient to permit work to be done without any danger or excessive discomfort. All air supply lines shall be supplied with check valves and carried as near to the face as practicable. A man-lock shall be used solely for the compression or decompression of persons, and not for the passage of plant and material and shall be maintained in a reasonably clein and sufficiently warm state. However, any hand tool or hand instruments used for the purpose of the work may be carried into the man-lock. Where it is not reasonably practicable to provide a separate manlock for use by persons only, the lock when it is in actual use for compression or decompression of a person or persons shall not be put, simultaneously, to any other use and shall be in a reasonably clean and sufficiently warm stale. 1207.6.3. Valves Exhaust valves shall be provided, having risers extending to the upper part of the chamber. These shall be operated, whenever necessary specially after a blast. Precautions shall be taken that men are not allowed to resume work after a blast until the gas and smoke are cleared. 1207.6.4. Medical supervision and certification Every employee absent from work for 10 or more consecutive days due to illness or any other disability shall be required to pass the regular physical examination by the doctor before being permitted to return to work. After a person has been employed continuously in compressed air for a period of 2 months, he shall be re-examined by the doctor and
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shall not be permitted to work until such re-examination has been made and the report is satisfactory. No person known to be addicted to the excessive use of intoxicants shall be permitted to work in compressed air. The doctor shall, at all times, keep a complete and full record of examinations made by him, which shall contain dates of examinations, a clear and full description of the person examined, his age and physical condition at the time of examination and a statement as to the period such a person has been engaged in such employment. Records shall be kept at the place where the work is in progress and shall be subject to inspection by authorised officers. Every man lock shall always have a doctor or a responsible person in attendance. In case the person in charge is not a doctor he must have positive means of promptly communicating with and securing the services of a competent doctor in case of emergency, Such arrangements shall invariably be subject to the approval of the Engineer. if the air pressure exceeds 0.2 MPa gauge or if 50 or more men are employed, it is obligatory for the person in charge of medical lock to be a doctor experienced in this type of work. All cases of compressed-air illness shall be reported and copies of all such reports shall be kept on file at the place of work. 1207.6.5. Lighting All lighting in compressed air chambers shall be operated only by electricity. Two independent electric lighting systems with independent sources of supply shall be used. These shall be so arranged that the emergency source shall become automatically operative in case of failure of the regularly used source. The minimum intensity of light on any walkway ladder, stairway, or lower working level shall be one-quarter (1/4) candlepower. In all work places, the lighting shall always be such as to enable workmen to see their way about clearly. All external parts of lighting fixtures and electrical equipment lying within 2.5 metres above the floor shall be constructed of non-combustible, non-absorbing insulating materials. If metal is used it must be effectively earthed. Portable lamp shall have non-combustible, non-absorbing insulating sockets, approved handles, basket guards and approved cables. The use of worn or defective portable and pendant conductors, shall be prohibited.
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Section 1200
1207.6.6. Safety against fire hazard No oil, gasoline, or other combustible material shall be stored within 30 metres of any shaft, caisson, or tunnel opening. However, oil may be stored in suitable tatiks in isolated fireproof buildings, provided such buildings are not less than 15 metres from any shaft, caisson, or tunnel opening or any building directly connected thereto. Positive means shall be taken to prevent leaking flammable liquids from flowing into areas specifically mentioned in the preceding paragraph. Where feasible, a fire hose connected to a suitable source of water shall he provided at the top of every caisson. Where lire mains are not accessible, a supply of water shall be stored in tanks near the top of every caisson, provided fire pails or suitable pumps are kept available. Approved fire extinguishers shall also be provided. 1207.6.7. Sanitation Properly heated, lighted and ventilated dressing rooms shall be provided for all employees engaged in compressed air work. Such rooms shall contain lockers and benches and be open and accessible to men during intermission between shifts. Adequate toilet accomodation of one for every twenty five employees shall be provided. Care shall be taken to keep all parts of the caissons and other working compartments, including locker rooms, dry rooms, rest rooms, and other equipment in a good sanitary condition and free from refuse, decaying, or other objectionable matter. No nuisance shall be tolerated in the air chamber. Smoking shall be strictly prohibited and all matches and smoking materials shall be left out of the locker rooms. A separate dry-room shall be provided where working clothes may be dried within reasonable time. 1207.6.8. Protection against gases In all cases where gas is expected including alluvium impregnated with decayed vegetable matter the use of Davy Safety Lamp shall be compulsory. 1207,6.9. Additional safety provisions
a)
The weight of the pneumatic platform and that of steining and kentledge, if any, shall be sufficient to resist the uplift from air inside, skin friction being rtglected in this case. If, at any section the total weight acting downwanls is
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leas than the uplift pressure of air inside, additional kentledge shall be placed on the well. If it is not possible to make the well heavy enough during excavation, blowing down may be used. The men should be withdrawn and air pressure reduced, The well should then begin to move with small reduction in air psessure. Blowing down should only be used when the ground is such that it will not heave up inside the chamber when the pressure is reduced. When the well does not move with the seduction in air pressure, kentledge should be added~,Blowing down should be in short stages and the drop should not exceed, 03 metre at any stage. To control sinking during blowing down, use of packings are recomsnended. b) The pneumatic sinking plant and other allied machinery shall not only be of proper design and make, but also shall be worked by competent and well trained personnel. Every part of the machinery and its fixtures shall be minutely examined before installation and use. Availability ofappropriate spares, standbys, safety of personnel as recommended in 15:4138 for working in compressed air must be ensured at site. Codes far safety and for working in compressed air and other labour laws and practices prevalent in the country, as specified to provide safe, efficient and expeditious sinking shall be followed, inflammable materials shall not be taken into air locks and smoking shall be prohibited. Wherever gases are suspected to be issuing out of dredge hole, the sante shall be analysed by trained personnel and necessary precautions adopted to avoid hazard to life and equipment, Where blasting is resorted to, it shall be carefully controlled and all precautions regarding blasting shall be observed. Workers shall be allowed inside after blasting only when a competent and qualified person has examined the chamber and steining thoroughly and found the same to be safe,
c)
d)
1207.7. Precautions During Sinking

a) When the wells have to be sunk close to each other and clear distance between them is not greater than the diameter of wells, sinking shall be taken up on all wells and they shall be sunk altemately so that sinking of wells proceeds uniformly. Simultaneous and even dredging shall be carried out in the wells in such a manner that the difference in the levels of the sump and cutting edge in the adjacent wells does not exceed half the clear gap between them. Plugging of all the wells shall be done together. During sinking of dumb-bell or double D-shaped wells, the excavation in both the dredge holes should be carried out simultaneously and equally. Bore chart shall be referred to constantly during sinking for taking adequate care while piercing different types of strata. The type of soil as obtained during the well sinking should be compared with bore chart s& as to take prompt decisions. Before seasonal floods all wells on which sinking is in progress shall be sunk to sufficient depths below the designed scour level. Punher~theyshall be temporarily filled and plugged so that they do not suffer any tilt or shift during the floods. All necessary precautions shall be taken against any possible damage to the
b) c)
d)
e)
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foundations of existing structures in the vicinity of the wells, prior to commencemnt of dredging from inside the welL
f)
The dredged material shall not be allowed to accumulate over the well. It shall be dumped and spread, as far away as possible, and then continuously and simultaneously removed, as directed by the Engineer. In case the river stream flows along one edge of the well being sunk, the dredged material shall not be dumped on the dry side of the bank but on the side on which the over current flows. Very deep rump shall not be made below the well curb, as it entails risk of jumping (sudden sinking) of the well. The depth of rump shall be generally limited to one-sixth of the outes diameter/least lateral dimension of the well in plan. Normally, the depth of sump shall not exceed 3.0 metres below the level of the cutting edge unless otherwise specifically permitted by the Engineer. hi case a well sinks suddenly with a jerk, the steinjpg of the well shall be examined to the satisfaction of the Engineer to see that no damage has occurred to it, In pneumatic sinking, the well shall not, at any time, be dropped to a depth greater than 500 mm by the method of blowing down, Dewatering shall be avoided if sand blows are expected. Any equipment and men workmg inside the well shall be brought out of the well as soon as there are any indications of a sand-blow. Sand blowing in wells can often be minimised by keeping the level of water inside the well higher than the water table and also by adding heavy kentledge. In soft strata prone to settlement/creep, the constmction of the abutment wells shall be taken up only after the approach embankment for a sufficient distance near the abutment has been completed.
g)
h)
i)
j)
k) I)
1207.8. Tilts and Shifts The inclination of the well from the vertical is known as tilt and the horizontal displacement of the centre of the well at the founding level from its theoretical position is known as shift. Unless otherwise specified, the tilt of any well shall not exceed 1 (horizontal) in 80 (vertical), and the shift at the Well base shall not be more than 150 mm in any resultant direction. Tilts and shifts shall be carefully checked and recorded in the format vide Appendix 1200/11 regularly during sinking operations. For the purpose of measuring the tilts along the two axes of the bridge, reduced level of the marks painted on the surface of the steining of the well shall be taken. For determination of shift, locations of the ends of the two diameters shall be precisely measured along the two axes, with reference to fixed reference points. Whenever any tilt is noticed, adequate preventive measures like placing eccentric kentledge, pulling, strutting, anchoring or dredging
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Section
1200
Well Foundations
unevenly and depositing dredge material unequally, putting obstacles below cutting edge. Water jetting etc., shall be adopted before any further sinking. After correction, the dredged material shall be spread out uniformly. A pair of wells close to each other have a tendency to come closer while sinking. Timber struts may be introduced in between the steining of these wells to prevent tilting. Tilts occurring in a well during sinking in dipping rocky strata can be safeguarded by suitably supporting the curb. In the event of a well developing tilt or shift beyond the specified permissible values, the Contractor shall have to carry out, at his own cost, suitable remedial measures to the satisfaction of the Engineer, to bring the tilt and shift within permissible values, as far as practicable. If the resultant tilt and / or shift of any well exceeds the specified permissible values, generally it should not exceed I in 50 and 300 mm respectively. The well so sunk shall be regarded as not conforming to specifications and a sub-standard work. The Engineer in his sole discretion, may consider accepting such a well, provided (1) Calculations for foundation pressures and steining stresses, accounting rot the
actual tilt and shift furnished by the Contractor show that the well is safe. Any remedial measures required to bring the stresses within permissible values (such as increase in the dimension of the well cap, provision of dummy weights oct the well cap etc, shall be carried out by the Contractor without claiming for any extra cost, (ii) The Contractor shall agree to reduction in rates in accordance with Clause
1215(g).
In case the Engineer, in his discretion, rejects the well, the Contractor shall dismantle the rejected well to the extent directed by the Engineer and remove the debris. Further, the Contractor shall, at his own risk and expense complete the bridge with modified span arrangement acceptable to the Engineer. 1207,9. Seating of Wells The well shall be uniformly seated at the founding strata. it shall be ensured by test borings that the properties of the soil encountered at the founding strata and upto a depth of one and a half times the well diameter is identical to that adopted in the design. The procedure for test borings shall satisfy the provisions of these specifications. In case the soil encountered is inferior to that adopted in design,
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the well shall be re-designed by the Engineer adopting the soil properties actually encountered and the founding level intimated to the Contractor, who shall carry out the work. In case of seating of wells in hard rocky strata, where the rock profile is steeply sloping, pneumatic methods of sinking may be adopted to seat the well evenly as directed by the Engineer. The decision of adopting pneumatic sinking shall be taken by the Engineer. The cutting edge may also be embedded for a suitable depth in the rocky strata, as decided by the Engineer keeping in view the quality of rock. As an additional measure of safety, the well shall be anchored to the rocky strata by anchor bars provided in the steining of the well, as shown on the drawing irrespective of the fact that tension develops or not at the base of the well under design loads. After the well has been evenly seated on good hard rock, arrangements shall be made to facilitate proper inspection in dry and visible conditions before the bottom plug is laid.
1208. BOrIOM PLUG

For bottom plug, the concrete mix shall be designed (in dry condition) to attain the concrete strength as mentioned on the drawing and shall contain 10 per cent more cement than that required for the same mix placed dry, to cater for underwater concreting. However, the total cement content shall not be less than 363 kg/cu.m. of concrete with a slump in the range of 150 mm to 200 mm. Admixtures may be added to the concrete to impart the required characteristics indicated herein. Concrete for the bottom plug shall be laid by trernie pipe method. Tremie concrete when started shall be continued without interruption for full concreting in the bottom plug. The concrete production equipment and placement equipment should be sufficient to enable under water concreting within stipulated time. Necessary standby equipment should
be available for emergency situation.
Before commencing plugging, all loose material from the bottom of the well shall be removed. Concreting shall be done in one continuous operation till the dredge hole is filled upto the required height and thereafter sounding shall be taken upto ensure that the concrete has been laid to the required height.
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Least disturbance shall be caused to the water inside the well while laying concrete in the bottom plug. Concrete shall not be disturbed in any way for at least 14 days. In order to check any rise in the level of the bottom plug soundings should be taken at the close of concreting and once every day for the subsequent 3 days. The soundness of the bottom plug may be tested by dewatering the well by 5 metres below the surrounding water level and checking the rise of water. The rate of rise shall preferably be less than 10 cms per hour. In case the rate is higher, suitable remedial measures as directed by the Engineer, shall be taken by the Contractor at his own cost. 1209. SAND FILLING Sand filling shall commence after a period of 3 days of laying of bottom plug. Also, the height of the bottom plug shall be verified before starting sand filling. Sand shall be clean and free from earth, clay clods, roots, boulders, shingles, etc. and shall be compacted as directed. Sand filling shall be carried out upto the level shown on the drawing, or as directed by the Engineer. 1210. TOP PLUG After filling sand upto the required level a plug of concrete shall be provided over it as shown on the drawing, or as directed by the Engineer. 1211 WELL CAP A reinforced cement concrete well cap will be provided over the top of the steining in accordance with the drawing. Formwork will be prepared conforming to the shape of well cap. Concreting shall be carried out in dry condition. A properly designed false steining may be provided where possible to ensure that the well cap is laid in dry conditions. The bottom of the well cap shall be laid preferably as low as possible, taking account the water level prevalent at the time of casting. Bond rods of steining shall be anchored into the well cap.
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1212. TOLERANCES The permissible tilt and shift shall not exceed I (horizontal) in 80 (vertical) and the shift at the well base shall not be more than 150 mm in any resultant direction. For the well steining and well cap the permissible tolerances shall be as follows
a) b) c) d) Variation in dimension Misplacement from specified position in plan Variation of levels at the top : 50mm : 15 mm : 25mm
-
10
mm
Surface irregularities measured with 3 m straight edge: 5 mm
1213. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall inSt the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 1214. MEASUREMENTS FOR PAYMENT All quantities shall be measured from the drawing, or as ordered by the Engineer, excepting those required to be provided by the Contractor at his cost.
a) b) The cutting edge shall be measured in tonnes based on the net weight of metal used in it, as per Section 1900. The concrete in curb, well steining and well cap shall be measured in cubic metres in each of the items as per Section 1700. The reinforcements shall be measured in tonnea separately in each of the items, as per Section 1600. The measurement for well sinking shall be made in twining metres for different depths and in different types of strata (for example, predominantly sand/ clay soil, soft rock, hard rock, etc) as specified in the Contract. The depth of sinking shall be measured from the level specified in the Contract. If no level has been specified in the Contract, sinking shall be measured from she low waler level or from the level at which the cutting edge was laid, whichever is higher. The qusntity of concrete in bottom and top plug shall be measured in cubic metres as per Section 1700. The quantity of sand filling shall be measured in cubic metres.
c)
d) e)
fl
Pneumatic sinking, where required shall be paid as a separate item and shall be measured in cubic metres of material to be excavated.
1215. RATE
a) The Contract unit rates ofcutting edge shall cover all costs of labour, material, tools, plant and equipment, including placing in position, samplinj and testing,
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Steel Work
and, supervision, all as per respective Section of Stnsctural and as described in this section, h)
The Contract unit rates for concrete in curb, steining, bottom plug, top plug and well cap, shall cover all costs of labour, material, tools, plant and equipment, forthwork and staging including placing in position, sampling and testing, and, supervision, all as per respective Section of Stnsctural Concrete and as described in this section. The Contract unit rates for reinforcement in curb, steining, and well cap, shall cover all costs of labour, material, tools, plant and equipment, including bending to shape, placing in position, sampling, testing and supervision, all as per respective Section of Steel Reinforcement and as described in this section. The Contract unit rates for sand filling shall cover all costs of labour, material, tools, plant and equipment, including placing in position, sampling, testing and supervision, all as described in this section. The Concrete unit rates for sinking shall cover the costs of labour, tools, and equipment and plant and for all operations and other incidentals for sinking of well including seating exceptingrprovisions of pneumatic sinking as described in this Section. The unit rates shall specify the strata such as types of soil, rock, etc. The rate shall cover all testing and supervision required for the work. The Contract unit rate of material to be excavated by pneumatic sinking shall cover all costs & labour, material, tools, plant and other equipment and other incidentals and safety provisions and supervision required for pneumatic sinking as per this Section. Reduction in contract unit rates for sinking as a penalty, in pursuance of clause 1207,8.
c)
d)
e)
I)
g)
If any well with tilt and/or shift exceeding beyond permissible values is accepted by the Engineer, the Contractor shall give a ~reductionin the rates as follows
S,Nu, Amount of tilt and/or shift
.
Per eent deduetlors on the rate(s) for sinkIng of whole sidl
1. 2. 3. 4. 5. 6.
Tilt exceeding the specified permissib4e value but equal to or within 1 in 60 Tilt exceeding 1 in 60 but equal to or within I in 50 lilt exceeding I in 50 Shift exceeding the specified pennissible value but equal to or within 200 mm Shift exceeding 200 mm but equal to or within 300 mm Shift exceeding 300 mm
5 per cent
10 per cent 20 per cent 2 per cent
per cent
10 per cent
Penalties for excessive tilt and shift shall be deducted separately.
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Brick Masonry
1300 Brick Masonry
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Brick Masonry
Secuon 1300
1301. DESCRIPTION This work shall consist of construction of structures with bricks jointed together by cement mortar in accordance with the details shown on the drawings or as approved by the Engineer. 1302. MATERIALS All materials to be used in the work shall conform to the requirements laid down in Section 1000. 1303. PERSONNEL Only trained personnel shall be employed for construction and supervision. 1304. CEMENT MORTAR Cement and sand shall be mixed in specified proportions given in the drawings. Cement shall be proportioned by weight, taking the unit weight of cement as 1.44 tonne per cubic metre. Sand shall be proportioned by volume taking into account due allowance for bulking. All mortar shall be mixed with a ~ninimum quantity of water to produce desired workability consistent with maximum density of mortar. The mix shall be clean and free from injurious type of soil/acid/alkali! organic matter or deleterious substances. The mixing shall preferably be done in a mechanical mixer operated manually or by power. Hand mixing can be resorted to as long as uniform density of the mix and its strength are assured subject to prior approval of the Engineer. Where permitted, specific permission is to be given by the Engineer. Hand mixing operation shall be carried out on a clean water-tight platform, where cement and sand shall be first mixed dry in the required proportion by being turned over and over, backwards and forwards several times till the mixture is of uniform colour. Thereafter, minimum quantity of water shall be added to bring the mortar to the consistency of a stiff paste. The mortar shall be mixed for at least two minutes after addition of water. Mortar shall be mixed only in such quantity as required for immediate use. The mix which has developed initial set shall not be used. Initial set of mortar with ordinary Portland Cement shall normally be considered to have taken place in 30 minutes after mixing. In case the mortar has stiffened during initial setting time because of evaporation of water, the same can be re-tempered by adding water 381
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Section 1300
Brick Masonry
as frequently as needed to restore the requisite consistency, but this re-tempering shall not be permitted after 30 minutes. Mortar unused for more than 30 minutes shall be rejected and removed from site of work. 1305. SOAKING OF BRICKS All bricks shall be thoroughly soaked in a tank filled with water for a minimum period of one hour prior to being laid. Soaked bricks shall be removed &om the tank sufficiently in advance so that they are skin dry at the time of actual laying. Such soaked bricks shall be stacked on a clean place where they are not contaminated with dirt, earth, etc. 1306. JOINTS The thickness of joints shall not exceed 10mm, All joints on exposed faces shall be tooled to give concave finish. 1307. LAYING All brickwork shall be laid in an English bond, even and true to line, in accordance with the drawing or as directed by the Engineer, plumb and level and all joints accurately kept Half and cut bricks shall not be used except when necessary to complete the bond. Closer in such cases shall be cut to the required size and used near the ends of the walls. The bricks used at the face and also at all angles forming the junction of any two walls shall be selected whole bricks of uniform size, with hue and rectangular faces. All bricks shall be laid with frogs up on a full bed of mortar except in the case of tile bricks. Each brick shall be properly bedded and set in position by slightly pressing while laying, so that the mortar gets-into all their surface pores to ensure proper adhesion. All head and side joints shall be completely filled by applying sufficient mortar to brick already placed and on brick to be placed. All joints shall be properly flushed and packed with mortar so that no hollow spaces are left. No bats or cut bricks shall be used except to obtain dimensions of the different courses for specified bonds or wherever a desired shape so requires. The brick work shall be built in uniform layers, and for this purpose wooden straight edge with graduations indicating thickness of each course including joint shall be used. Corners and other advanced work shall be raked back. Brickwork shall be done true to plumb or in specified batter. All courses shall be laid truly horizontal and
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vertical joints shall be truly vertical. Vertical joints in alternate courses shall come directly one over the other. During construction, no part of work shall rise more than one metre above the general construction level, to avoid unequal settlement and improper jointing. Where this is not possible in the opinion of the Engineer, the works shall be raked back according to the bond (and not toothed) at an angle not steeper than 45 degrees with prior approval of the Engineer. Toothing may also be permitted where future extension is contemplated. Before laying bricks in foundation, the foundation slab shall be thoroughly hacked, swept clean an~wetted. A layer of mortar not less than 12 mm thick shall be spread on the surface Of the foundation slab and the first course of bricks shall be laid. 1308. JOINTING OLD AND NEW WORK Where fresh masonry is to join with masonry that is partially/entirely set, the exposed jointing surface of the set masonry shall be cleaned, roughened and wetted, so as to effect the best possible bond with the new work. All loose bricks and mortar or other material shall be removed. ln the case of vertical or inclined joints, it shall be further ensured that proper bond between the old and new masonry is obtained by interlocking the bricks. Any portion of the brickwork that has been completed shall remain undisturbed until thoroughly set. In case of sharp corners specially in skew bridges, a flat cutback of 100 mm shall be provided so as to have proper and bonded laying of bricks; 1309. CURING Green work shall be protected from rain by suitable covering and shall be kept constantly moist on all faces for a minimum period of seven days. Brick work carried out during the day shall be suitably marked indicating the date on which the work is done so as to keep a watch on the curing period. The top of the masonry work shall be left flooded with water at the close of the day. Watering may be done carefully so as not to disturb or wash out the green mortar. During hot weather, all finished or partly completed work shall be covered or wetted in such a manner as will prevent rapid drying of the brickwork. During the period of curing of brick work: it shall be suitably protected from all damages. At the close of days work or for other
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period of cessation, watering and curing shall have to be maintained. Should the mortar perish i.e. become dry, white or powdery through neglect of curing, work shall be pulled down and rebuilt as directed by the Engineer. If any stains appear during watering, the same shall be removed from the face. 1310. SCAFFOLDING The scaffolding shall be sound, strong and safe to withstand all loads likely to come upon it. The holes which provide resting space for horizontal members shall not be left in masonry under one metre in width or immediately near the skew backs of arches. The holes left in the masonry work for supporting the scaffolding shall be filled and made good. Scaffolding shall be got approved by the Engineer. However, the Contractor shall be responsible for its safety. 1311. EQUIPMENT All tools and equipment used for mixing, transporting and laying of mortar and bricks shall be clean and free from set mortar, dirt or other injurious foreign substances. 1312. FINISHING OF SURFACES 1312.1. General All brickwork shall be finished in a workmanlike manner with the thickness of joints, manner of striking or tooling as described in thdse above specifications. The surfaces can be finished by jointing or pointing or by plastering as given in the drawings. For a surface which is to be subsequently plastered or pointed, the joints shall be squarely raked out to a depth of 15 mm, while the mortar is still green. The raked joints shall be well brushed to remove dust and loose particles and the surface shall be thoroughly washed with water, cleaned and wetted. The mortar for finishing shall be prepared as per Clause 1304. 1312.2. Jointing In jointing, the face of the mortar shall be worked out while still green to give a finished surface flush with the face of the brick work. The faces of brick work shall be cleaned to remove any splashes of mortar during the course of raising the brick work.
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Section 1300
1312.3. Pointing Pointing shall be carried out using mortar not leaner than 1:3 by volume of cement and sand or as shown on the drawing. The mortar shall be filled and pressed into the raked joints before giving the required finish. The pointing shall be ruled type for which it shall, while still green, be ruled along the centre with half round tools of such width as may be specified by the Engineer. The super flush mortar shall then be taken off from the edges of the lines and the surface of the masonry shall be cleaned of all mortar, The work shall conform to IS:2212. 1312.4. Plastering Plastering shall be done where shown on the drawing. Superficial plastering may be done, if necessary, only in structures situated in fast flowing rivers or in severely aggressive environment. Plastering shall be started from tOp and worked down. All putlog holes shall be properly filled in advance of the plastering while the scaffolding is being taken down. Wooden screeds 75 mm wide and of the thickness of the plaster shall be fixed vertically 2.5 to 4 metres apart, to act as gauges and guides in applying the plaster. The mortar shall be laid on the wall between the screeds using the plasters float and pressing the mortar so that the raked joints are properly filled. The plaster shall then be finished off with a wooden straight edge reaching across the screeds. The straight edge shall be worked on the screeds with a small upward and sideways motion 50 mm to 75 mm at a time. Finally, the surface shall be finished off with a plasterers wooden float. Metal floats shall not be used. When recommencing the plastering beyond the work suspended earlier, the edges of the old plaster shall be scrapped, cleaned and wetted before plaster is applied to the adjacent areas. No portion of the surface shall be left unfinished for patching up at a later period. The plaster shall be finished true to plumb surface and to the proper degree of smoothness as directed by the Engineer. The average thickness of plaster shall not be less than the specified thickness. The minimum thickne~ over~any portion of the surface shall not be less than the specified thickness by more than 3mm.
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Brick Masonry
Any cracks which appear in the surface and all portions which sound hollow when tapped, or are found to be soft or otherwise defective, shall be cut in rectangular shape and re~doneas directed by the Engineer. 1312.5. Curing of Finishes Curing shall be commenced as soon as the mortar used for finishing has hardened sufficiently not to be damaged during curing. It shall be kept wet for a period of at least 7 days. During this period, it shall be suitably protected from all damages. 1312.6. Scaffolding for Finishes Stage scaffolding shall be provided for the work. This shall independent of the structure. be
1313. ARCHITECTURAL COPING FOR WINGIRETURN/ PARAPET WALL This work shall consist of providing an Architectural coping for wing/return/parapet walls. The material used shall be cement mortar 1:3 or as shown on the drawings prepared in accordance with Clause 1304. The cement mortar shall be laid evenly to an average thickness of 15 mm to the full width of the top of the wall and in continuation a band of 15 mm thickness and 150 mm depth shall be made out of the mortar along the top outer face of the walls. 1314. ACCEPTANCE OF WORK All work shall be true to the lines and levels as indicated on the drawing or as directed by the Engineer, subject to tolerances as indicated in these specifications. Mortar cubes shall be tested in accordance with !S:2250 for compressive strength, consistency of mortar and its water retentivity. The frequency of testing shall be one sample for every 2 cubic meties of mortar, subject to a minimum 3 samples for a days work. In case of plaster finish, the minimum surface thickness shall not be less than the specified thickness by more than 3mm. 1315. MEASUREMENTS FOR PAYMENT All brick work shall be measured in cubic metres. Any extra work done by the Contractor over the specified dimensions shall be ignored.
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386
Brick Masonry
Section 1300
In arches, the length of areh shall be measured as the mean length between the extrados and intrados. The work of plastering and pointing shall be measured in square metres of the surface treated. Architectural coping shall be measured in linear metres. 1316. RATE The contract unit rate for brick work shall include the cost of all Labour, materials, tools and plant, scaffolding and other expenses incidental to the satisfactory completion of the work, sampling, testing and supervision as described in these specifications and as shown on the drawings. The contract unit rate for plastering shall include the cost of all Labour, materials, tools and plant, scaffolding and all incidental expenses, sampling and testing and supervision as described in these specifications. The contract unit rate for pointing shalt include erecting and removal of scaffolding, all labour, materials, and equipment incidental to complete the pointing, raking out joints, cleaning, wetting, filling with mortar, trowelling; pointing and watering, sampling and testing and supervision as described in these specifications. The contract unit rate for architectural coping shall include cost of all labour, materials, tools and plant, sampling and testing and supervision as described in these specifications.
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387
Stone Masonry
1400 Stone Masonry
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Stone Masonry
Section 1400
1401. DESCRIPTION This work shall consist of the construction of structures with stones jointed together by cement mortar in accordance with the details shown on the drawings and these specifications or as approved by the Engineer. 1402. MATERIALS All materials used in stone masonry shall conform to Section 1000 except cement mortar for stone masonry which shall conform to Clause 1304. 1403. PERSONNEL Only trained personnel shall be employed for construction and supervision. 1404. TYPE OF MASONRY The type of masonry used for structures shall be random masonry (coursed or uncoursed) or coursed rubble masonry (First sort). However, for bridge work generally, course rubble stone masonry shall be used. The actual type of masonry used for different parts of structures shall be specified on the drawings. For facing work, ashlar masonry shall be used where indicated on the llrawings. 1405. CONSTRUCTION OPERATIONS 1405.1. General Requirements The dressing of stone shall be as specified for individual type masonry work and it shall also conform to the general requirements of 15:1597 and requirement for dressing of stone covered in 15:1129. Other specific requirements are covered separately with respect to particular types of rubble stone work. 1405.2. Laying 1405.2.1. The masonry work shall be laid to lines, levels, curves and shapes as shown in the plan. The height in cach course shall be kept same and every stone shall be fine tooled on all beds joints and face full and true. The exposed faces shall be gauged out, grooved, regulated and sunk or plain moulded as the case may be. The faces of each stone between the draft be left rough as the stone comes from quarry except where sacrificial layer is to be provided or plastering is resorted to due to aggressive environment.
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391
Section 1400
Stone Masonry
1405.2.2. Stones shall be sufficiently wetted before laying to prevent absorption of water from mortar. Stratified stones must be laid on their natural beds. All bed joints shall be normal to the pressure upon them. Stones in the hearting shall be laid on their broadest face that gives a better opportunity to fill the spaces between stones. The courses of the masonry shall ordinarily be pre-determined. They shall generally be of the same height. When there is to be variation in the height of courses, the larger courses are to be placed at lower levels, heights of courses decreasing gradually towards the top of the wall. The practice of placing loose mortar on the course anti pouring water on it to fill the gaps in stones is not acceptable. Mortar may be fluid mixed thoroughly and then poured in the joints. No dry or hollow space shall be left anywhere in the masonry and each stone shall have all the embedded faces completely covered with mortar. In tapered walls, the beds of the stones and the planes of course should be at right angles to the batter. In case of bridge piers with batter on both sides, the course shall be horizontal. The bed which is to receive the stone shall be cleaned, wetted and covered with a layer of fresh mortar. All stones shall be laid full in mortar both in bed and vertical joints and settled carefully in place with a wooden mallet immediately on placement and solidly embedded in mortar before it has sel Clean chips and spalls shall be wedged into the mortar joints and bed wherever necessary to avoid thick beds or joints of mortar. When the foundation masonry is laid directly on rock, the face stones of the first course shall be dressed to fit into rock snugly when pressed down in the mortar bedding over the rock. No dry or hollow space shall be left anywhere in the masonry and each stone shall have all the embedded faces completely covered with mortar, For masonry works over rock, a levelling course of 100 mm thickness and in concrete M 15 shall be laid over rock and then stone masonry work shall be laid without foundation concrete block. Face works and hearting shall be brought up evenly but the top of each course shall not be levelled up by the use of flat chips. For sham corners specially in skew bridges, through stones shall be used in order to avoid spalling of corners. In case any stone already set in mortar is disturbed or the joints
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392
Stone Masonry
SecLion 1400
broken, it ~hallbe taken out without disturbing the adjoining stones and joints. Dry mortar and stones thoroughly cleaned from the joints and stones and the stones reset in fresh mortar. Attempt must never be made to slide one stone on top of another, freshly laid. Shaping and dressing shall be done before the stone is laid in the work. No dressing and hammering, which will loosen the masonry, will be allowed after it is once placed. All necessary chases for joggles, dowels and clamps should be formed before hand. Sufficient transverse bonds shall be provided by the use of bond stone extending from the front to the back of the wall and in case of thick wall from outside to the interior and vice versa. In the latter case, bond stones shall overlap each other in their arrangement. In case headers are not available, precast headers of M 15 concrete shall be used. Cast~in-situheaders are not permitted. Stones shall break joint on the face for at least half the height of the course and the bond shall be carefully maintained through~ out. In band work at all angle junctions of waIls, the stones at each alternate course shall be carried into each of the respective walls so as to unite the work thoroughly. The practice of building up thin faces tied with occasional through stones and filling up the middle with small stuff or even dry packing is not acceptable. All quoins and the angles of the opening shall be made from selected stones, carefully squared and bedded and arranged to bond alternately long and short in both directions~ All vertical joints shall be truly vertical. Vertical joints shall be staggered as far as possible. Distance between the nearer vertical joints of upper layer and lower shall not be less than half the height of the course. Only rectangular shaped bond stones or headers shall be used. Bond stones shall overlap each other by 150 mm or more. All connected masonry in a structure shall be carried up nearly at one uniform level throughout but when ,breaks are unavoidable the masonry shall be raked in sufficiently long steps to facilitate jointing of old and new work. The stepping of raking shall not be more than 45 degrees with the horizontal.
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393
section 1400
Stone Masonry
14053. Random Masonry (Uncoursed and Coursed) 1405.3.1. Dressing : Stone shall be hammer dressed on the face, the sides and beds to enable it to come in proximity with the neighbouring stone. The bushing on the exposed face shall not be more than 40 mm. 1405.32. insertion of chips : Chips and spalls of stone may be used wherever necessary to avoid thick mortar beds or joints and it shall be ensured that no hollow spaces are left anywhere in the masonry. The chips shall not be used below hearting stones to bring these upto the level of face stones. Use of chips shall be restricted to filling of interstices between the adjacent stones in hearting and they shall not exceed 20 per cent of the quantity of stone masonry~. 1405.3.3. Hearting stones : The hearting or interior filling of the wall face shall consist of rubble stones not less than 150 mm in any direction, carefully laid, hammered down with a wooden mallet into position and solidly bedded in mortar. The hearting should be laid nearly level with facing and backing. 1405.3.4. Bond stones : Through bond stones shall be provided in masonry upto 600 mm thickness and in case of masonry above 600 mm thickness, a set of two or more bond stones overlapping each other at least by 150 mm shall be provided in a line from face to back. in case of highly absorbent types of stones (porous limestone and sandstones, etc.,) the bond stone shall extend only about two-third into the wall, as through stones in such cases may give rise to penetration of dampness and therefore, for all thicknesses of such masonry, a set of two or more bond stones overlapping each other by at least 150 mm shall be provided, One bond stone or a set of bond stones shall be provided for every 0.50 sq. m. of the masonry surface. 1405.3.5. Quoin stone: Quoin stone i.e. stone specially selected and neatly dressed for forming an external angle in masonry work, shall not be less than 0.03 cubic metre in voltime. 1405.3.6. Plum stone : The plum stones are selected long stones embedded vertically in the interior of the masonry to form a bond between successive courses and shall be provided at about 900 mm intervals. 1405.3.7. Laying: The masonry shall be laid with or without courses as specified. The quoins shall be laid header and stretcher alternately. Every stone shall be fitted to the adjacent stone so as to form neat
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394
Stone Masonry
Section
1400
and close joint. Face stone shall extend and bond well in the back. These shall be arranged to break joints, as much as possible, and to avoid long vertical lines of joints. 1405.3.8. Joints : The face joints shall not be more than 20 mm thick, but shall be sufficiently thick to prevent stone-to-stone contact and shall be completely filled with mortar. 1405.4. Square Rubble Coursed Rubble (First Sort) 1405.4.1. Dressing : Face stones shall be hammer dressed on all beds and joints so as to give them rectangular shape. These shall be square on all joints and beds. The bed joints shall be chisel drafted for at least 80 mm back from the face and for at least 40 mm for the side joints. No portion of the dressed surface shall show a depth of gap more than 6 mm from the straight edge placed on it. The remaining unexposed portion of the stone shall not project beyond the surface of bed and side joints. The requirements regarding bushing shall be the same as for random rubble masonry. 1405.4.2. Hearting stones : The hearting or interior filling of the wall face shall consist of flat bedded stone carefully laid, on prepared beds in mortar. The use of chips shall be restricted to the filling of interstices between the adjacent stones in hearting and these shall not exceed 1Q per cent of the quantity of masonry. While using chips it shall be ensured that no hollow spaces are left anywhere in the masonry. 1405.4.3. Bond stones : The requirements regarding through or bond stone shall be the same as for random rubble masonry, but these, shall be provided at 1.5 metre to 1.8 metre apart clear in every course. 1405.4.4. Quoin stone : The quoins shall be of the same height of the course in which these occur and shall be formed of header stones not less than 450mm in length. They shall be laid lengthwise alternately along each face, square in their beds which shall be fairly dressed to a depth of at least 100 mm.
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1405.4.5. Face stone : Face stones shall tail into the work for not less than their heights and at least one-third of the stones shall tail into the work for a length not less than twice their height. These shall be laid as headers and stretchers alternately. 1405.4.6, Laying: The stones shall be laid on horizontal courses and all vertical joints should be truly vertical. The quoin stones should be laid header and stretcher alternately and shall be laid square
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395
Section 14(X)
Stone Masonry
on their beds, which shall be rough chisel dressed to a depth of at least 100 mm. 1405.4.7. Joints : The face joints shall not be more than 10 mm thick, but shall be sufficiently thick to prevent stone-to-stone contact and shall be completely filled with mortar. 1405,5. Ashlar Masonry (Plain Asbiar) 1405.5.1. Dressing : Every stone shall be cut to the required size and shape, chisel dressed on all beds and joints so as to be fn~efrom all bushing. Dressed surface shall not show a depth of gap of more than 3 mm from straight edge placed on it. The exposed faces and joints, 6 mm from the face shall be fine tooled so that a straight edge can be laid along the face of the stone in contact with every point. All visible angles and edges shall be true and square and free from chippings. The corner stones (quoins) shall be dressed square and corner shall be straight and vertical. 1405.5.2. Bond stones : Through bond stones shall be provided in masonry upto 600 mm thickness and in case of masonry above 600 mm thickness, a set of two or more bond stones overlapping each other at least by 150 mm shall be provided in a line from face to back. In case of highly absorbent types of stones (porous limestone and sandstones, etc.,) the bond stone shall extend only about ,two-third into the wall, as through stones in such cases may give rise to penetration of dampness and, therefore, for all thicknesses of such masonry a set of two or more bond stones overlapping each other by at least 150 mm shall be provided. One bond stone or a set of bond stones shall be 1.5 metres to 1.8 metres apart clear in every course. 1405.5.3. Laying : The face Stone shall be laid header and stretcher alternately, the header being arranged to come as nearly as possible in the middle of stretchers above and below. Stones shall be laid in regular courses not less than 300 mm in height and all courses of the same height unless otherwise specified. No stone shall be less in width than its height or less in length than twice its height, unless otherwise specified. 1405.5.4. Joints : All joints shall be full of mortar. These shall not be less than 3 mm thick. Face joints shall be uniform throughout, and a uniform recess of 20 mm depth from face shall be left with the help of a stone plate during the progress of work.
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396
Stone Masonry
Section 1400
1405.6L Pointing Pointing shall be carried out using mortar not leaner than 1:3 by volume of cement and sand or as shown on the drawing. The mortar shall be filled and pressed into the raked out joints before giving the required finish. The pointing shall conform to Clause 1312.3 of the specification. The work shall conform to 15:2212. The thickness of joints shall not be less than 3 mm for Ashlar masonry. However, the maximum thickness of joints in different works shall be as follows:
Random Rubble Coursed Rubble Ashlar Maonry 20 mm L5 mm
5 mm
l405.7. Curing Curing shall conform to Clauses 1309 and 1312.5 1405.8. Scaffolding For scaffolding Clause 1310 shall apply. 1405.9. Weep Holes Weep holes shall conform to Clause 2706. 1405.10. Jointing with Existing Structures For Jointing with existing structures, the specifications given under Clause 1308 shall apply. 1406. ARCHITECTURAL COPING FOR WING/RETURNI PARAPET WALLS Architectural coping for wing/return/parapet walls shall conform to :lause 1311 1407, TESTS AND STANDARD OF ACCEPTANCE All work shall be done to the lines and levels as indicated on he drawing or as directed by the Engineer subject to tolerances as pecified in these specifications. Mortar cubes shall be taken in accordance with 15:2250 for compressive strength, consistency of mortar and its water retentivity. The frequency of testing shall be one sample for every two cubic metres of mortar sul~jectto a minimum 3 samples for a thys work. 1408, MEASUREMItNTS FOR PAYMENT Stone masonry shall be measured in cubic metres.
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397
Section 1400
Stone Masonry
In arches, the length of arch shall be measured as the mean length between the extrados and intrados. The work of pointing shall be measured in square metres. Architectural coping shall be measured in linear metres. 1409. RATE The contract unit rate for stone masonry shall include the cost of all labour, materials, tools and plant, scaffolding, sampling and testing, supervision and other expenses incidental to the satisfactory completion of the work as described herein above. The contract unit rate for pointing shall include erecting and removal of scaffolding, all labour, materials and equipment incidental to complete pointing, raking out joints, cleaning, wetting, filling with mortar, trowelling, pointing and watering, sampling and testing and supervision as described in these specifications. The contract rate for architectural coping shall include the cost of all labour, materials, tools and plant, sampling and testirg and supervision as described in these specifications.
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398
Formwork
1500 Formwork
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Formwork 1501. DESCRIPTION
Section 1500
Formwork shall include all temporary or permanent forms required for forming the concrete of the shape, dimensions and surface finish as shown on the drawing or as directed by the Engineer, together with all props, staging, centering, scaffolding and temporary construction required for their support. The design, erection and removal of formwork shall conform to IRC:87 Guidelines for Design and Erection of Falsework for Road Bridges and these specifications. 1502. MATERIALS All materials shall comply with the requirements of IRC:87. Materials and components used for formwork shall be examined for ~lamage or excessive deterioration before use / re-use and shall be used only if found suitable after necessary repairs. In case of timber formwork, the inspection shall not only cover physical damages but also signs of attacks by decay, rot or insect attack or the development of splits. Forms shall be constructed with metal or timber. The metal used for forms shall be of such thickness that the forms remain true to shape. All bolts should be countersunk. The use of approved internal steel ties or steel or plastic spacers shall be permitted. Structural steel tubes used as support for forms shall have a minimum wall thickness of 4 mm. Other materials conforming to the requirements of IRC:87 may also be used if approved by the Engineer. 1503. bESIGN OF FORMWORK 1503.1. The Contractor shall furnish the design and drawing of complete forniwork (i.e. the forms as well as their supports) for approval of the Engineer before any erection is taken up. If proprietary system of formwork is used, the Contractor shall furnish detailed information as per Appendix 1500/i to the Engineer for approval. Notwithstanding any approval or review of drawing and design by the Engineer, the Contractor shall be entirely responsible for the adequacy and safety for formwork. 1503.2. The design of the formwork shall conform to provisions of IRC:87. It shall ensure that the forms can be conveniently removed without disturbing the concrete. The design shall facilitate proper and safe access to all parts of formwork for inspection. 1503.3. In the case of prestressed concrete superstructure, careful
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401
Section 1500
Formwork
consideration shall be given to redistribution of loads on props due to prestressing. 1504. WORKMANSHIP 1594,1. The formwork shall be robust and strong and the joints shall be leak-proof. Balli shall not be used as staging. Staging must have cross bracings and diagonal bracings in both directions. Staging shall be provided with an appropriately designed base plate resting on firm strata. 1504.2. The number of joints in the formwork shall be kept to a minimum by using large size panels. The design shall provide for proper soldiers to facilitate alignment. All joints shall be leak proof and must be properly sealed. Use of PVC JOINT sealing tapes, foam rubber or PVC T-section is essential to prevent leakage of grout. 1504.3. As far as practicable, clamps shall be used to hold the forms together. Where use of nails is unavoidable minimum number of nails shall be used and these shall be left projecting so that they can be withdrawn easily. Use of double headed nails shall be preferred. 1504.4. Use Qf ties shall be restricted, as far as practicable. Wherever ties are used they shall be used with HDPE sheathing so that the ties can easily be removed. No parts prone to corrosion shall be left projecting or near the surface. The sheathing shall be grouted with cement mortar of the same strength as that of the structure. 1594.5. Unless otherwise specified, or directed, chamfers or fillets of sizes 25 mm x 25 mm shall be provided at all angles of the form work to avoid sharp corners. The chamfers, bevelled edges and mouldings shall be made in the formwork itself, Opening for fixtures and other fittings shall be provided in the shuuering as directed by the Engineer. 1504.6. Shuttering for walls, sloping members and thin sections of considerable height shall be provided with temporary openings to permit inspection and cleaning out before placing of concrete. 1504.7. The formwork shall be constructed with precamber to the sofflt to allow for deflection of the formwork. Pre-camber to allow for deflection of formwork shall be in addition to that indiated for the perthanent structure in the drawings. 1504.8. Where centering trusses or launching trusses are adopted
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402
Formwork
Section 1500
for casting of superstructure, the joints of the centering trusses, whether welded, riveted or bolted should be thoroughly checked periodically. Also, various members of the centering trusses should be periodically examined for proper alignment and unintended deformation before proceeding with the concreting. They shall also be periodically checked for any deterioration in quality due to steel corrosion. 1504.9. The formwork shall be so made as to produce a finished concrete true to shape, line and levels and dimensions as shown on the drawings, subject to the tolerances specified in respective sections of these specifications, or as directed by the Engineer. 1504.10. Where metal forms are used, all bolts and rivets shall be countersunk and well ground to provide a smooth, plane surface. Where timber is used it shall be well seasoned, free from loose knots, projecting nails, splits or other defects that may mar the surface of concrete. 1504.11. Forms shall be made sufficiently rigid by the use of ties and bracings to prevent any displacement or sagging between supports. They shall l~estrong enough to withstand all pressure, ramming and vibration during and after placing the concrete. Screw jacks or hard wood wedges where required shall be provided to make up any settlement in the formwork either before or during the placing of concrete. 1504.12. The formwork shall take due account of the calculated amount of positive or negative camber so as to ensure the correct final shape of the structures, having regard to the deformation of false work, scaffolding or propping and the instantaneous or deferred deformation due to various causes affecting prestressed structures. 1504.13. Suitable camber shall be provided to horizontal members of structure, specially in Ion~spans to counteract the effects of deflection. The formwork shall be so fixed as to provide for such camber, 1504.14. The formwork shall be coated with an~approved release agent that will effectively prevent sticking and will not stain the concrete surface. Lubricating (machine oils) shall be prohibited for use as coating. 1505. FORMED SURFACE AND FINISH The formwork shall be lined with material approved by the Engineer so as to provide a smooth finish of uniform texture and appearance. This material shall leave no stain on the concrete and so fixed to its backing as not to impart any blemishes. It shall be of the same type and obtained from only one source throughout
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403
Section 1500
Formwork
for the construction of any one structure. The contractor shall make good any ithperfections in the resulting finish as required by the Engineer. Internal ties and embedded metal parts shall be carefully detailed and their use shall be subject to the approval of tfie Engineer. 1506. PRECAUTIONS
-.
(i)
Special measures in the design of formwork shall be taken to ensure that it does not hinder the shrinkage of concrete, The sof fit of the fomiwork shall be so designed as to ensure that the formworit does not restrain the shortening and/or hogging of beams during prestressissg. The forms may be removed at the earliest opportunity subject to the minimum time for removal of forms with props retained in position. Where necessary, forsnwork shall be so arranged that the soffit form, properly supported on props only can be retained irs position for such period as may be required by matu:ring conditions. Any cut-outs or openings provided in any stmcturai member to facilitate erection of formwork shall be closed with the same grade of concrete as the adjoining structure immediately after removal of fomswork ensuring watertight joints. Provision shall be made for safe access en, to and about the forrnwork at the levels as required. Close watch shall be maintained to check for settlement of formwork during concreting. Any settlement of fomswork during concreting shall ho promptly rectified. base plates
(ii)
(iii)
(iv) (v)
(vi) Water used for curing should not be allowed to stagnate near the supporting the staging and should be properly drained.
1507. PREPARATION OF FORMWORK BEFORE CONCRETING The inside surfaces of forms shall, except in the case of permanent form work or where otherwise agreed to by the Engineer be coated with a release agent supplied by approved manufacturer or of an approved material to prevent adhesion of concrete to the formwork. Release agents shall be applied strictly in accordance with the manufacturers instructions and shall not be allowed to come into contact with any reinforcement or prestressing tendons and anchorages. Different release agents shall not be used in formwork for exposed concrete. Before re-use of forms, the following actions shall be taken
(i) (ii) The contact surfaces of the forms shall be cleaned carefully and dried before applying a release agent It should be ensured that the release agent is appropriate to the surface to be coated, The same type and make of release agent shall be used throughout on similar fomswork materials and different types should not be mixed. 404
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Formwork
Section 1500
(iii) The form surfaces shall be evenly and thinly coated with eleare ageuL The vertical surface shall be treated before horizontal surface and any excess wiped
Out.
(iv) The release agent shall not come in contact with reinforcement or the hardened concrete
All forms shall he thoroughly cleaned immediately before con~ creting. The Contractor shall give the Engineer due notice before placing any concrete in the forms to permit him to inspect and approve the formwork, but such inspection shall not relieve the contractor of his responsibility for safety of formwork, men, machinery, materials and finish or tolerances of concrete. 1S08. REMOVAL OF FORMWORK The scheme for removal of formwork (i.e. de-shuuering and decentering) shall be planned in advance and furnished to the Engineer for scrutiny and approval. No formwork or any part thereof shall be removed without prior approval of. the Engineer. The formwork shall be so removed as not to cause any damage~ to concrete. Centering shall be gradually and uniformly lowered in such a manner as to permit the concrete to take stresses due to its own weight uniformly and gradually to avoid any shock or vibration. Where not specifically approved, the time of removal of formwork (when ordinary Portland Cement is used without any admixtures at an ambient temperatures exceeding 10 degrees Celsius) shall be as under
a) Walls, piers, abutments, colwnns and vertical faces of structural members Soffits props left under) (with of Slabs Props (left under slabs) Softit of Girders (with props left under) Props (left under girders)
:
12 to 48 hours as may 1~e decided by the Engineer 3 days 14 days 7 days 21 days
b) c) d) e)
Where there are re-entrant angles in the concrete sections, the formwork should be removed at these sections as soon as possible after the concrete.has set, in order to avoid cracking due to shrinkage of concrete.
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405
Section 1500
Formwork
1509. RE-USE OF FORMWORK When formwork is dismantled, its individual components shall be examined for damage and damaged pieces shall be removed for rec tification. Such examination shall always be carried Out before being used again. Before re-use all components shall be cleaned of deposits of soil,, concrete o~ other unwanted materials. Threaded parts shall be oiled after cleaning. All bent steel props shall be straightened before re-use. The maximum deviation from straightness is 1/600 of the length. The maximum permissible axial loads in used props shall be suitably reduced depending upon their condition. The condition of the timber components, plywood and steel shuttering plates shall be examined closely for distortion and defects before re-use. 1510. SPECIALISE1) FORMWORK Specialised formwork may be required in the case of slipform work, underwater concreting, segmental construction etc. Such specialised formwork shall be designed and detailed by competent agencies and a set of complete working drawings and installation instructions shall be supplied to the Engineer. The site personnel shall be trained in the erection and dismantling as well as operation of such specialised formwork. In case proprietary equipment is used, the supplier shall supply drawings, details, installation instructions, etc.~ the form of in manuals along with the formwork. Where specialised formwork is used, close co-ordination with the design of permanent structure is necessary. For slipform the rate of slipping the formwork shall be designed for each individual case taking into account various parameters including the grade of concrete, concrete strength, concrete temperature, ambient temperature, concrete admixtures, etc. In the case of segmental construction, the concrete mix shall be normally designed for developing high early strength so that the formwork is released as early as possible. in order to verify the time and sequence of striking/removal of specialised formwork, routine field tests for the consistency of concrete and strength development are mandatory and shall be carried out before adoption. For specialised formwork, the form lining material may be either plywood or steel sheet of appropriate thickness., Plywood is preferred where superior quality of surface is desired, whereas steel sheeting is normally used where large number of repetitions are involved. 406
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Formwork
Section 1500
1511. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 1512. MEASUREMENTS FOR PAYMENT Unless stated otherwise the rate for concrete in Plain Concrete or Reinforced Concrete or Prestressed Concrete shall be deemed to include all formwork required in accordance with this section and shalt not be measured separately. Where it is specifically stipulated in the Contract that the formwork shall be paid for separately, measurement of formwork shall be taken in square metres of the surface area of concrete which is in contact with formwork. 1513. RATE The unit rate of the Plain Concrete or Reinforced Concrete or Prestressed Concrete as defined in respective sections shall be deemed to cover the costs of all formwork, including cost of all materials, labour, tools and plant required for design, construction and removal of formwork and supervision as described in this section including properly supporting the members until the concrete is cured, set and hardened as required. Where the contract unit rate for formwork is specifically provided as a separate item, it shall include the cost of all materials, labour, tools and plant required for design, construction and removal of formwork and supervision as~described in this Section including properly supporting the members until the concrete is cured, set and hardened as required.
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407
Steel Reinforcement (Untensioned)
16D0 Steel Reinforcement (Untensioned)
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Section 1600
1601, DESCRIPTION This work shall consist of furnishing and placing coated or uncoated mild steel or high strength deformed reinforcement bars (untensioned) of the shape and dimensions shown on the drawings and conforming to these Specifications or as approved by the Engineer. 1602. GENERAL Steel for reinforcement shall meet with the requirements of Section
1000.
Reinforcements may be either mild steel/medium tensile steel or high strength deformed bars. They may be uncoated or coated with epoxy or with approved protective coatings. 1603. PROTECTION OF REINFORCEMENT Uncoated reinforcing steel shall be protected from rusting or chloride contamination. Reinforcements shall be free from rust, mortar, loose mill scale, grease, oil or paints. This may be ensured either by using reinforcement fresh from the factory or thoroughly cleaning all reinforcement ui remove rust using any suitable method such as sand blasting, mechanical wire brushing, etc., as directed by the Engineer. Reinforcements shall be stored on blocks, racks or platforms and above the ground in a clean and dry condition and shall be suitably marked to facilitate inspection and identification. Portions of uncoated reinforcing steel and dowels projecting from concrete, shall be protected within one week after initial placing of concrete with a brush coat of neat cement mixed with water to a consistency of thick paint. This coating shall be removed by lightly tapping with a hammer or other tool not more than one week before placing of the adjacent pour of concrete. Coated reinforcing steel shall be protected against damage to the coating. If the coating on the bars is damaged during transportation or handling and cannot be repaired, the same shall be rejected. 1604. BENDING OF REINFORCEMENT Bar bending schedule shall be furnished by the Contractor and got approved by the Engineer before start of work. Reinforcing steel shall conform to the dimensions and shapes given in the approved Bar Bending Schedules.
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411
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Section 1600
Bars shall be bent cold to the specified shape and dimensions or as directed by the Engineer using a proper bar bender, operated by hand or power to obtain the correct radii of bends and shape. Bars shall not be bent or straightened in a manner that will damage the parent material or the coating. Bars bent during transport or handling shall be straightened before being used on work and shall not be heated to facilitate straightening. 1605. PLACING OF REINFORCEMENT
a) The reinforcement cage should generally be fabricated in the yard at ground level and then shifted and placed in position. The reinforcement shall he placed strictly in accordance with the dr%wings and shall be assembled in position only when the structure is otherwise ready for plac:ing of concrete. Prolonged time gap between assembling of reinforcements and casting of concrete, which may result in rust formation on the surface, shall not be permitted. Reinforcement bars shall be placed accurately in position as shown on the drawings. The bars, crossing one another shall be tied together at every intersection with binding wire (annealed), conforming to lS:280 to make the skeleton of she reinrorcement rigid such that the reinforcement does not get displaced during placing of concrete, or any other operation, The diameter of binding wire shall not be lesa than 1 mm. liars shall he kept in position usually by the following methods: (i) In caseof beam and slab construction, industrially produced polymer rover blocks of thickness equal to the specified cover shall be placed between the bars and formwork subject to satisfactory evidence that the polymer composition is not hannful to concrete and reinforcement. Cover blocks made of concrete may be permiued by the Engineer, provided they have the same strength and specification as those of the member. tn case of dowels Mr columns and walls, the vertical reinforcement shall be kept in position by means of timber templates with slots cut in them accurately, or with cover Socks tied to the reinforcement. Timber templates shall be removed after the concreting has progressed upto a level just below their location.
b)
c)
(ii)
(iii) Layers of reinforeernents shall be separated by spacer bars at approximately one metre intervals. The minimum diameter of spacer bars shall be 12 mm or equal to maximum size of main reinfoscanent or maximum size of coarse aggregate, whichever is greater. Horizontal reinforcement shall not be allowed to sag between supports. (iv) Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting wiies etc, or other subsidiary reinforcement shall be provided to fix the reinforcements firmly in its correct position. (v) d) Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks etc., as devices for positioning reinforcement shall noI~ permitted. be
liars coated with epoxy or any other approved protective coating shall be
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Section 1600
placed on supports that do not damage the coating. Supports shall be installed in a manner suchthat planes of weakness are not created in hardened concrete. The coated reinforcing steel shall be held in place by use of plastic or plastic coated binding wires especially manufactured for the purpose. Reference shall be made to Section 1000 for other requirements. e) Placing and fixing of reinforcement shall be inspected and approved by the Engineer before concrete is deposited.
1606. BAR SPLICES 1606.1. Lapping All reinforcement shall be furnished in full lengths as indicated on the drawing. No splicing of bars, except where shown on the drawing, will be permitted without approval of the Engineer. The lngths of the splice shall be as indicated on drawing or as approved by the Engineer. Where practicable, overlapping bars shall not touch each other, and shall be kept apart by 25 mm or 1 !/4 times the maximum size of coarse aggregate, whichever is greater. If this is not feasible, overlapping bars shall be bound with annealed steel binding wire, not less than 1 mm diameter and twisted tight in such a manner as to maintain minimum clear cover to the reinforcement from the concrete surface. Lapped splices shall be staggered or located at points, along the span where stresses are low. 1606.2. Welding 1606.2.1. Splicing by welding of reinforcement will be permitted only if detailed on the drawing or approved by the Engineer. Weld shall develop an ultimate strength equal to or greater than~thatof the bars connected. 1606.2.2. While welding may be permitted for mild steel reinforcing bars conforming to 15:432, welding of deformed bars conforming to lS:i 786 shall in general be prohibited. Welding may be permitted in case of bars of other than S 240 grade including special welding grade of S 415 grade bars conforming to 15:1786, for which necessary chemical analysis has been secured and the carbon equivalent (CE) calculated from the chemical composition using the formula Mn Cr+Mg+V Ni+Cu CE= C+-j-+ ~ + is 0.4 or less. 1606,2.3. The method of welding shall conform to 15:2751 and 15:9417 and to any ~upplernentalpecifications to the satisfaction of the s Engineer. 413
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Section 1600
Welding may be carried out by metal arc welding process. Oxyacetelene welding shall not be permissible. Any othtr process may be tised subject to the approval of the Engineer and necessary additional requirements to ensure satisfactory joint performance. Precautions on over heating, choice of electrode, selection of correct turrent in arc welding etc., should be strictly observed. All bars shall be butt welded except for smaller diameter bars (diameter of less than 20 mm) which may be lap welded. Single-V or Double-V butt joints may generally be used. For vertical bars single bevel or double bevel joints may be used. Welded joints shall be located well away from bends and not less than twice the bar diameter away from a bend. Generally, shop welding in controlled conditions is to be preferred, where feasible. Site welding where necessary shall, however, be permitted when the facilities, equipment, process, consumables, operators, welding procedure are adequate to produce and maintain uniform quality at par with that attainable in shop Nelding to the satisfaction of the Engineer. Joint welding procedures which are to be ~employed shall invariably be established by a procedure specification. All welders and welding operators to be employed shall have to be qualified by tests prescribed in IS:2751. inspection of welds shall conform to IS:822 and destructive or non-destructive testing may be undertaken when deemed necessary. Joints with weld defects detected by visual inspection or dimensional check inspection shall not be accepted. Suitable means shall be provided for holding the bars securely in position during welding. It must be ensured that no voids are left in welding. When welding is done in 2 or 3 stages, previous surface shall be cleaned properly. Bars shall be cleaned of all loose scale, rust, grease, paint and other foreign matter before carl%ring out welding. Only competent and experienced welders shall be employed on the work with the approval of the Engineer. No welding shall be done on coated bars. M.S. electrodes used for welding shall conform to IS:8l4. 1606.2.4. Welded joints shall prefeiably be located at points where steel will not be subject to more than 75 per cent of the maximum permissible stresses and welds so staggered that at any one section, not more than 20 per cent of the bars are welded.
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Section
1600
1606.2.5. Welded pieces of reinforcement shall be tested, Specimens shall be taken from the site and the number and frequency of tests shall be as directed by the Engineer. 1606.3. Mechanical Coupling of Bars Bars may be joined with approved patented mechanical devices as indicated on the drawing or as approved by the Engineer e.g. by special grade steel sleeves swftgged on to bars in end to end contact or by screwed couplers. In case such devices are permitted by the Engineer, they shall develop at least 125 per cent of the characteristic strength of the reinforcement bar. 1607, TESTING AND ACCEPTANCE The material shall be tested in accordance with relevant IS specifications and necessary test certificates shall be furnished. Additional tests, if required, will be got carried out by the Contractor at his own cost. The fabrication, furnishing and placing of reinforcement shall be in accordance with these specifications and shall be checked and accepted by the Engineer. 1608. MEASUREMENTS FOR PAYMENT Reinforcement shall be measured in length including hooks, if any, separately for different diameters as actually used in work, excluding overlaps. From the length so measured, the weight of reinforcement shall be calculated in tonnes on the basis of IS: 1732. Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and annealed steel wire or other methods, for binding and placing shall not be measured and cost of these items shall be deemed to be included in the rates for reinforcement. 1609. RATE The contract unit rate for coated/uncoated reinforcement shall cover the cost of material, fabricating, transporting, storing, bending, placing, binding and fixing in position as shown on the drawings as per these specifications and as directed by the Engineer, including all labour, equipment, supplies, incidentals, sampling, testing and supervision. The unit rate for coated reinforcement shall be deemed to also include cost of all material, labour, tools and plant, royalty, transportation and expertise required to carry out the work. The rate shall also cover sampling, testing and supervision required for the work.
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Structural Concrete
1700 Structural Concrete
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Structural Concrete
Section 1700
1701. DESCRW~ION The work shall consist of furnishing and placing structural concrete and incidental construction in accordance with these specifications and in conformity with the lines, grades and dimensions, as shown on the drawings Or as directed by the Engineer. 1702. MATERIALS All materials shall conform to Section 1000 of these Specifications. 1703. GRADES OF CONCRETE 1703.1. The grades of concrete shall be designated by the characteristic strength as given in Table 1700-I, where the characteristic strength is defined as the strength of concrete below which not more than 5 per cent of the test results are expected to fall.
TABLE 1700-1. ,Grade Designation M 15 M 20 M 25 M 30 M 35 M 40 M 45 M 50 M 55 Specified characteristic Compressive strength of 150 mm tithes at 28 days, in MPa 15 20 25 30 35 40 45 50 55
1703.2. The lowest grades of concrete in bridges and corresponding minimum cement contents and water-cement ratios shall be maintained as indicated in Tables 1700-2 and 1700-3.
TABLE 1700-2 FOR BRIDGES WITH PRFSTRESSED CONCREFE OR THOSE
WITH INDIVIDUAL SPAN LENGTHS MORE THAN 30 M OR THOSE THAT ARE BUILT WITH INNOVATIVE DESIGN/CONSTRUCTION (A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO Structural Member
Mlii. cement content for all exposure

condlilom (kglcnin)
Max. water cement ratio Exposure conditions Normal Severe
a) b) c)
FCC members
RCC members PSC members
360
400
,
0.45 0.45
0.40
400
0.45 0.40 0.40
419
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Section 1700 (B) MINIMUM STRENGTH OF CONCRETE Member
Stiucuiral Concrete
Conditions of Exposure Moderate Severe M30
a)
b)
c)
PCCniranbers RcCmernbers PSCmembers
M25~
,
M35 M35
M40 M40
TABLE 1700-3. FOR BRUSGES OTHER THAN THOSE MENTIONED IN TABLE

1700~2AND FOR CULVERTS AND OTHER INCIDENTAL CON-
STRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO Structural Member ~
Mtn. cement content (kg/cii,m)

Exposure conditions Normal Severe 250
Max. water cement
ratio
Exposure conditions Normal Severe
~ a) b)
FCC members RCC members
310
400
310
0.50 0.45
0.45 0.40
(B) MINIMUM STRENGTH OF CONCRETE Member Conditions of Exposure

Moderate Severe M20 M25
a) b)
PCCmembers RCCmembers
MiS
M20
Notes Applicable to Tables 1700-2 and 1700-3

(I) The minimum cement content is based on 20 mm aggregate (nominal max. size), For 40mm and larger size aggregates, it may be reduced suitably but the reduction shall not be more than 10 per cent For underwater concretinj, the cement content shall be increased by 10 per cent.
(ii)
Cmii) Severe conditions of exposure shall mean alternate wetting and drying due to sea spray, alternate wetting and drying combined with freezing and buried in soil having corrosive effect (iv) Moderate conditions of exposure shall mean other that those mentioned in (iii) abovt
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The cement content shall be as low as possible but not less than the quantities specified above. In no case shall it exceed 540 kg/cu.m. of concrete. 1703.3. Concrete used in any component or structure shall be specified by designation along with prescribed method of design of mix i.e. Design Mix or Nominal Mix. For all items of concrete, only Design Mix shall be used, except where Nominal Mix concrete is permitted as per drawing or by the Engineey.Nominal Mix may be 420
Structural Concrete
Section
1700
permitted only for minor bridges and culverts or other incidental construction where strength requirements are upto M 20 only. Nominal Mix may also be permitted for non-structural concrete or for scr~d below open foundations. 1703.4. If the Contractor so elects, the Engineer may permit the use of higher grade concrete than that specified on the drawing, in which event the higher grade concrete shall meet the specifications applicable thereto without additional compensation. 1704. PROPORTIONING OF CONCRETE Prior to the start of construction, the Contractor shall design the mix in case of Design Mix Concrete or propose no?ninal mix in case of Nominal Mix Concrete, and submit to the Engineer for approval, the proportions of materials, including admixtures to be used. Water-reducing admixtures (including plasticisers or super-plasticisers) may be used at the Contractors option, subject to the approval of the Engineer. Other types of admixtures shall be prohibited, unless specifically permitted by the Engineer. 1704.1. Requirements of Consistency The mix shall have the consistency which will allow proper placement and consolidation in the required position. Every attempt shall be made to obtain uniform consistency. The optimum consistency for various types of structures shall be as indicated in Table 1700-4, or ~s directed by the Engineer. The slump of concrete shall be checked as per IS:5 16.
TABLE 17004 TYPE
I (a) (b) 2. 3. Structures with exposed inclinedsurface requiring low slump concrete to allow proper compaction plain cement concrete
SLUMP (mm)
25 25
RCC structures with widely spaced reinforcements; e.g. solid columns, piers, abatments, footings, well steining RCC struclures with fair degree of congestion of reinforcement; e.g. pier and abutment caps, box culverts well curb, well cap, walls with thickness greater than 300 mm RCC and PSC structures with highly congested reinforcements e.g. deck slab girders, box girders, walls with thickness less than 300 mm Underwater concreting through tremie e.g. bottom plug, cast-in-situ piling
40 50
50
75
4.
75
125
5.
100
200
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421.
Section 1700
Structural Concrete
1704.2. Requirements for Designed Mixes 1704.2.1. Target mean strength The target mean strength of specimen shall exceed the specified characteristic compressive strength by at least the current margin.
(i) The current margin for a concrete mix shall be determined by the Contractor and shall be taken as 1.64 times the standard deviation of sample test results taken from at least 40 separate batches of concrete of nominally similar proportions produced at site by the same plant under similar supervision, over a period exceeding 5 days, but not exceeding 6 months. Where there is insufficient data to satisfy the above, the current margin for the initial design mix shall be taken as given in Table 1700-5
(ii)
Concrete Grade
TABLE 1700.5. Current Margin CMPa)
Target Mean Strength
(MPa)
25
M 15
M 20 N4 25 M 30
10 JO 11
12 12 12 13 13 14
30 36
42
M 35
M 40
47
52
M 45 M 50
M 55
58
63 69
The initial current margin given in the Table 1700-5 shall be used tifl sufficient data is available to determine the current margin as per sub-clause (i) above, 1704.2.2. Trial mixes The Contractor shall give notice to enable the Engineer to be present at the making of trial mixes and preliminary testing of the cubes. The Contractor shall prepare trial mixes, using samples of approved materials typical of those he proposes to use in the works, for all grades to the Engineers satisfaction prior to commencement of concreting. The initial trial mixes shall generally be carried out in an established laboratory approved by the Engineer. In exceptional cases, the Engineer may permit the initial trial mixes to be prepared at the site laboratory of the Contractor, if a full fledged concrete laboratory has been established well before the start of construction, to his entire satisfaction. In all cases complete testing of materials forming the constituents of proposed Design Mix shall have been carried out prior to making trial mixes. Sampling and testing procedures shall be in accordance with these specifications.
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Structural Concrete
Section 1700
When the site laboratory is utilised for preparing initial mix design, the concreting plant and means of transport employed to make the trial mixes shall be similar to that proposed to be used in the works. Test cubes shall be taken from trial mixes as follows. For each mix, set of six cubes shall be made from each of three consecutive batches. Three cubes from each set of six shall be tested at an age of 28 days and three at an earlier age approved by the Engineer. The cubes shall be made, cured, stored, transported and tested in accordance with these specifications. The average strength of the nine cubes at 28 days shall exceed the specified characteristic strength by the current margin minus 3.5 MPa. 1704.23. Control of strength .of design mixes
a) Adjustment to Mix Proportions Adjustments to mix proportions arrived as in the trial mixes shall be made subject to the Engineers approval, in order to minimise the variability of strength and to maintain the target mean strength. Such adjustments tall not be taken to imply any change in the current margin. b) Change of Current Margin When required by the Engineer, the Contractor shall recalculate the current margin in accajdance with Clause 1704.2.1. The recalculated value shall be adopted as directed by the Engineer, and is shall become the current margin for concrete produced subsequently. c) Additional Trial Mixes During production, the Contractor shall carry out trial mixes and tests, if required by the Engineer, before substantial changes are made in the material or in the proportions of the materials to be used, except when adjustments to the mix proportions are carried out in accordance with sub-clause Ca) above. 1704.3.
Requirements of Nominal Mix Concrete
Requirements for nominal mix concrete unless otherwise specified, shall be as detailed in Table 1700-6.
TABLE 1700-6. PROPORTIONS FOR NOMINAL MIX CONCRETE
Concrete
Grade
Total Quantity of dry aggregate Proportion of fine to by mass per 50 kg of cement to be Coarse aggregate taken as the sum of Individual (by mass)
masses of flue and coarse aggregates (kg)
MIS
350
Generally 1:2, subject to upper limit 1:1.5 and lower limit of 1:2.5 do--
M20
250
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Section 1700
Structural Concrete
1704.4, Additional Requirements Concrete shall meet with any other requirements as specified on the drawing or as directed by the Engineer. Additional requirements shall also consist of the following overall limits of deleterious substances in concrete a) The total chloride content of all constituents or concrete as a percentage of mass
of cement in mix shall be limited to values given below:
-
Prestiessed Concrete Reinforced concrete exposed to chlorides in service (e.g. structures located near sea coast) Other reinforced concrete construction
: : :
0.1 per cent 0,2 per cent 0.3 per cent
b)
The total sulphuric anhydride (SO,) content of all the constituents of concrete as a peitentage of mass of cement in the mix shall be limited so 4 per cent
1704.5. Suitability of Proposed Mix Proportions The Contractor shall submit the following information for the Engineers approval
a) 6) c) Nature and source of each material Quantities of each material per cubic metre cYf fully compacted concrete Either of the following (i) appropriate existing data as evidence of satisfactory previous perfosmance for the target mean strength, current margin, consistency and water/cement 1 ratio and any other additional requirement(s) as specific (ii) full details of tests on trial mixes.
d) Statement giving the proposed mix proportions for nominal mix concrete. Any change in the source of material or in the mix proportions shall be subject to the Engineers prior approval. t705. ADMIXTURES Use of admixtures such as superplasticisers for concrete may be made with the approval of the Engineer. As the selection of an appropriate concrete admixture is an integral part of the mix design, the manufacturers shall recommend the use of any one of his products only after obtaining complete knowledge of all the actual constituents of concrete as well as methodologies of manufacture, transportation and compaction of concrete proposed to be used in the project. 1706. SiZE OF COARSE AGGREGATE The size (maximum nominal) of coarse aggregates for concrete to
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Structural Concrete
Section
1700
be used in various components shall be given as Table 1700-7.

Components
I) ii) iii) iv)
TABLE 1700-7. Maximum Nominal Size of Coarse Aggregate

(mm) 20 40
RCC
well curb
RCCJPCC well steining Well cap or Pile Cap Solid type piers and abutments
40
20
RCC
work in girders,slabs, wearing coat, kerb, approach slab, hollow piers and abutments, pier/abutment caps, piles PSC work Any other item
v) vi)
20 As specified by Engineer
Maximum nominal size of aggregates shall also be restricted to the smaller of the following values
a) b) 10 mm less than the minimum lateral clear distance between main reinforcements 10 mm less than the minimum clear cover to the reinforcements
The proportions of the various individual size of aggregates shall be so adjusted that the grading produces densest mix and the grading curve corresponds to the maximum nominal size adopted for the concrete mix. 1707. EQUIPMENT Unless specified otherwise, equipment for production, transportation and compaction of concrete shall be as under
a) For Producsicm of Concrete i) For overall bridge length of test than 200 metres - batch type concrete mixer diesel or electric operated, with a minimum size of 200 litres, automatic water measuring system and integral weigher (hydraulic/pneumatic type) For overall bridge length of 200 metres or more - concrete batching and mixing plant fully automatic with minimum capacity of 15 cu.m.per hour.
ii)
All measuring devices of the equipment shall be maintained in a clean and serviceable condition. Its accuracy shall be checked over the range in use, when set up at each site and thereafter periodically as directed by the Engineer. The accuracy of the measuring devices shall fall within, the following limits:
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425
Section 1700 Measurement of Cement Measurement of Water Measurement of Aggregate Measurement of Admixture b)
Structural Concrete 3
per cent of the quantity of cement in each batch 3 per cent of the quantity of water in each batch
3 per cent of she quantity of aggregate in each batch

5 per cent of the quantity of admixture in each batch depending upon actual requirement minimum 2 scones capacity minimum 0.5 tonne capacity
For Concrete Transportation i) Concrete dumpers ii) Powered hoists iii) asutes iv) Buckets handled by cranes v) Transit truck mixer vi) Concrete pump vji) Concrete distributor booms viii) Belt conveyor ix) Cranes with skips x) Tremies For Compaction of Concrete i)
c)
ii)
iii)
Internal vibrators Form vibrators Screed vibrasors
size 25 mm to 70 mm minimum 500 watts full width of carriageway (upto two lanes)
1708. MIXING CONCRETE
Concrete shall be mixed either in a concrete mixer or in a batching and mixing plant, as per these specifications, Hand mixing shall not be permitted. The mixer or the plant shall be at an approved location considering the properties 9f tl~emixes and the transportation arrangements available with the Contractor. The mixer or the plant shall be approved by the Engineer. Mixing shall be continued till materials are uniformly distributed and a uniform colour of the entire mass is obtained, and each individual particle of the coarse aggregate shows complete coating of mortar containing its proportionate amount of cement. In no case shall mixing be done for less than 2 minutes. Mixers which have been out of use for more than 30 minutes shall be thoroughly cleaned before putting in a new batch, Unless otherwise agreed to by the Engineer, the first batch of concrete from the mixer shall contain only two thirds of the normal quantity of coarse aggregate. Mixing plant shall be thoroughly cleaned before changing from one type of cement to another.
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Structural Concrete
Section 1700
1709. TRANSPORTING, PLACING AND COMPACTION OF CONCRETE The method of transporting and placing concrete shall be approved
by the Engineer. Concrete shall be transported and placed as near as practicable to its final position, so that no contamination, segregation or loss of its constituent materials takes place. Concrete shall not be freely dropped into place from a height exceeding 1.5 metres. When concrete is conveyed by chute, the plant shall be of such size and design as to ensure practically continuous flow. Slope of the chute shall be so adjusted that the concrete flows without the use of excessive quantity of water and without any segregation of its ingredients. The delivery end of the chute shall be as close as possible to the point of deposit. The chute shall be thoroughly flushed with water before and after each working period and the w~terused for this purpose shall be discharged outside tbe formwork. All formwork and reinforcement contained in it shall be cleaned and made free from standing water, dust, snow or ice immediately before placing of concrete. No concrete shall be placed in any part of the structure until the approval of the Engineer has been obtained. If concreting is not started within 24 hours of the approval being given, it shall have to be obtained again from the Engineer. Concreting then shall proceed continuously over the area between the construction joints. Fresh concrete shall not be placed against concrete which has been in position for more than 30 minutes unless a proper construction joint is formed. Except where otherwise agreed to by the Engineer, concrete shall be deposited in horizontal layers to a compacted depth of not more than 450 mm when internal vibrators are used and not exceeding 300 mm in all other cases. Concrete when deposited shall have a temperature of not less than 5 degrees Celsius, and not more than 40 degrees Celsius. It shall be compacted in its final position within 30 minutes of its discharge from the mixer, unless carried in properly designed agitators, operating continuously, when this time shalt be within 1 hour of the addition of cement to the mix and within 30 minutes of its discharge from the agitator. It may be necessary to add retarding admixtures to concrete if trials show
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Section 1700
Structural Concrete
that the periods indicated above are unacceptable. In all such matters, the Engineers decision shall be final. Concrete shall be thoroughly compacted by vibration or other means during placing and worked around the reinforcement, tendons or duct formers, embedded fixtures and into corners of the formwork to produce a dense homogeneous void-free mass having the required surface finish. When vibrators are used, vibration shall be done continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that does not promote segregation. Over vibration shall be avoided to minimise the risk of forming a weak surface layer. When external vibrators are used, the design of formwork and disposition of vibrator shall be such as to ensure efficient compaction and to avoid surface blemishes. Vibrations shalt not be applied through reinforcement and where vibrators of immersion type are used, contact with reinforcement and all inserts like ducts etc., shall be avoided. The internal vibrators shall be inserted in an orderly manner and the distance between insertions should be about one and a half times the radius of the area visibly affected by vibration. Additional vibrators in serviceable condition shall be kept at site so that they can be used in the event of breakdowns. Mechanical vibrators used shall comply with IS:2502, IS:2506, JS:2514 and IS:4656.
1710. CONSTRUCTION JOINTS
Construction joints shall be avoided as far as possible and in no case the locations of such joints shall be changed or increased from those shown on the drawings, except with express approval of the Engineer. The joints shalkbe provided in a direction perpendicular to the member axis. Location, preparation of surface and concreting of Construction joints shall conform to the additional specifications given in Appendix 1700/!.
1711. CONCRETING UNDER WATER When it is~ necessary to deposit concrete under water, the methods, equipment, materials and proportions of mix to be used shall be g~t approved from the Engineer before any work is started. Concrete shall contain 10 per cent more cement than that required for the same mix placed in the dry.
Concrete shall not be placed in water having a temperature below
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Structural Concrete
Section 1700
5 degrees Celsius. The temperature of the concrete, when deposited, shall not be less than 16 degrees Celsius, nor more than 40 degrees Celsius. Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if practicable, and in any case to reduce the flow of water to less than 3 metres per minute through the space into which concrete is to be deposite4. Coffer dams or forms in still water shall be sufficiently tight to prevent loss of mortar through the joints in the walls. Pumping shall not be done while concrete is being placed, or until 24 hours thereafter. To minimise the formation of laltance, great care shall be exercised not to disturb the concrete as far S possible while it is being deposited. All under water concreting shall be carried out by tremie method only, using tremie of appropriate diameter. The number and spacing of the tremies should be worked out to ensure proper concreting. The tremie concreting when started should continue without interruption for the full height of the member being concreted. Tht concrete production and placement equipment should be sufficient to enable the underwater concrete to be completed uninterrupted within the stipulated time. Necessary stand-by equipment should be available for emergency situation. The top section of the tremie shall have a hopper large enough to hold one full batch of the mix or the entire contents of the transporting bucket as the case may be. The tremie pipe shall not be less than 200 mm in diameter and shall be large enough to allow a free flow of concrete and strong enough to withstand the external pressure of the water in which it is suspended, even if a partial vacuum develops inside the pipe. Preferably, flanged steel pipe of adequate strength~for the job shall be used. A separate lifting device shall be provided for each tremie pipe with its hopper at the upper end. Unless the lower end of the pipe is equipped with an approved automatic check valve, the upper end of the pipe shall be plugged with a wadding of gunny sacking or other approved material before delivering the concrete to the tremie- pipe through the hopper; so that when the concrete is forced down from the hopper to the pipe, it will force the plug (and along with it any water in the pipe) down the pipe and out of the bottom end, thus establishing a continuous stream of concrete. It will be necessary to raise slowly the tremie in order to allow a uniform flow of concrete, but it shall not be emptied so that water is not allowed to enter above the concrete in the pipe. At all times after placing of concrete is started and until all the requiycd
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429
Section 1700
Structural Concrete
quantity has been placed, the lower end of the tremie pipe shall be kept below the surface of the plastic concrete. This will cause the concrete to build up from below instead of flowing out over the surface and thus avoid formation of layers of laitance. If the charge in the tremie is lost while depositing, the tremie shall be raised above the concrete surface and unless sealed by a check valve, it shall be replugged at the top end, as at the beginning, before refilling for depositing further concrete. 1712. ADVERSE WEATHER CONDITIONS 1712.1. Cold Weather Concreting Where concrete is to be deposited at or near freezing temperature, precautions shall be takel) to ensure that at the time of placing, it has a temperature of not less than 5 degrees Celsius and that the temperature of the concrete shall be maintained above 4 degrees Celsius until it has thoroughly hardened. When necessary, concrete ingredients shall be heated before mixing but cement shall not be heated artificially other than by the heat transmitted to it from other ingredients of the concrete. Stock-piled aggregate may be heated by the use of thy heat or steam. Aggregates shall not be heated directly by gas or on sheet metal over fire. In general, the temperature of aggregates or water shall not exceed 65 degrees Celsius. Salt or other chemicals shall not be used for the prevention of freezing. No frozen material or materials containing ice shall be used. All concrete damaged by frost shall be removed, It is recommended that concrete exposed to freezing weather shall have entrained air and the water content of the mix shall not exceed 30 litres per 50 kg of cement. 1712.2. Hot Weather Conditions When depositing concrete in very hot weather, precautions shall be taken so that the temperature of wet concrete does not exceed 40 degrees Celsius while placing. This shall be achieved by stacking aggregate under the shade and keeping them moist, using cold water, reducing the time between mixing and placing to the minimum, cooling formwork by sprinkling water, starting curing before concrete dries out and restricting concreting as far as possible to early mornings and late evenings. When ice is used to cool mixing water, it will be considered a part of the water in design mix. Under no circumstances shall the mixing operation be considered complete until all ice in the mixing drum has melted. The Contractor will be required to state his methodology for the Engineers approval when temperatures of concrete are likely to exceed 40 degrees Celsius during the work.
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430
Structural Concrete 1713. PROTECTION AND CURING
Section 1700
Concreting operations shall not commence until adequate arrangements for concrete curing have been made by the Contractor. Curing and protection of concrete shall start immediately after compaction of the concrete to protect it from
a) b) c) Premature drying out particularly by solar radiation High internal thermal gradients Leaching our by rain and flowing water Rapid cooling during the first few days after placing Low temperature or frost Vibration and impact which may disrupt the concrete and interfere with its bond to the reinforcement and wind
d) e)
Where members are of considerable size and length, with high cement content, accelerated curing methods may be applied, as approved by the Engineer. 1713.1. Water Curing Water for turing shall be as specified in Section 1000. Sea water shall not be used for curing. Sea water shall not come into contact with concrete members unless it has attained adequate strength. Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding or by covering with a layer of sacks, canvas, Hessian or similar materials and shall be kept constantly wet for a period of not less than 14 days from the date of placing of concrete. 1713.2. Steam Curing Where steam curing is adopted, it shall be ensured that it is done in a suitable enclosure to contain the live steam in order to minimise moisture and heat losses. The initial application of the steam shall be after about four hours of placement of concrete to allow the initial set of the concrete to take place. Where retarders are used, the waiting period before application of the steam shall be increased to about six hours. The steam shall be at 100 per cent relative humidity to prevent loss of moisture and to provide excess moisture for proper hydration of the cement. The application of steam shall notbe directly on the concrete and the ambient air temperature shall increase at a rate not exceeding
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Structural Concrete
5 degrees Celsius per hour until a maximum temperature of 60 degrees Celsius to 70 degrees Celsius is reached. The maximum temperature shall be maintained until the concrete has reached the desired strength. When steam curing is discontinued, the ambient air temperature shall not drop at a rate exceeding 5 degrees Celsius per hour until a temperature of about 10 degrees Celsius above the temperature of the air to which the concrete Will be exposed, has been reached. The concrete shall not be exposed to temperatures below freezing for at least six days after curing. 1713.3, Curing Compounds Curing compounds shall only be permitted in special circumstances and will require specific approval of the Engineer. Curing compounds shall not be used on any surface which requires further finishing to be applied. All construction joints shall be moist, cure4 and no curing compound will be permitted in locations where concrete surfaces are required to be bonded together. Curing compounds shall be continuously agitated during use. All concrete cured by this method shall receive two applications of the curing compound. The first coat shall be applied immediately after acceptance of concrete finish. If the surface is dry, the concrete shall be saturated with waler and curing compound applied as soon as the surface film of water disappears. The second application, shall be made after the first application has set. Placement in more than two coats may be required to prevent streaking. 1714. FINISHING Immediately after the removal of forms, exposed bars or bolts, if any, shall be cut inside the concrete member to a depth of ai least 50 mm below the surface of the concrete and the resulting holes filled with cement mortar. All fins caused by form joints, all cavities produced by the removal of form ties and all other holes and depressions, honeycomb spots, broken edges or corners, and other defects, shall be thoroughly cleaned, saturated with water, and carefully pointed and rendered true with mortar of cement and fine aggregate mixed in the proportions used in the grade of concrete that is being finished and of as dry a consistency as is possible to use. Considerable pressure shall be applied in filling and pointing to ensure thorough filling in all voids. Surfaces which have been pointed shall be kept moist for a period of
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twenty four hours. Special prepackaged proprietary mortars shall be used where appropriate or where specified in the thawing. All construction and expansion joints in the completed work shall he left carefully tooled and free from any mortar arid concrete. Expansion joint filler shall be left exposed for its full length with clean and true edges, Immediately on removal of forms, the concrete work shall be examined by the Engineer before any defects are made good.
a) b) The work that has sagged or contains honeycombing to an extent detrimental to structural safety or architectural a~earassceshall be rejected. Surface defect of a minor nature may be accepted. On acceptance of such work by the Engineer, the same shall be rectified as directed by the Engineer.
1715. TOLERANCES Tolerances for dimensions/shape of various components shall be as indicated in these specifications or shown on the drawings or as directed by the Engineer. 1716. TESTS AND STANDARDS OF ACCEPTANCE 1716.1. Concrete shall conform to the surface finish and tolerance as prescribed in these specifications for respective components. 1716.2, Random sampling and lot by lot of acceptance inspection shall be made for the 28 days cube strength of concrete. 1716.2.1. Concrete under acceptance shall be notionally divided into loLs for the purpose of sampling, before commencement of work. The delimitation of lots shall be determined by the following
(i) (ii) No individual lot shall be more than 30 cu.m. in volume At least one cube formthg an item of the sample representing the lot shall be taken from concrete of the same grade and mix proportions cast on any day.
(iii) Different grades of mixes of concrete shall be divided into separate lots (iv) Concrete of a lot shall be used in the same identifiable component of the bridge
1716,2.2. Sampling and testing I. Concrete for making 3 test cubes shall
2,
be taken from a batch of concrete at point of delivery into construction, according to procedure laid down in 15:1199. A randorrt sampling procedure to ensure that each of the concrete batches forming the lot under acceptance inspection has equal chance of being chosen for taking cubes shall be adopted.
3.
150 mm cubes shall be made, cured and tested at the age of 28 days for compressive strength in accordance with 15:516. The 28~daytest strength result
for each cube shall form an item of the sample.
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1716.2.3. Test specimen and sample strength Three test specimens shall be made from each sample for testing at 28 days. Additional cubes may he required for various purposes such as to determine the strength of concrete at 7 days or for any other purpose. The test strength of the sample shall be the average of the strength of 3 cubes. The individual variation should not be more than per 15 cent of the average. 1716.2.4. Frequency : The minimum frequency of sampling of concrete of each grade shall be in accordance with Table 1700-8
TABLE I7OO~8
Quantity of Concrete In work, m 1-5 6~15 No. of samples 1 2 3 4 4 plus one additional sample for each 5 or part thereof actditional 50 m
16-30
31-50 51 and above
At least one sample shall be taken from each shift of work, 17 16.2.5. Acceptance criteria Compressive Strength When both the following conditions are met, the concrete complies with the specified compressive strength
a) b) The mean strength determined from any group of fourconsecutive samples should exceed the specified characteristic compressive strength. Strength of any sample is not less than the specified characteristic compressive strength minus 3 MPa.
The quantity of concrete represented by the test results include the batches from which the first and last samples were taken, together with all intervening batches. Chloride and Sulphate Content The total chloride and sulphuric anhydride (SO 3) content of all the constituents of concrete as a percentage of mass of cement in the mix shall not exceed the values given in this section of the specifications. 1716.3. Density of Fresh Concrete Where minimum density of fresh concrete is specified, the mean of any four consecutive samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 per cent of the specified value,
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1716,4. Density of Hardened Concrete Where minimum density of hardened concrete is specified, the mean of any four consecutive samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 per cent of the specified value. 1716.5. Permeability Test The concrete should pass the following test if it is properly compacted and is not considered permeable.
(i)
(ii) Prepare a cylindrical test specimen
150
mm dia and 160 mm Isigh
After 28 days of curing, the test specimcn is fitted in a machine such that thc specimen can be placed in water under pressure upto 7 bars. A typical machine is shown in Appen4Lz 1700/fl.
(iii) At first a pressure of one bar ir applied for 48 hours, followed by 3 bars for 24 hours and 7 bars for next 24 hours. (iv) After the passage of the above period, the specimen is taken out and split in the middle by compression applied on two round bars on opposite sides above and below, (v) The water penetration in the broken core is to be measured with a scale and the depth of penetration assessed in mm (max. permissible limit 25 mm).
1716.6. If the concrete is not able to meet any of the standards of acceptance as prescribed, the effect of such deficiency on the Structure shall be investigated by the Contractor as directed by the Engineer. The Engineer may accept the concrete as sub-standard work. Any additional work required by the Engineer for such acceptance shall be carried out by the Contractor at his cost. In case the concrete is not found to be acceptabiL after investigation, the Contractor shall remove the rejected concrete forthwith. 1717. MEASUREMENTS FOR PAYMENT Structural concrete shall be measured in cubic metres. In reinforced or prestressed concrete, the volume occupied by reinforcement or prestressing cables and sheathing shall not be deducted. The slab shall be measured as running continuously through and the beam as the portion below the slab. 1718. RATE The contract unit rate for structural concrete shall cover costs of all materials, labour, tools, plant and equipment required for mixing, transporting and placing in position, vibrating and compacting, finithing and curing as per this Section or as directed by the Engineer, including all
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incidental expenses, sampling and testing, quality assurance and supervision. Unless mentioned separately as an item in the Contract, the contract unit rate for concrete shall also include the cost of providing, fixing and removing formwork required for concrete work as per Section 1500. Where concrete is found to be acceptable as sub-standard work, the Contractor shall pay a discount over the contract unit rate, as decided by the Engineer. For deficiency in compressive strength of concrete when accepted by the Engineer, the reduction in rate may be applied as under Per cent reductton Design Strength Observed Strength x 100 Design Strength
.
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Prestressing
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Prestressing 1801. DESCRIFFION
Section 1800
Structural concrete containing prestressed steel reinforcement to introduce precompression is termed as prestressed concrete. The work shall be carried out in accordance with the drawing and these specifications or as approved by the Engineer. Concrete and untensioned steel for the construction of prestressed concrete members shall conform to the requirements of sections 1700 and 1600 for Structural Concrete and Steel Reinforcement respectively in so far as the requirements of these Sections apply and are not specifically modified by requirements set forth herein. 1802. MATERIALS ~J8O2.1. materials shall conform to Section 1000. All 1802.2. Sheathing ~4802.2,1.The sheathing ducts shall be of the spiral corrugated type, Unless otherwise specified, the material shall be Cold Rolled Cold Annealed (CRCA) Mild Steel conforming to !S:5 13 intended for mechanical treatment and surface refining but not for quench hardening or tempering. The material shall normally be bright finished. However, where specified, as in case of use in aggressive environment, galva.. aired or lead-cOated mild steel strips shall be used. The thickness of sheathing shall be as shown on the drawing, but shall not be less than 0.3 mm, 0.4 mm and 0.5 mm for sheathing ducts having internal diameter of 50 mm, 75 mm and 90 mm respectively. For bigger diameter of ducts, thickness of sheathing shall be based on recommendations of prestressing system supplier or as directed by the Engineer. The sheathing shall conform to the requirement as per tests specified in Appendix 1800/!.
L~
For major projects, the sheathing ducts should preferably be manufactured at the project site utilising appropriate machines. With an arrangement, long lengths of sheathing ducts may be used with consequent reduction in the number of joints and couplers. Where sheathing duct joints are unavoidable, such joints shall be made
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slurry tight by the use of corrugated threaded sleeve couplers which may be tightly screwed onto the outer side of the sheathing ducts. The length of the coupler should not be less than 150 mm but should be increased upto 200 mm wherever practicable. The joints between the ends of the coupler and the duct shall be sealed with adhesive seating tape to prevent penetration of cement slurry during concreting. The couplers of adjacent ducts should be staggered wherever practicable. As far as possible, couplers should not be located in curved zones. The corrugated sleeve couplers are being conveniently manufactured using the sheath making machine with the next higher size of die set. 1802.2.2. The intemat area of the sheathing duct shall be in accordance with the recommendations of the system manufacturer and shall be about three times the area of the tendons. In case of 6T13, t2Tt3 and t9Tl3 sizes of tendons comprising 12/13 mm dia strands, the inner diameter of the sheathing shall not be less than 50 mm, 75 mm and 90 mm respectively or those shown in the drawing, which ever is greater. Where prestressing tendons are required to be threaded after concreting the diameter of sheathing shall be about 5 mm larger than that required as above. 1862,2.3. In severe environment, cables shall be threaded after concreting. In such cases a temporary tendon shall be inserted in the sheathing or the sheathing shall be stiffened by other suitable method rluring concreting. 1802.3. Anchorages 1802.3,1. Anchorages shall be procured from authorised manufacturers only. Anchorages shall conform to BS:4447. Test certificates from a laboratory fully equipped to carry out the tests shall be furnished to the Engineer. Such test certificates shall not be more than i2 months old at the time of making the proposal for adoption of a particular system for the project. No damaged anchorages shall be used. Steel parts shall be protected from corrosion at alt times. Threaded paris shall be protected by greased wrappings and tapped holes shall be protected by suitable plugs until used. The anchorage components shall be kept free from mortar and loose rust and any othc deleterious coating. 440
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1800
1802.3.2. Swages of prestressing strand and button-heads of prestressing wire, where provided shall develop a strength of at least 95 per cent of the specified breaking load of the strand or wire as the case may be. Where swaging/button-heading is envisaged, the Contractor shall furnish details of his methodology and obtain approval of the Engineer, prior to his taking up the work. 1802.3.3. Untensioned Steel reinforcements, around anchorages shall conform to the details of prestressing system and as shown on the drawing. 1803. TESTING OF PRESTRESSING STEEL AND ANCHORAGES All materials specified for testing shall be fumished free of cost and shall be delivered in time for tests to be made welt in advance of anticipated time of use. All wire, strand or bars to be shipped to the site shall be assigned a lot number and tagged for identification purposes. Anchorage assemblies to be shipped shall he like-wise identified; All samples submitted shall be representative of the lot to he furnished and in the ease of wire or strand, shalt be taken from the same master roll, The Contractor shalt furnish samples of at least 5.0 in length selected from each tot for testing. Also, two anchorage assemblies, complete with distribution plates of each size or types to be used, shall he furnished alongwith short lengths of strands as required. \/1804 WORKMANSHIP 1804,1. Cleaning Tendons shall he free from loose rust, oil, grease, tar, paint, mud or any other deleterious substance. Cleaning of the steel may be carried out by immersion in suitable solve!nt solutions, wire brushing or passing through a pressure box containing carbonindum powder. Flowever, the tendons shalt not be brought to a polished condition, i804.2. Straightening High tensile steel wire and strand shall be supplied in coils nf sufficiently large diameter such that tendons shall retain their physical properties and shall he straight as it unwinds fror the coil. Tendons of any type that are damaged, kinked or bent shalt not be used,
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Section 1800
Prestressing
The packing of prestiessing wire/strand shall be removed only just prior to making of cable for plaeemeni Suitable stands shall be provided to facilitate uncoiling of wire~1strandswithout damage to steel. Care shall be taken to avoid the possibility of steel coming into,contact with the ground. 1804.3. Positioning 1804.3.1. Post-Tensioning Prestressing tendons shall be accurately located and maintained in position, both vertically and horizontally, as per drawings. Tendons shall be so arranged that they have a smooth profile without sudden bends or kinks. The locationing of prestressed cables shall be such as to facilitate easy placement and vibration of concrete in between the tendons. High capacity tendon shall be used to reduce the number of cables thereby eliminating the necessity of grouping. The selected profiles of the tendons shall be such that theic anchorages are not located in the top deck surface. Where two or more rows of cables have to be used, the cables shalt be vertically in line to enable easy flow of concrete. The clear vertical and horizontal distances between any two cables shall in no case be less than 100mm anywhere along the length of the superstructure. .Where precast segments are used, the clear distance shall be at least 150 mm. Sheathing shall be placed in correct position and profile by providing suitable ladders and spacers. Such ladders may be provided a. ~ntervals approximately 1.0 m. Sheathing shall be tied rigidly of with such ladders/spacer bars so that they do not get disturbed during concreting. The method of supporting and fixing shall be such that profile of cables is not disturbed during vibrations, by pressure of wet concrete, by workmen or by construction traffic. Sheathing in which the permanent tendon will not be in place during concreting shall have a temporary tendon inserted or shall be stiffened by some other method to the approval of the Engineer. The temporary tendon shall be pulled out before threading the permanent tendon into place by a special threading machine or other contrivance. Where possible tendons shalt not be placed until immediately
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Section 1800
prior to stressing. Tendons shall be handled with care to avoid damage or contaminatiqn, to either the tendon or the sheathing. Any tendons damaged or contaminated shall be cleaned or replaced. 1804.3.2. Pre-Tensioning. Prestressing steel shall be accurately located and maintained in position, both vertically and horizontally, as per drawings. 1804.3.3. Each anchorage device shall be set square to the line of action of the corresponding prestressing tendon and shall be positioned securely to prevent movement during concreting. The anchorage devices shall be c!eaned to the satisfaction of the Engineer prior to the placing of concrete. After concreting, any mortar or concrete which adheres to bearing or wedging surfaces, shall be removed immediately. 1804.4. Cutting Cutting and trimming of wires or strands shall be done by suitable mechanical or Ilame cutters. When a flame cutter is used, care shall he taken to ensure that the Ilame does not come in contact with other stressed steel. The location of flame cutting of wire or strand shall be kept beyond 75 mm of where the tendon will be gripped by the anchorage or jacks. In post-tensioning the ends of prestressing steel projecting beyond the anchorages, shall be cut after the grout has set, 1804.5. Pnitection of Prestressing Steel Prestressing steel shall be continuously protected against corrosion, until grouted. The corrosion protector shall have no deleterious effect on the steel or concrete or, on the bond strength of steel to concrete. (Jrouting shall conform to these specifications or as directed by the Engineer. In the case of external prestressing, steel shall be encased in suitable polyethelene pipes before grouting. 1804.6. Sheathing ihe joints of all sheathings shall he. water-tight. Special attention shall be paid to the junction at the anchorage end, where the sheathing must~tightly fit on the protruding trumpet end of anchorage and thereafler sealed preferably with heat shrink tape, to make it waterproof.
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Section 1800
Prestressing
The heat-shrink tape is supplied in the form of bandage rolls which can be used for all diameters of sheathing ducts. The bandage is coated on the underside with a heat sensitive adhesive so that after heating the bandage material shrinks on the sheathing duct and ensures fonnation of a leak-proof joint. The heating is effected by means of a soft gas flame. A sheath making machine should be positioned at the site of work for large projects so that sheathing can be prepared as and when it is required for construction. The sheathing and all joints shall be water tight. Any temporary opening in the sheathing shall be satisfactorily plugged and all joints between sheathing and any other part of the piestressing system shall be e.fiectively sealed to prevent entry of mortar, dust, water or other deleterious matter. Sheathing shall be neatly fitted at joints without internal projection or reduction of diameter.
Enlarged portions of the sheathing at couplings or anchorages
shall be of sufficient tength to provide for the extension of the tendons. 1804.7. Grout Vents Groi~t vents of at least 20 mm diameter shall be provided at both ends of the sheathing and at all valleys and crests along its length. Additional vents with plugs shall also be provded along the length of sheathing such that the spacings of consecutive vents do not exceed 21) rn. Each of the grout vents shall be provided with a plug or similar device capable of withstanding a pressure Of 1.0 MPa without
the loss of water, air pressure or grout.
1804.8
Anchorages
All bearing surflices of the anchorages shall be cleaned prior to concretmg and tensioning. Anchor cones, blocks and plates shall he securely positioned and maintained during concreting such that the centre line of the duct passes axially through the anchorage assembly. The~ anchorages shall he recessed from the concrete surface by a minimum cover of 11)1) mm. After the prestressing operations are completed and prestressing wires/strands are cuL, the surface shall he painted with two coats of epoxy of suitable formulation having a dry film thickness of 80
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Prcstressing
Section 1800
microns per coat and entire recess shall be filled with concrete or non-shrink/pre-packaged mortar or epoxy concrete. 1804.9. Structural Concrete Structural concrete shall conform to Section 1700. The formwomk shall conform to Section 1500. \/t8O5. SUPERVISION Al! prestressing and grouting operations shall be undertaken by trained personnel only. A representative of supplier of the prestressing system shall be present during all tensioning and grouting operations and shall ensure, monitor and certify their correctness. TENSIONING EQUiPMENT All tensioning equipment shall be procured from authorised manufacturers only and be approved by the Engineer prior to use. Where hydraulic jacks are used, they shall be power-driven unless otherwise approved by the Engineer. The tensioning equipment shalt satisfy the following requirements
(i) (ii) The means of attachments of the prestressing steet tensioning apparatus shalt be safe and secure. to the jack or any other
~fl.
Where two or more wires/strands constitute a tendon, a single multipill stressing jack shalt be used which is capable of tensioning simulsaneou sty atl the wi reel strands of the tendon. Suitable facilities for handling and attaching the multi~ putt jack to the tendons shalt be provided. The tensioning equipment shalt be such that it can apply controtted total force gradually on the concrete without inducing dangerous tecondary stresses in steel, anchorage or concrete; and
(iii)
(iv) Means shalt be provided for direct measurement of the force by use of dynamo~ meters or pressure gauges fined in the hydraulic system itself to determine the pressure in the jacks. Facilities shalt also be provided for the tinear measurement of the extension of prestressing steel to the nearest mm and of any slip of the gripping devices at trai~sfer.
All dynamo meters and pressure gauges including a master gauge shall be calibrated by an approved laboratory immediately prior to use and then at intervals not exceeding 3 months and the true force determined from the calibration curve. Pressure gauges shall be concentric scale type gauges accurate to within two per cent of their full capacity. The minimum nominal size of gauge shall be 100 mm. The gauge shall be so selected that when the tendon is stressed to 75 per cent of its breaking load, the gauge is reading between 50 per cent and 80 per cent of its full capacity.
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Section t800
Prestressing
Suitable safety devices shall be fitted to protect pressure gauges against sudden release of pressure. Provision shall be made for the attachment of the master gauge to be used as a check whenever requested for by the Engineer. POST-TENSiONING Tensioning force shall be applied in gradual and steady steps and carried out in such a manner that the applied tensions and elongations can be nieasured at all times. The sequence of stressing, applied tensions and elongations shall be in accordance with the approved drawing or as directed by the Engineer. It shall be ensured that in no case, the load is applied to the concrete before it attains the strength specified on the drawing or as stipulated by the preStressing system supplier, whichever is more. After prestressing steel has been anchored, the force exerted by the tensioning equipment shall be decreased gradually and steadily so as to avoid shock to the prestressing steel or 2nchorage. The tensioning force applied to any tendon shall be determined by direct reading of the pressure gauges or dynamo-meters and by comparison of the measured elongation with the calculated elongation. The calculated elongation shall be invariably adjusted with respect to the modulus of elasticity of steel for the particular lot as given by the manufacturer. The difference between calculated and observed tension and elongation during prestressing operations shall be regulated as follows:
a) tf the calculated elongation is reached before the specified gauge pressure is obtained, continue tensioning titt attaining the specified gauge pressure, provided the elongation does not exceed t .05 times the catculated elongation. If 1.05 times the catculated elongation is reached before the specified gauge pressure it auaincd, stop stressing and inform the Engineer. tf the catcutated elongation has not been reached at the specified gauge pressure, continue tensioning by intervats f 5 kg/sq. c.m. until the calculated elongation is reached provided the gauge pressure does not exceed 1.05 times the specified gauge pressure. tf the otongation at 1.05 times the specified gauge pressure is less than 0.95 times the calculated elongation, the following measures must be taken, in succession, to determine the cause of this lack of discrepancy i) ii) Check the correct functioning of the acit, pump and teada.
b)
c)
Desension the cable. Slide it in its duct to check that it is not blocked by 446
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Prestressing mortar which has entered through holes in if free. iii)
Section 1800
the sheath. Retension the cable
Re establish the modulus of elasticity of steel for the particular lot from an approved laboratory.
If the required elongation is still not obtained, further finishing operations such as cutting or sealing, should not be undertaken without the approsal of the Engineer. d) When stressing from one end only, the slip at the end remote from the jack shall be accurately measured and an appropriate allowance made in the measured extension at the jacking end.
A complete record of prestressing operations along with elongation and jack pressure data shall be maintained in the format given in Appendix /800/Ii. The number of stages of prestressing and grouting shall be reduced to a minimum, preferably 2 in the case of simply supported girders. ~ GROUTING OF PRESTRESSED TENDONS Grouting shall conform to Appendix 1800/I!!. A record of grouting operations shall be maintained in the format given in Appendix 1800/ IV. 1809. PRE-TENSIONJNG 1809,1. General The planning and construction aspects of the tensioning bed, tensioning bench, abutments at location of anchorage, steam curing system, formwork of the concrete elements and arrangements for demoulding, lifting, stacking and transportation of the pre-tensioned concrete elements are all specialised items and shall be entrusted to engineers specifically experienced in this type of work. 1809.2. Stressing Bed for Pre-tensioning The abutments and bed for pre-tensioning of tendons shall be designed to withstand the total tensioning force. A notice shall be displayed adjacent to the stressing bed showing the maximum tensioning force permitted. Where concrete elements are cast and prestressed individually, the stressing bench or moulds shall be rigid enough to sustain the reaction of the prestressing force without distortion. In the long line method of prestressing, sufficient locator plates should be distributed throughout the length of the bed to ensure that
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Section 1800
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the wires are maintained in their proper position during concreting. The moulds shall be free to slide in the direction of their length and thus permit the transfer of the prestressing force to alt the concrete elements along the whole line. Sufficient space shall be left in between the ends of concrete elements to permit access for cutting the strands/wires after transfer. Holddowns or deflectors shalt be used for holding or deflecting the tendons in required position firmly. Deflectors which are in contact with the tendon shall have a diameter not less than the tendon or 15 mm, whichever is greater. The tensioning force required to be applied as stated on the drawings shalt be the force remaining in the strands/wires after all strands/wires have been inchored to the abutments of the stressing bed and after the anchorage slip has already taken place. The tensioning force shall be determined by direct reading of the pressure gauges or dynamo-meters and by the measured elongation after slip. The Contractor shall submit method of tensioning the tendons including the arrangement and layout of prestressing beds and all tendon deflection points to the Engineer for approval before manufacture commences. lhe Contractor shall carry out trial stressing operations to establish the frictional resistance offered by the hold-downs and the slip during anchoring. Where sheathing of pre-tensioned tendons is required to prevent bond over a specified length, it shall consist of plastic tubing or other material approved by the Engineer and shall be of a quality, diameter and thickness such that bond shall be effectively prevented. The tubing shall be fastened to the tendon in such a manner that cement mortar cannot enter. The Engineer may order that the pull-in of the tendon be measured during the transfer of prestress. The Contractor shall also submit calculations showing that the holddowns have been designed and constructed to withstand concentrated loads resulting from the application of the tensioning force. 1809.3, Tensioning Procedure The tensioning of the wires and strands shall be done not too much in advance of concreting. The tensioning force shall be applied gradually and uniformly.
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In order to remove slack and to lift tendons off the bed floor, an initial force approved by the Engineer shall be applied to the tendons. Allowance shall be made for this force in calculating the required elongation. Tendons shall be marked for measurement of elongation after the initial force has been applied. When required by the Engineer, tendons shall be marked at both the jacking end and dead end of the stressing bed and at couplers if used so that slip and draw-in may be measured. Where deflected strands have been specified, the Engineer may direct the elongation or strain gauge measurements be taken at various positions along the tendon to determine the force in the tendon at those positions. 1809,4. Transfer of Prestress While the process of tensioning can be accomplished by means of hydraulic jacks, some positive mechanical means shall be provided to maintain the tension during the entire period between the tensioning of the wires/strands and transfer of the prestressing force to the concrete element. Transfer of prestress shall not proceed until the Engineer has approved the proposed method. Tendons and deflection devices shall be released in such a pre-determined order that unacceptable tensile stresses are not induced in the concrete. Prior to transfer of the force to the units, all tendons shall be tested for tightness and any loose tendon shall be reported to the Engineer who will decide whether the ti1~itsaffected shall be rejected. The Engineer may require that tendons be marked at each end of any unit to allow measurement of the pull-in of the concrete. Tendons shall be released gradually and preferably simultaneously. Under no circumstances shall tendons be cut while under ten~ on. On completion of the transfer of prestress, the projecting lengths of tendon shall be cut off flush with the end surface of the unit, unless otherwise shown, by a method approved by the Engineer. In no case shall the transfer of prestressing force to the concrete elements take place before concrete attains the strength specified in the drawings. To determine the specified strength, additional cube testing shall be undertaken at the Contractors cost. In case steam curing is employed, the cubes shall be pLaced in the same environment as the
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Section 1800
Prestressing
concrete elements to obtain an accurate assessment of concrete strength at the time of transfer. The sequence of transfer of prestressing force shall be done strictly as indicated in the drawings and ensuring that eccentricities of the prestressing force in the vertical and horizontal directions of the concrete element is a minimum during the entire sequence. The maximum slip of any tendon during transfer shall not exceed 3 mm at any end of the concrete element. In case this slip is exceeded, the concrete element in question shalt be rejected. 1809.5. Protection of Ends The exposed ends of the tendons and the concrete surfaces of the ends of the units shall be wire brushed clean of alt rust, loose mortar, grease and dirt. The exposed ends of the tendons and concrete surface within 50 mm of tendons shalt be then abraded to provide a clean sound surface. An epoxy tar paint suitably formulated to give a dry film thickness of 80 microns per coat shalt then be immediately applied over the ends of the tendons unless otherwise directed. A second coat of paint shalt be applied prior to the drying out of the first coat. ifl SAFETY PRECAUTIONS DURING TENSIONING ~dare shalt be taken during tensioning toensure the safety of all persons in the vicinity. Jacks shall be secured in such a manner that they will be held in position, should they lose their grip on the tendons. No person shall be allowed to stand behind the jacks or close to the line of the tendons white tensioning is in progress. The operations of the jacks and the measurement of the elongation and associated operations shall be carried out in such a manner and from such a position that the safety of all concerned is ensured. A safety barrier shall be provided at both ends to prevent any tendon, which might become loose from recoiling unchecked. During actual tensioning operation, warning sign shall be displayed at both ends of the tendon, After prestressing, concrete shall neither be drilled nor any portion
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Prestressing
Section 1800
cut nor chipped away nor disturbed, without express approvat of the Engineer. No welding shall be permitted on or near tendons nor shall any heat be applied to tendons. Any tendon which has been affected by welding, weld spatter or heat shall be rejected. AND STORAGE OF UNITS Precast girders shall be transported in an upright position. Points of support and the direction of reactions with respect to the girder shall approximately be the same during transportation, and storage as when the girder is placed in final position. When members are to be stacked, they shall be firmly supported at such bearing positions as will ensure that the stresses induced th them are always less than the permissible design stresses. Further, inclined side supports shall be provided at the ends and along the length of a precast girder to prevent lateral movements or instability. Care shall be taken during storage, hoisting and handling of the piecast units to prevent their cracking or being damaged. Units damaged by improper storing or handling shall be replaced by the Contractor at his expense.
ipt: TRANSPORTATION
N A~12. TOLERANCES
Permissible tolerances for positional deviation of Prestressing tendons shalt be limited to the following
a) h) c) Variation 1mm the specified horizontal profite Variation 1mm the specified vertical pmfile Variation 1mm the specified position in member
5 mm
5 mm 5 mm
$13, TESTS AND STANDARDS OF ACCEPTANCE ~the materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria, The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. \$4. MEASUREMENTS, FOR PAYMENT Prestressed Concrete shall be measured in cubic metres. The volume occupied by mild steel reinforcement /HYSD bars, high tensite steel, sheathing and anchorages shall not be deducted. High tensile (prestressing) steel shall be paid for separately and its length shall be measured as actually !icorporated in the finished work.
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451
Section 1800
Prestressing
From the length so measured its weight shall be calculated in tonnes on theoretical basis and paid for. Anchorage devices, additional length of cables for attaching jack, ducts or sheathing, grout, non-prestressed steel reinforcement fixed to the anchorage devices, making of recesses and filling the same, protection by painting with epoxy and furnishing samples for testing shall all be deemed to be included in the item of high tensile steel and shall not be measured separately. RATE The contract unit rate for cast-in-place prestressed concrete shall cover the cost of all materials, labour, tools and plant required for mixing, placing in position, vibrating and compacting, finishing as per directions of the Engineer, curing and other incidental expenses for producing concrete of specified strength to complete the structure or its components as shown on the drawings and according to specifications. The contract unit rate shall also include the cost of making, fixing and removing of all centring and forms required for the work unless otherwise specified in the Contract. For precast prestressed concrete members, the rate in addition to above shall also include the cost of all materials, labour, tools and plant required to transport and place these members in their final position as shown on the drawings and as directed by the Engineer. The cdntract unit rate for high tensile steel shall cover the cost of material, labour, tools and plant required for manufacturing, placing, tensioning, anchoring and grouting the high tensile steel in the prestressed concrete as shown on the drawings and as per specifications herein above or as directed by the Engineer. The cost of anchorage devices, additional length of cables for attaching jack, ducts or sheathing, grout, non-prestressed steel reinforcement fixed to the anchorage devices, making of recesses and filling the s~me, rotection by painting with epoxy and furnishing samples for testing p shall all be included in the unit rate: Rate shall also include payments if any to be made to the supplier of the prestressing system who has to monitor, ensure and certify the correctness of all operations.
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Structural Steel
1900 Structural Steel
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Structural Steel 1901. DESCRIFFION
Section 1900
This work shall include furnishing, fabricating, transporting, erecting and painting structural steel, rivet steel, cast steel, steet forgings, cast iron and other incidental metal construction of the kind, size and quantity in conformity with the drawings and these specifications or as desired by the Engineer. 1902. GENERAL General requirements relating to the supply of material shall conform to the specifications of IS:1387, for the purpose of which the supplier shall be the Contractor and the purchaser shall be the Engineer. Finished rolled material shall be free from cracks, flaws, injurious seams, laps, blisters, ragged and imperfect edges and other defects. It shall have a smooth and uniform finish, and shall be straightened in the mill before shipment. They shall also be free from loose mill scale, rust, pits or other defects affecting its strength and durability. The acceptance of any material on inspection at the mill i.e. rolling mills, foundry or fabricating plant where material for the work is manufactured, shall not be a bar to its subsequent rejection, if found defective. Unless specified otherwise, high tensile steel rivet conforming to IS: 1149 shall be used for members of high tensile steel conforming to 15:961 and shall not be used for mild steel members. Unless specified otherwise, bolted connection of structural joints using high tensile friction grip bolts shall comply with requirements of 15:4000. Cast iron shall not be used in any portion of the bridge structure, except where it is subject to direct compression. 1903. MATERIALS 1903.1. All materials shall conform to Section 1000. Special requirements are given below Mild steel for bolts and nuts shall conform to 15:226 but have a minimum tensile strength of 44 kg/sq. mm. and minimum percentage elongation of 14. High tensile steel for bolts and nuts shall conform to IS:961 but with a minimum tensile strength of 58 kg/sq. mm. High strength friction grip bolts shall be permitted for use only on satisfactory
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Section 1900
Structural
Steel
evidence of performance to the requirements (not covered by these specifications) specified by the Engineer or included in the special provisions. For cast steel, the yield stress shall be determined and shall not be less than 50 per cent of the minimum tensile strength. Plain washers shall be of steel. Tapered or other specially shaped washers shall be of steel, or malleable cast iron. Parallel barrel drifts shall have a tensile strength not less than 55 kg/sq.mm. with elongation of not less than 20 per cent measured on a gauge length of 44So (So = cross sectional!! area). 1903.2. Materials for castings and forgings, fasteners and welding consumables shall be as under 1903.2.1. Castings and Forgings : Steel castings and forgings shall comply with the requirements of the following Indian Standards, as appropriate IS: 1030 Carbon Steel Castings for General Engineering purposes IS:1875 Carbon Steel Billets, blooms, slabs, bars for forgings IS:2004 Carbon Steel Forgings for General Engineering purposes IS:2644 High Tensile Steel Casings lS:4367 Alloy & tool steel forgings for general industrial use 1903,2.2. Fasteners : Bolts, nuts, washers and rivets shall comply with the following or relevant IS Standards as appropriate IS: 1929 Hot forged steel rivets for hot closing (12-36mm dia) IS:2l55 IS:1363 Cold forged steel rivets for hot closing (6-16mm dia) Hexagon head bolts, screw and nuts product grade C
IS:1364 Hexagon head bolts, screw & nuts product grade A & B IS: 1367 Technical supply conditions for threaded steel fastener (Parts 1 to 18) IS:3640 IS:3757 IS:6623 IS:6639 IS:5624 Hexagon fit bolts High tensile friction grip bolts High strength structural nuts Hexagon bolts for steel structure Foundation bolts 456
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Structural Steel IS:7002 IS:5369 IS:5370 IS:5372 IS:5374 ES:6610 IS:6649
Section 1900 Prevailing torque type steel hexagon lock nuts Plain washers and lock washers general requirements Plain washers with outside dia = 3 X inside dia
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Taper washers for channels (ISMC) Taper Washers for I beams (ISMB)
Heavy washers for steeL structures Hardened and tempered washers for high strength structural bolts and nuts 1903.2.3. Welding consumables Welding consumables Shall comply with the following Indian Standards as appropriate IS:814 Covered Electrodes for Metal Arc Welding of structural (Part 1) steel for welding other than sheets IS:8 14 For welding Sheets (Pail 2) IS: 1278 Filler rods and wires for gas welding IS: 1395 Low and medium alloy Steel covered electrodes for manual Metal Arc Welding IS:36l3 Acceptance Tests for wire flux combinations for submerged arc welding of structural steel IS:7280 Bare wire electrodes for gas shielded arc welding of structural steel 15:6419 Welding rods and bare electrodes for gas shielded arc welding of structural steel IS:6560 Molybdenum and chromium-molybdenum low alloy steel welding rods and bare electrodes for gas shielded arc welding
1903.3. In aggressive environment, corrosion resistant steel can be used. These are low-alloyed steels containing a total of 1 per cent 2 per cent alloys, in particular, copper, chromium, nickel and phosphorous.
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1903.4. Paints
All materials for paints and enamels shall conform to the requiremetns specified on the drawings or other special provisions laid down by the Engineer.
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Section
1900
Structural Steel
The type of paints which can be used shall be as follows

a) Ordinary i.e. pants based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy I,) c) d) e)

1) g) Chanical Resistant before use).
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one pack type (ready for use) and two pack type (mixed
Vinyl
Chlorinaied rubber Bituminous Epoxy Polyurethane
h)
Zinc rich
Unless otherwise specified, paints shall conform to the relevant IS specifications. The paints which have been tested for the following qualities as per specifications given in the relevant IS codes only shall be used
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Weight test (weight for 10 litre of paint, thoroughly mixed) Drying time Consistency Dry thickness and rate of consulnl*ion.
1904. FABRICATION 1904.1. General All work shall be in accordance with the drawings and as per these specifications with care being taken that all parts of an assembly fit accurately together. All members shall carry mark number and item number and, if required, serial number. Unless specifically required under the contract, corresponding parts need not be interchangeable, but the parts shall be match marked as required under Clause 1904.7. Templates, jigs and other appliances used for ensuring the accuracy of the work shall be of mild steel; where specially required, these shall be bushed with hard steel. All measurements shall be made by means of steel tape or other device properly calibrated. Where bridge materials have been used as templates for drilling, these shall be inspected and passed by the Engineer before they are used in the finished structure. All structural steel members and parts shall have straight edges and blunt surfaces. If necessary, they shall be straightened or flattened by
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Structural
Steel
Section
1900
pressure unless they are required to be of curvilinear forms. They shall also be free from twist. Pressure applied for straightening or flattening shall be such as would not injure the materials. Hammering shall not be permitted. Adjacent surfaces or edges shall be in close contact or at uniform distance throughout. The Contractor shall submit his programme of work to the Engineer for his approval at least 15 days before the commencement of fabrication. This programme shall include the proposed system of identification and erection marks together with complete details of fabrication and welding procedures. The Contractor shall prepare shop drawings for fabricating any member and obtain approval of the Engineer before the start of work. Complete information regarding the location, type, size and extent of all welds shall be clearly shown on the shop drawings. These drawings shall distinguish between shop and field welds. 1904.2. Preparation of Edges and Ends All structural steel-parts, where required, shall be sheared, cropped, sawn or flame cut and ground accurately to the required dimension and shape. End/edge planing and cutting shall be done by any one of the following prescribed methods or left as rolled
a) b) Shearing, cropping, sawing 1 machining, machine flame cutting. to a smooth edge. Hand flame cutting with subsequent grinding
c)
Sheared edges of plate not more than 16 mm thick with subsequent grinding th smooth profile, which are for secondary use such as ssiffeners and gussets.
If ends of stiffeners are required to be fitted, they shall be ground, so that the maximum gap over 60 per cent of the contact area does not exceed 0.25 mm. Where flame cutting or shearing is used, at least one of the following requirements shall be satisfied.
a)
b) c)
The cut edge is not subjected to applied stress.

The edge is incorporated in weld. The hantness of cut edge does not exceed 350
HV30.
d)
e)
The material is removed from edge to the extent of 2 mm or minimum necessary, so that the hardness is less than 350 HV 30.
Edge is suitably heat treated by approved method to the satisfaction of the Engineer and shown that cracks had not developed by dye penetrant or magnetic particle test. 459
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Section 1900 f)
Structural Steel
Thickness of plate is less than 40 mm for machine flame cutting for snateriak confomiing to l&226 and IS:2062, The requirement of hardness below 350 IN 30 of flame cur edges thould be specified by the Engineer.
Wherever specified by the Engineer, the flame cut edges shall be ground or machined over and above the requirement (a) to (1). Where machining for edge preparation in butt joint is specified, the ends shall be machined after the members have been fabricated. Outside edges of plate and section, which are prone to corrosion shall be smoothed by grinding or filing. In the case of high tensile steel at least 6 mm of the material from the flame cut edge shall be removed by machining. Longitudinal edges of all plates and cover plates in plate girders and buiIt.~up members shall be machined except in the following cases
a) b) c) d) e) Rolled edges of single universal plates or flats may nor be machined. Covers to single flange pktes may be left unmachined. Machine flame cutting instead of machining is acce~ablefor edges of single plates in compression and for edges of single plates, 25 mm or less thick, in tension. Edges of ~ingte shaped plates over 25 mm thick not capable of being machined by ordinary method may be machine flame cut and the and surface ground. Edges of universal plates or flats of the same nominal width used in tiers may be left unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12 mm thick and over shall be machined and those less than 12 mm thick may be sheared and ground. The ends of plates and sections forming the main components of plate girders or of built~up members shall be machined, machine flame cut, sawn or hand flame cut and ground. Where ends of stiffeners are required to be fitted, they shall be machined, machine flame cut, sawn, sbeared and ground, or hand flame cut and ground. The ends of lacing bar shall be rounded unless otherwise required. Other edges and ends of mild steel parts may be sheared and any burrs at edges shall be removed. 1904.3. Preparation of Boles 1904,3.1. Drilling and punching Holes for rivets, black bolts, high. strength bolts and countersunk bolts/rivets (excluding close tolerance and turn fined bolts) shall be either punched or drilled. The diameter
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Structural Steel
Section 1900
of holes shall be 1.5 mm larger for bolts/rivets less than 25 mm dia and 2.0 mm., for more than or equal to 25 mm. All holes shall be drilled except for secondary members such as, floor plate, hand rails etc. Members which do not carry the main load can be punched subject to the thickness of member not exceeding 12 mm for material conforming to lS:226. Holes through more than one thickness of material or when any of the main material thickness exceeds 20 mm for steel conforming to lS:2062 or 16 mm for steel conforming to IS:961, IS:8500, shall either be sub-drilled or sub-punched to a diameter of 3 mm less than the required size and then reamed to the required size. The reaming of material more than one thickness shall be done after assembly. Where several plates or sections form a compound member, they shall, where practicable, be firmly connected together by clamps or tacking bolts, and the holes be drilled through the group in one operation. Alternatively, and in the case of repetition work, the plates and sections may be drilled separately from jigs and templates. Jigs and templates shall be checked at least once after every 25 operations. All burrs shall be removed. In the case of repetition of spans, the erection of every span shall not be insisted upon, except where close tolerance or turned bolts are used, provided that methods are adopted to ensure strict interchangeability. In such cases, one span in ten or any number less than ten of each type shall be erected from pieces selected at random by the Engineer and should there be any failure of the pieces to fit, all similar spans shall be erected complete. In the event of spans being proved completely interchangeable, all corresponding parts shall carry the same mark so that sorting of the materials at site is facilitated. 1904.3.2. Block drilling : Where the number of plates to be riveted exceeds three or the total thickness is 90 mm or more, the rivet holes, unless they have been drilled through steel bushed jigs, shall be drilled out in place 3 mm all round after assembling. In such cases, the work shall be thoroughly bolted together. 1904.3.3. Size of holes: The sizes of holes in millimetres are given in Table 1900-i below:
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Sec lion 1900 TABLE 1900-i
Structural Steel
DtAMVFER OF HOLES FOR RIVV1S ma of Holes (mm) 13.5 15.5 17.5 19.5 21.5 23.5 25.5 29.0 32.0 35.0
Nozninaldia of Rivets (mm)

12 14 16 18 20 22 24 27 30 33
1904.3.4. Close tolerance bolts and barrel bolts : Holes for close. tolerance and turn fitted bolts. The diameter of the holes shall be equal to the nominal diameter of the bolt shank minus 0.15 mm to 0.0 mm. The members to be connected with close tolerance or tum fitted bolts shall be firmly held together by service bolts or clamped and drilled through all thicknesses in one operation and subsequently reamed to required size within specified limit of accuracy as specified in 15:919 tolerance grade H8. The holes not drilled through all thicknesses at one operation shall be drilled to smaller size and reamed after assembly. 1904.3.5, Holes for high strength friction grip bolts : All holes shall be drilled after removal of burrs. Where the number ofplies in the grip does not exceed three, the diameters of holes shall be 1.6 mm larger than those of bolts and for more than three plies in grip, the diameters of hole in outer plies shall be as above and dia of holes in inner plies shall not be less than 1.6 mm and not more than 3.2 mm larger than those in bolts, unless otherwise specified by the Engineer. 1904.3.6. Removal of burrs : The work shall be taken apart after drilling and all burrs left by drilling and the sharp edges of all rivet holes completely removed. 1904.4. Rivet and Riveting The diameter of rivets shown on the drawings shall be the size before heating. Each rivet shall be of sufficient length to form a head of the standard dimensions as given in IS handbook on Steel Sections, Part I. It shall be free from burrs on the underside of the head.
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Structural Steel
Section 1900
When countersunk heads are required, the heads shall fill the countersunk. The included angle of the head shall be as follows a) For plates over 14 mm thickness 90 degrees
b) For plates upto and including 14 mm thickness 120 degrees
The tolerance on the diameter of rivets shall be in accordance with IS: 1148 and IS: 1149 for mild steel rivets and high tensile steel rivets respectively and unless otherwise specified, the tolerance shall be minus tolerance. Rivets shall be driven when hot so as to fill the hole as completely as possible and shall be of sufficient length to form a head of standard dimension. When counter-sunk head is required, the head shall fill the counter-sunk hole. Projection after counter-sinking shall be ground off wherever necessary. Rivets shall be heated uniformly to a light cherry red colour between 650 degrees Celsius to 700 degrees Celsius for hydraulic riveting and orange colour for pneumatic riveting of mild steel rivets and shall be red hot from head to the point when inserted and shall be upset in its entire length so as to fill the hole as completely as possible when hot. Rivets, after being heated and before being inserted in the hole shall be made free from scale by striking the hot rivet on a hard surface. Wherever possible, the rivets shall be machine driven, preferably by direct acting riveters. The driving pressure shall be maintained on the rivets for a short time after the upsetting is completed. High tensile steel rivets shall be heated upto 1100 degrees Celsius. Any rivet whose point is heated more than prescribed, shall not be driven. Where flush surface is required, any projecting metal shall be chipped or ground off. Before riveting is commenced, all work shall be properly bolte up so that the various sections and plates are in close contact throughout. Drifts shall only be used for drawing the work into position and shall not be used to such an extent as to distort the holes. Drifts of a larger size than the nominal diameter of the hole shall not be used. The riveting shall be done by hydraulic or pneumatic machine unless otherwise specified by the Engineer. Driven rivets, when struck sharply on the head by a quarter pound rivet testing hammer, shall be free from movement and vibrations. Assembled riveted joint surfaces, including those adjacent to the rivet
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Section 1900
Structural Steel
heads, shall be free from scale, dirt, loose scale, burrs, other foreign materials and defects that would prevent solid seating of parts. All loose or burnt rivets and rivets with cracked or badly formed defective heads or with heads which are unduly eccentric with the shanks, shall be removed and replaced. In removing rivets, the head shall be sheared off and the rivet punched out SO as not to injure the adjacent metal and, if necessary, they shall be drilled out. Recupping or recaulking shall not be permitted. The parts not completely riveted in the shop shall be secured by bolts to preventdamage during transport and handling. 1904.5. Bolts, Nuts and Washers 1904.5.1. Black bolts (black all over) : Black bolts are forged bolts in which the shanks, heads and nuts do not receive any further treatment except cutting of screw threads. They shall be true to shape and size and shall have the standard dimensions as shown on the drawings, 1904.5.2. Close tolerance bolts : Close tolerance bolts shall be faced under the head and turned on the shank. 1904.5.3. Turned barrel bolts: The diameter of the screwed portion of turned barrel bolts shall be 1.5 mm smaller than the diameter of the barrel unless otherwise specified by the Engineer. The diameter of the bolts as given on the drawing shall be the nominal diameter of the barrel. The length of the barrel shall be such that it bears fully on all the parts connected. The threaded portion of each bolt shall project through the nut by at least one thread. Faces of heads and nuts bearing on steel work shall be machined. 1904.5.4. High strength friction bolts and bolted connections: The general requirement shall be as per relevant IS specifications mentioned in clause 5.3 of (Fasteners) of IRC:24. Unless otherwise specified by the Engineer, bolted connections of structural joints using high tensile friction grip bolts shall comply with requirements mentioned in IS:4000. 1904.5.5. Washers : In all cases where the full bearing area of the bolt is to be developed, the bolt shall be provided with a steel washer under the nut of sufficient thickness to avoid any threaded portion of the bolt being within the thickness of the parts bolted together and to prevent the nut when screwed up, from bearing on the bolt. For close tolerance or turned barrel bolts, steel washers whose faces give a true bearing shall be provided under the nut. The washer shall have a hole diameter not less than 1.5 mm larger than the barrel and
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Structural Steel
Section 1900
a thickness of not less than 6 mm so that the nut when screwed up, will not bear on the shoulder of the bolt. Taper washers with correct angle of taper shall be provided under all heads and nuts bearing on bevelled surfaces. Spring washers may be used under nuts to prevent slackening of the nuts when excessive vibrations occur. Where the heads or nuts bear on timber, square washers having a length of each side not less than three times the diameter of bolts or round washers having a diameter of 3h/~ times the diameter of bolts and with a thickness not less than one quarter of diameter shall be provided. 1904.5.6. Studs : Ordinary studs may be used for holding parts together, the holes in one of the parts being tapped to take the thread of the stud. Counter-sunk studs may be used for making connections where the surfaces are required to be clear of all obstruction, such as protruding heads of bolts or rivets, studs may also be welded on the steel work in the positions required. 1904.5.7. Service bolts: Service bolts shall have the same clearance as black bolts and where it is required that there should be no movement prior to final riveting, sufficient drifts or close tolerance bolts shall be used to locate the work. 1904.5.8. Tightening bolts: Bolted connection joints with black bolts and high strength bolts shall be inspected for compliance of codal requirements. The Engineer shall observe the installation and tightening of bolts to ensure that correct tightening procedure is used and shall determine that all bolts are tightened. Regardless of tightening method used, tightening of bolts in a joint should commence at the most rigidly fixed or stiffest point and progress towards the free edges, both in initial snugging and in final tightening. The tightness of bolts in connection shall be checked by inspection wrench, which can be torque wrench, power wrench or calibrated wrench. Tightness of 10 per cent bolts, but not less than two bolts, selected at random in each connection shall be checked by applying inspection torque. If no nut or bolt head is turned by this application, connection can be accepted as properly tightened, but if any nut or head has turned all bolts shall be checked and, if necessary, re-tightened. 465
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Section 1900
Structural Steel
1904.5.9. Drifts : The barrel shall be drawn or machined to the required diameter for a length of not less than one diameter over the combined thickness of the metal through which the drifts have to pass. The diameter of the parallel barrel shall be equal to the nominal diameter of the hole subject to a tolerance of +0 mm and 0.125 mm. Both ends of the drift for a length equal to 11/2 times the diameter of the parallel portion of the bar shall be turned down with a taper to a diameter at the end equal to one-half that of parallel portion. 1904.6. Pins and Pin Holes 1904.6.1. Pins : The pins shall be parallel throughout and shall have a smooth surface free from flaws. They shall be of sufficient length to ensure that all parts connected thereby shall have a full bearing on them. Where the ends are threaded, they shall be turned to a smaller diameter at the ends for the thread and shall be provided with a pilot nut, where necessary, to ~protecthe thread when t being drawn t~ place. Pins more than 175 mm in length or diameter shall be forged and annealed. 1904.6.2. Pin holes : Pin holes shall be bored true to gauge, smooth, straight at right angles to the axis of the member and parallel with each other, unless otherwise required. The tolerance in the length of tension members from outside to outside of pin boles and of compression members from inside to inside of pin holes shall be one millimetre. In built-up members, the boring shall be done after the members have been riveted or welded. The specified diameter of the pin hole shall be its minimum diameter. The resulting clearance between the pin and the hole shall not be less than 0.5 mm and not more than 1.0 mm. 1904.7. Shop Erection and Match Marking Before being dispatched, the steel work shall be temporarily erected in the fabrication shop for inspection by the Engineer either wholly or in such portion as the Engineer may require so that he may be satisfied both in respect of the alignment and fit of all connections. For this purpose, sufficient number of parallel drifts and service bolts tightly screwed up shall be employed. All parts shall fit accurately and be in accordance with drawings and specifications. The steel work shall be temporarily assembled at place of fabrication.
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Structural Steel
Section 1900
Assembly shall be of full truss or girder, unless progressive truss or girder assembly, full chord assembly, progressive chord assembly or special complete structure assembly is specified by the Engineer. The field connections of main members of trusses, arches, continuous beams, spans, bends, plate girders and rigid frame assembled, aligned, accuracy of holes and camber shall be checked by Engineer and then only reaming of sub-size holes to specified size shall be taken up. After the work has been passed by the Engineer and before it is dismantled, each part shall be carefully marked for re-erection with distinguishing marks and stamped with durable markings. Drawings showing these markings correctly shall be supplied to the Engineer. Unloading, handling and storage ~f steel work as per these specifications shall be the responsibility of the Contractor. The cost of repairs or of rejected material, its removal and the cost of transporting replacement material to the site shall be borne by the Contractor. Where close tolerance or turned barrel bolts are used for those cases where interchangeability is not insisted upon, each span shall be erected and members of each span marked distinctly. 1904.8. Welding 1904.8.1. All welding shall be done with the prior approval of the Engineer and the workmanship shall conform to the specifications of IS:823 or other relevant Indian Standards as appropriate. When material thickness is 20 mm or more, special precautions like preheating shall be taken as laid down in IS:823. Surfaces and edges to be welded shall be smooth, uniform and fret from fins, tears, cracks and other discontinuities. Surface shall also be free from loose or thick scale, slag rust, moisture, oil and other foreign materials. Surfaces within 50 mm of any weld location shall be free from any paint or other material that may prevent proper welding or cause objectionable fumes during welding. The general welding procedures including particulars of the preparation of fusion faces for metal arc welding shall be carried out in accordance with IS:9595. The welding procedures for shop and site welds including edge preparation of fusion faces shall be submitted in writing in accordance with Clause 22 of IS :9595 for the approval of the Engineer before commencing fabrication and shall also be as per details shown on the
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467
Section 1900
Structural Steel
drawings. Any deviation from above has to be approved by Engineer. Preparation of edges shall, wherever practicable, be done by machine methods. Machine flame cut edges shall be substantially as smooth and regular as those produced by edge planing and. shall be left free of slag. Manual flame cutting shall be permitted by the Engineer only where machine cutting is not practicable. Electrodes to be used for metal arc welding shall comply with relevant IS specifications mentioned in IRC:24. Procedure test shall be carried out as per IS:8613 to find out suitable wire-flux combination for welded joint. Assembly of parts for welding shall be in accordance with provisions of IS:9595. The welded temporary attachment should be avoided as far as possible, otherwise the method of making any temporary attachment shall be approved by the Engineer. Any scars from temporary attachment shall be removed by cutting, chipping and surface shall be finished smooth by grinding to the satisfaction of the Engineer. Welding shall not be done when the air temperature is less than 10 degrees Celsius. Welding shall not be done when the surfaces are moist, during periods of strong winds or in snowy weather unless the work and the welding operators are adequately protected. 1904.8.2. For welding of any particular type of joint, welders shall qualify to the satisfaction of the Engineer in accordance with appropriate welders qualification test as prescribed in any of the Indian Standards IS:817, IS:1966, IS: 1393, IS:7307 (part I), IS:7310 (Part I) and IS:7318 (part I) as relevant. 1904.8.3. In assembling and joining parts of a structure or of builtup members, the procedure and sequence of welding shall be such as to avoid distortion and minimise shrinkage stress. All requirements regarding pre-heating of parent material and interpass temperature shall be in accordance with provision of IS:9595. 19048.4. Peening of weld shall be carried out wherever specified by the Engineer
a) b) If specified, peening may be employed to be effective on each weld~1ayerexcept first. The peening should be carried out after weld has cooled by light blows from 468
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Structural Steel
Section 1900
a power hammer using a round nose tool. Care shall be taken to prevent scaling or flaking of weld and base metal from over peening.
1904.8.5. Where the Engineer has specified the butt welds are to be ground flush, the loss of parent metal shall not be greater than that allowed for minor surface defects. The ends of butt joints shall be welded so as to provide full throat thickness. This may be done by use of extension pieces, cross runs or other means approved by the Engineer. Extension pieces shall be removed after the joint has cooled and the ends of the weld shall be finished smooth and flush with the faces of the abutting parts. The joints and welds listed below are prohibited type, which do not perform well under cyclic loading.
a) b) c) d) e) f) Butt joints not fully welded throughout their cross-section Groove welds made from one side only without any backing grip Inteimittent groove welds Intermittent fillet welds Bevel-grooves and J-grooves in butt joints for other than horizontal position. Plug and slot welds
1904.8.6. The run-on and run-off plate extension shall be used providing full throat thickness at the end of butt welded joints. These plates shall comply with the following requirements.
(i) One pair of ~run-onand one pair of nm-off plates prepared from same thickness and profile as the parent metal shall be attached to start and finish of all butt welds preferably by clamps. When nm-on and run-off plates shall be removed by flame cutting, it should be rut at more than 3 mm from parent metal and remaining metal shall be removed by grinding or by an~ other method approved by the Engineer.
(ii)
1904.8.7. Welding of stud shear connectors : The stud shear connectors shall be welded in accordance with the manufacturers instructions including preheating. The stud and the surface to which studs are welded shall be free from scale, moisture, rust and other foreign material. The stud base shall not be painted, galvanised or cadmium plated prior to welding. Welding shall not be carried out when temperature is below 10 degrees Celsius or surface is wet or during periods of strong winds unless the work and the welder is adequately protected. The welds shall be visually free from cracks and shall be capable of developing at least the nominal ultimate strength of studs.
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Section 1900
Structural Steel
The procedural trial for welding the stud shall be carried out when specified by the Engineer. 1904.9. Tolerances Tolerances in dimensions of components of fabricated structural steel work shall be specified on the drawings and shall be subject to the approval of the Engineer before fabrication. Unless specified, all parts of an assembly shall fit together accurately within tolerances specified in Table 1900-2. A machined bearing surface, where specified by the Engineer, shall be machined within a deviation of 0.25 mm for surfaces that can be inscribed within a square of side 05 in.
TABLE 1900.2 A. 1. FABRICATION TOLERANCES INDIVIDUAL COMPONENTS Length a) Member with both ends finished for contact bearing b) Individual components of members with end plate conneution c) Other members I) Upto and including 12 M ii) Over 12 M Width Width of built-up girders b) Deviation in the width of members required to be inserted in other members 1 mm
+ 0 mm
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2 mm
2mm 3.5mm
2.
~3 mm +0 mm -3 mm
3.
Depth Deviation in the depths of solid web and open web girders Straightness a) Deviation from streighiness of columns
+3 mm -2 mm
4.
1) ii)
In elevation In plan
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1./3000 subject to a maximsin of 15 mm where L is length of member +5 rum -0mm 111000 subject to a maximum of 10 mm
5.
Deviation of centre line of web from centre line of flanges in built-up members at contart surfaces -
mm
470
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Structural Steel 6. Deviation from flatness of plate of webs of built-up members in a length equal to the depth of the member Tilt of flange of plate girders a) At splices and stiffeners, at supports, at the top flanges of plate girders and at bearings b) at other places
Section 1900 0.005 d to a maximum of 2 mm where d is depth of the member
7.
0.005 b to a minimum of 2 mm where b is width of the member
0.015 b
to a maximum of 4 mm where b is width of the member 111000. where L is nominal length of the diagonal
8,
Deviation from squareness of flange to web of columns and box girders Deviation from squareness of fixed base plate (not machined) to axis of column. This dimension shall be measured parallel to the longitudinal axis of the column at points where the outer surfaces of the column sections make contact with the base plate Deviation from squareness of machined ends to axes of columns Deviation from squareness of machined ends to axes of beams or girder Ends of members abutting at joints through cleats or end plates, permissible deviation from squareness of ends
9.
D/500,
where D is from the column axis to the point under consideration on the base plate
the distance
10.
D/1000, where D is as defined in 9 above D/1000, where D is as defined in 9 above 1/600 of depth of member subject to a maximum of 1.5 mm
11.
12.
1905. ERECTION 1905.1. General The provisions of this item shall apply to erection of steel bridge superstructures or main members of bridge superstructures, composed of steel, which span between supports. If the sub-structure and the superstructure are built under separate contracts, the department will provide the substructure, constructed to correct lines, dimensions and elevations properly finished and will establish the lines and the elevation required for setting steel.
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471
Section 1900
Structural Steel
The Contractor shall erect the structural steel, remove the temporary construction, and do all the work required to complete the construction included in the contract in accordance with the drawings and the specifications and to the entire satisfaction of the Engineer. 1905.2. Organisation and Equipment The Contractor shall submit erection plans prepared by the fabricator, showing a method and procedure of erection, compatible with the details of fabrication. A detailed scheme must be prepared showing stage-wise activities, with complete drawings and working phase-wise instructions. This should be based on detailed stage-wise calculation and take into account specifications and capacity of erection equipment machinery, tools, tackles to be used and temporary working loads as per Coclal provisions. The scheme should be based on site conditions e.g. hydrology, rainfall, flood timings and intensity, soil and sub-soil conditions in the river bed and banks, maximum water depth, temperature and climatic conditions and available working space, etc. The scheme should indicate precisely the type of temporary fasteners to be used as also the minimum percentage of permanent fasteners to be fitted during the stage erection. The working drawings should give clearly the temporary jigs, fixtures, clamps, spacer supports, etc. Unless otherwise provided in the contract, the contractor shall supply and erect all necessary falsework and staging and shall supply all labour, tools, erection plant and other materials necessary to carry out the work complete in all respects. The Contractor shall supply all rivets, bolts, nuts, washers, etc. required to complete erection at site with an allowance for wastage, etc., of 12 1/ per cent of the net number of field rivets, bolts, washers required, or a minimum of five number of each item. Service bolts and nuts, ordinary platters, washers and drifts for use in the erection of work shall be supplied at 60 per cent (45 per cern bolts and 15 per cent drifts) of the number of field rivets per span in each size (this includes wastage). A reduction in the quantities of service bolts, etc., may however, be specified by the Engineer if more than one span of each type is ordered. Prior to actual commencement of erection all equipment, machinery, tools, tackles, ropes, etc. need to be tested to ensure their efficient
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472
Structural Steel
Section 1900
working. Frequent visual inspection is essential in vulnerable areas to detect displacements, distress, drainages, etc. Deflection and vibratory tests shall be conducted in respect of supporting structures, launching truss as also the structure under erection and unusual observations reviewed; looseness of fittings are to be noted. For welded structures, welders qualificatons and skill are to be checked as per standard norms. Non-destructive tests of joints as per designers directives are to be carried out. Precision non-destructive testing instruments available in the market should be used for noting various important parameters of the structures frequently and systematic record is to be kept. Safety requirements should conform to IS:7205, IS :7273 and IS:7269 as applicable and should be a consideration of safety, economy and rapidity. Erection work should start with complete resources mobilised as per latest approved drawings and after a thorough survey of foundations and other related structural work. In case of work of magnitude, maximum mechanisation is to be adopted. The structure should be divided into erectable modules as per the scheme. This should be pre-assembled in a suitable yard/platform and its matching with members of the adjacent module checked by trial assembly before erection. The structure shall be set out to the required lines and levels. The stocks and masses are to be carefully preserved. The steelwork should be erected, adjusted and completed in the required position to the specified line and levels with sufficient drifts and bolts. Packing materials are to be available to maintain this condition. Organised Quality Surveillance checks need to be exercised frequently. Before starting work, the Contractor shall obtain necessary approval of the Engineer as to the method adopted for erection, the nnmber and character of tools and plants. The approval of the Engineer shall not relieve the Contractor of his responsibility for the safety of his method or equipment or from carrying out the work fully in accordance with the drawings and specifications. During the progress of work, the Contractor shall have a competent Engineer or foreman in charge of the work, who shall be adequately experienced in steel erection and acceptable to the Engineer.
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473
Section 1900
Structural Steel
1905.3. Handling and Storing of Materials

Suitable area for storage of structures and components shall be located near the site of work. The access road should be free from water logging during the working period and the storage area should be on levelled and firm ground. The store should be provided with adequate handling equipments e.g road mobile crane, gantries, derricks, chain pulley blocks, winch of capacity as required. Stacking area should be planned and have racks, stands sleeper, access tracks, etc., and properly lighted. Storage should be planned to suit erection work sequence and avoid damage or distortion. Excessively rusted, bent or damaged steel shall be rejected, Methods of storage and handling steel, whether fabricated or not shall be subject to the approval of the Engineer. Fabricated materials are to be stored with erection marks visible, such as not to come into contact with earth surface or water and should be accessible to handling equipment. Small fitting hand tools are to be kept in containers in covered stores. All materials, consumables, including raw steel or fabricated material shall be stored specification-wise and size-wise above the ground upon platforms, skids or other supports. It shall be kept free from dirt and other foreign matter and shall be protected as far as possible from corrosion and distortion. The electrodes shall be stored specificationwise and shall be kept in dry warm condition in properly designed racks. The bolts, nuts, washers and other fasteners shall be stored on racks above the ground with protective oil coating in gunny bags. The paint shall be stored under cover in air-tight containers. IS:7293 and IS:7969 dealing with handling of materials and equipments for safe working should be followed. Safety nuts and bolts as directed are to be used while working. The Contractor shall be held responsible for loss or damage to any material paid for by the Department while in his care or for any damage to such material resulting from his work. 1905.4. Formwork The formwork shall be properly designed, substantially built and maintained for all anticipated loads. The Contractor, if required, shall submit plans for approval to the Engineer. Approval of the plans, however, shall not relieve the Contractor of his responsibility. 474
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Structural Steel
Section 1900
1905.5, Straightening Bent Material The straightening of plates, angles and other shapes shall be done by methods not likely to produce fracture or any injury. The metal shall not be heated unless permitted by the Engineer for special cases, when the heating shall not be to a temperature higher than that producing a dark cherry red colour, followed by as slow cooling as possible. Following the straightening of a bend or buckle the surface shall be carefully investigated for evidence of fracture. Sharp kinks and bends may be the cause for rejection of material. 1905.6. Assembling Steel The parts shall be accurately assembled as shown on the drawings and match marks shall be followed. The material shall be carefully handled so that no parts will be bent, broken or otherwise damaged. Hammering which will injure or distort the members shall not be done. Bearing surface or surfaces to be in permanent contact shall be cleaned, before the members are assembled. The truss spans shall be erected on blocking, so placed as to give the proper camber. The blocking shall be left in place until the tendon chord splices are fully riveted and all other truss connections pinned and bolted. Rivets in splices of butt joints of compression members and rivets in railings shall not be driven until the span has been swung. All joint surface for bolted connections including bolts, nuts,washers shall be free from scale, dirt, burrs, other foreign materials and defects that would prevent solid seating of parts. The slope of surface of bolted parts in contact with bolt head and nut shall not exceed 1 in 20, plane normal to bolt axis, otherwise suitable tapered washer shall be used. All fasteners shall have a washer under nut or bolt head whichever is turned in tightening. Any connection to be riveted or bolted shall be secured in close contact with service bolts or with a sufficient number of permanent bolts before the rivets are driven or before the connections are finally bolted. Joints shall normally be made by filling not less than 50 per cent of holes with service bolts and barrel drifts in the ratio 4:1. The service bolts are to be fully tightened up as soon as the joint is assembled. Connections to be made by close tolerance or barrel bolts shall be completed as soon as practicable after assembly.
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475
Section
1900
Structural Steel
Any connection to be site welded shall be securely held in position by approved methods to ensure accurate alignment, camber and elevation before welding is commenced. The field riveting, welding, bolted and pin connection shall conform to the requirements of Clause l9()4 as appropriate. The correction of minor misfits involving harmless amounts of reaming, cutting and chipping will be considered a legitimate part of erection. However, any error in the shop fabrication or deformation resulting from handling and transportation which prevents proper assembling and fitting up of parts by moderate use of drifts o~ by a moderate amount of reaming and slight chipping or cutting shall be reported immediately to the Engineer and his approval of the method of correction obtained. The correction shall be made in the presence of the Engineer. 1905.7. Field Inspection 1905,7.1. General All materials, equipment and work of erection shall be subject to the inspection of the Engineer who shall be provided with all facilities ~nc!udinglabour and tools required at all reasonable times. Any work found defective is liable to be rejected. 1905.7.2. No protective treatment shall be applied to the work until the appropriate inspection and testing has been carried out. The stage inspection shall be carried out for all operations so as to ensure the correctness of fabrication and good quality. Girder dimensions and camber shall not he finally checked until all welding and heating operations are completed and the member has cooled to a uniform temperature. 1905.7.3, Testing of material : Structural steel shall be tested for mechanical and chemical properties as per various IS codes as may he applicable and shall conform to requirements specified in IS:226, IS:2062, IS:1l587, IS:1977, IS:8500 and IS:961, etc. Rivets, bolts, nuts, washers, welding consumables, steel forging, casting and stainless steel shall be tested for mechanical and chemical properties in the appropriate IS Code. Rolling and cutting tolerance shall be as per lS:1852. The thickness tolerance check measurements for the plate and rolled sections shall be taken at not less than 15 mm from edge.~
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476
Structural
Steel
Section 1900
Laminations in plates shall be carried Out by ultra-sonic testing or any other specified methods. Steel work shall be inspected for surface defects and exposed edge laminations during fabrication and blast cleaning. Significant edge laminations found shall be reported to the Engineer for his decision. Chipping, grinding, machining or ultrasonic testing shall be used to determine depth of imperfection. 1905.7.4. Bolted connections : Bolts and bolted connection joints with high strength friction grip bolts shall be inspected and tested, according to IS:4000. Rivets and riveted connection shall he inspected and tested for compliance of coda! requirements. The firmness of joint shall be checked by 0.2 mm filler gauge, which shall not go inside under the rivet head by more than 3 mm. There shall not be any gap between members to be riveted. Driven rivets shall be checked. with rivet testing hammer. When stnick sharply on head with rivet testing hammer, rivet shall be free from movement and vibration. All loose rivets and rivets with cracks, badly formed or deficient heads or with heads which are eccentric with shanks, shall be cut out and replaced. The alignment of plates at all bolted splice joints and welded butt joints shall be checked for compliance with coda! requirements. Testing of flame cut and sheared edges is to be done, where the hardness criteria given in the code are adopted. Hardness testing shall be carried out on six ~pecimens. 1905.7.5. Welding and welding consumables : Welding procedure, welded connection and testing shall be in compliance with cbdal requirements. All facilities necessary for stage inspection during welding and on completion shall be provided to the Engineer or their inspecting Authority by manufacturer. Adequate means of identification either by identification mark or other record shall be provided to enable each weld to be traced to the welder(s) by whom it was carried out.
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477
Section
1900
Strucunal Steel
All metal arc welding shall be in compliance with IS:9595 provisions. The method of inspection shall be in accordance with IS:822 and extent of inspection and testing shall be in accordance with the relevant standards or in the absence of such a standard, as agreed with the Engineer. Procedure tests The Destructive and Non-Destructive test of weld shall be carried out according to IS:7307 (Part I). Non-Destructive Testing of Welds One or more of the following methods may be applied for inspection or testing of weld
(i) Visual Inspection All welds shall be visually inspected, which should cover all defects of weld such as size, porosity, crack an the weld or in the HAZ (Heat Affected Zone) etc. Suitable magnifying glass may be used for visual inspection. A weld shall be acceptable by visual inspection if it shows that a) b) c) d) e) The weld has no cracks. Through fusion exists between weld and base metal and between adjacent layers of weld metal. Weld profiles are in accordance with requisite clauses of IS:9595 or as agreed with the Engineer The weld shall be of full cross section, except for the ends of intermittent fillet welds outside their effeclive length. When weld is transverse to the primaay stress, undercut shalt not be more than 025 mm deep in the part that is undercut and shall not be more than 0.5 mm deep when the weld is parallel to the primary stress in the part that is undercut. The fillet weld in any single continuous weld shall be permitted to under nan the nominal fillet weld size specified by 1.6 mm without correction provided that undersize ponion of the weld does not exceed 10 per cent of the length of the weld. On the web.to..flange welds on girders, no undernan is permitted at the ends for a length equal to twice the width of the flange. The piping porosity in fillet welds shall not exceed one in each 100 mm of weld length and the maximum diameter shall not exceed 2.4 mm, except for fillet welds connecting ssiffeners to web where the sum of diameters of piping porosity shall not exceed 9.5 mm in any 25 mm length of weld and shall not exceed 19 mm in any 300 man length of weld. The full penetration groove wetd in butt joints transv~rseto the direction of computed tensile stress shall have no piping porosity. For all other groove welds, the piping porosity ~haIi not exceed one in 100 mm of length and the maximum diameter shall not exceed 2.4 mm. 478
1)
g)
h)
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Structural Steel (ii)
Section 1900
Magnetic Particle and Radiographic Inspection: Welds that are subject to radiographic or magnetic particle testing in addition to visual inspection shall have no crack. Magnetic particle test shall be carried out for detection of crack and other discontinuity in the weld according to IS:5334. Radiographic test shall be carried out for detection of intemal flaws in the weld such as crack, piping porosity inclusion, lack of fusion, incomplete penetration, etc. This test mat be carried out as per 15:1182 and 15:4853. Acceptance Criteria The weld shall be unacceptable if radiographic or magnetic particle testing shows any of the type of discontintrities indicated in the code.
(iii) Ultrasonic Inspection : The Ultrasonic testing in addition to visual inspection shall be carried out for detection of internal flaws in the weld such as cracks, piping porosity inclusion, lack of fusion, incomplete penetration, etc. Acceptance criteria shall be as per 15:4260 or any other relevant IS Specification and as agreed to by the Engineer. iv) Liquid Penetration Inspection The liquid penetrant teat shall be carried out for detection of surface defect in the weld, as per 15:3658, in addition to visual inspection. The non-destnjctive testing of following welds be carried out using one of the method or methods described at (ii),(iii) and (iv) above, as may be agreed to by the Engineer. a) b) c) ci) All transverse butt welds in tension flange 10 per cent of the length of longitudinal and transverse butt welds in tension flanges. 5 per cent of the length of longitudinal and transverse butt welds in conspression flanges. All transverse butt welds in webs adjacent to tension flanges as specified by the Engineer.
The particular length of welds in webs to be tested shall be agreed with the Engineer, in case of (b) or (c). Where specified by the Engineer, bearing stiffeners or bearing diaphragms adjacent to welds, flange plates adjacent to web/flange welds, plates at cruciform welds, plates in box girder construction adjacent to corner welds or other details shall be ultrasonically tested after fabrication. Any lamination, lamellar tearing or other defect found shall be recorded and reported to Engineer for his decision. Testing of Welding for Cast Steel The testing of weld for cast steel shall be carried out as may be agreed to by the Engineer. Stud Shear Connectors Stud shear connectors shall be subjected to the following tests
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479
Structural Steel
Section 1900
to the Engineer who will determine whether the component/member may be accepted without rectification, with rectification or rejected. 1906. PAINTING 1906.1. General Unless otherwise specified, all metal work shall be given approved shop coats as well as field coats of painting. The item of work shall include preparation of metal surfaces, application of protective covering and drying of the paint coatings and supply of all tools, scaffolding, labour and materials necessary. Coatings shall be applied only to dry surfaces and the coated surfaces shall not be exposed to rain or frost before they are dry. The coatings shall be applied to all surfaces excluding shear connectors and inner surfaces of fully sealed hollow sections. Care shall be taken during coating of adjacent surfaces to build up primer on the shear~ connectors. 1906.1.1. Types of paints (i) Ordinary Paints These include paints based on drying oils, alkyd resin, modified alkyd resin, phenolic varnish epoxy, etc. Alkyd resin paints for the protection of steel structures are based partly on natural oils and partly on synthetic resins. These paints shall be used for steel structures in atmospheres which are not too aggressive. Oil based paints can be used for steel structures in cases where the surface preparation cannot be ideal. Ordinary painting can generally be sub-divided into two groups: a) Primary Coats This shall be applied immediately after the surface preparation and should have the properties of adhesion, corrosion inhibition and imperviousness to water and air. b) Finishing Coats These are applied over the primary coat and should have the properties of durability, abrasion resistance, aesthetic appearance and smooth finish.
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481
Section 1900
Structural Steel
(ii) Chemical Resistant Paints The more highly corrosion resistant paints can be divided into two main groups
a) b) One pack paints (ready for use) Two pack paints (mixed before use)
The two pack paints shall be mixed together immediately before use since they are workable thereafter only for a restricted period of time and dry up as a result of a reaction between their components and yield hard tough films with resistance to abrasion. (iii) Vinyl Paints These are based on polyvinyl resins such as polyvinyl-chloride (PVC) and polyvinyl-acetate, etc. Certain types of vinyl resin paints yield thick, relatively soft and rubber like coatings with good chemical resistance. They can be repainted without difficulty. (iv) Chlorinated Rubber Paints These paints also have good chemical resistance. The main fields of applications shall be in aggressive environments. In general, chlorinated rubber paints do not have a high gloss. (v) Bituminous Paints As a paint vehicle, bituminous is inferior, but because of the low price, this should be applied in greater thickness (upto several millimetres) and may be suitable for some situations. A significant advantage of bitumen paints is their impermeability to ingress of water. However, bituminous paints do not withstand effectively detrimental effects of oil. (vi) Epoxy Paints These resin paints have good adherence to a well prepared substrata. They are mechanically strong and resistant to chemicals. A disadvantage of epoxy resin paints is that it can rapidly become dull when exposed to strong sunlight. These disadvantages do not, however, greatly influence their protective power. (vii) Polyurethane Paints The chemical and mechanical behaviour of polyurethane paint resembles those of epoxy paint very much. However, polyurethane paint retains its gloss for a longer period. Because of the high price of
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482
Structural Steel
Section 1900
polyurethane paint, a combination of the two viz., polyurethane and epoxy paints may sometimes be used. (viii) Zinc Rich Paints Instead of introducing an inhibitive pigment into paint, metallic zinc can be used and such paints can provide cathodic protection to steel, 1906.1.2. Surfaces which are inaccessible for cleaning and painting after fabrication shall be painted as specified before being assembled for riveting. All rivets, bolts, nuts, washers etc., are to be thoroughly cleaned and dipped into boiling linseed oil conforming to IS:77. All machined surfaces are to be well coated with a mixture of white lead conforming to IS:34 and Mutton Tallow conforming to IS:887. For site paintings, the whole of the steel work shall be given the second cover coat after final passing and after touching up the primer and cover coats, if damaged in transit. 1906.1.3. Choice of painting system The choice of suitable painting system is dependent on factors such as:
-
Available application methods viz, brush, roller or spray Durability in a specific environment Availability of skilled manpower Cost I benefit etc.
It is therefore necessary to consult various manufacturers of paint and ascertain the above aspects while deciding on the appropriate choice of painting system. 1906.1.4, Quality of paint The paints which have been tested for the following qualities as per the specifications given in the relevant IS codes should only be used Weight Test (weight per 10 litre of paint thoroughly mixed)
-
Drying time Flexibility and Adhesion Consistency
Dry thickness and rate of consumption
1906.1.5. Unless otherwise specified, all painting and protective coating work shall be done in accordance with IS:l477 (Part 1).
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483
Section 1900
Structural
Steel
1906.2. Surface Preparation Steel surface to be painted either at the fabricating shop or at the site of work shall be prepared in a thorough manner with a view to ensuring complete removal of mill scale by one of the following processes as agreed to between the fabricator and the Engineer:
a) Dsy or wet git / Sand blasting Pickling which should be restricted to single plates, ban and sections F1an~ecleaning
b)
c)
Primary coat shall be applied as soon as practicable after cleaning and in case of flame cleaning, primary coat shall be applied while the metal is still warm. All slag from welds shall be removed before painting. Surfaces shall be maintained dry and free from dirt and oil. Work out of doors in frosty or humid weather shall be avoided. 1906.3. Coatings Prime coat to be used shall conform to the specification of primers approved by the Engineer. Metal coatings shall be regarded as priming coatings. Primer shall be applied to the blast cleaned surface before any deterioration of the surface is visible. In any case, the surface shall receive one coat of primer within 4 hours of abrasive blast cleaning. All coats shall be compatible with each other. When metal coatings are used, the undercoat shall be compatible with the metal concerned. The undercoat and finishing coat shall preferably be from the same manufacturer. Successive coats of paints shalt be of different shades or colours and each shall be allowed to dry thoroughly before the next is applied. Particular care shall be taken with the priming and painting of edges, corners, welds and rivets. Typical guidelines for epoxy based paints and the conventional panting system for bridge girders as given below may be complied with a) Epoxy Based Painting
i) ii) Surface preparation Remove oil/grease by use of petroleum hydrocarbon solution (IS:1745) and Grit blasting to near white metal surface. Paint system: 2 coats of epoxy zinc phosphate primer 5 coats = 200 micron 60 micron Total
b) Conventional Painting System for areas where corrosion is not severe 484
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Structural
Steel
Section 1900
Priming Coat One heavy coat or ready mixed paint, red lead primer conforming to IS:102 or One coat of ready mixed zinc chrome primer conforming to IS: 104 followed by one coat of ready mixed red oxide zinc chrome primer conforming to IS:2074. or Two coats of zinc chromates red oxide primer conforming to IS:2074 Finishing Coats Two cover coats of red oxide paint conforming to IS:123 or any other approved paint shall be applied over the primer coat. One coat shall be applied before the fabricated steel work leaves the shop. After the steel work is erected at site, the second coat shall be given after touching tip the primer and the cover coats if damaged in transit. c) Conventional Painting System for areas where corrosion is severe Primh~gCoat Two coats of ready mixed red lead primer conforming to IS:102 or One coat of ready mixed zinc chrome primer conforming to IS: 104 followed by one coat of zinc chromate conforming oxide primer to IS:2074. Finishing Coats : Two coats of aluminum paint conforming to IS:2339 shall be applied over the primer coat. One coat shall be applied before the fabricated steel work leaves the shop. After the steel work is erected at site, the second coat shall be given after touching up the primer and the cover coats if damaged in transit. 1906.4. Painting in the Shop All fabricated steel shall be painted in the shops after inspection and acceptance with at least one priming coat, unless the exposed surfaces are subsequently to be cleaned at site or are metal coated. No primer shall be applied to galvanised surfaces.
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485
Section
1900
Structural
Steel
Shop contact surfaces, if specifically required to be painted, shall be brought together while the paint is still wet. Field contact surfaces and surfaces to be in contact with cement shall be painted with primer only. No paint shall be applied within 50mm of designed location of field welds. Paint shall be completely dried before loading and transporting to site. Surface not in contact but inaccessible alter shop assembly shall receive the fully specified protective treatment before assembly. Where surfaces are to be welded, the steel shall not be painted or metal coated within a suitable distance from any edges to be welded if the specified paint or metal coating would be harmful to welders or is expected to impair the quality of site welds. Exposed machined surfaces shall be adequately protected. 1906.5. Painting at Site Surfaces which will be inaccessible after site assembly shall receive the full specified protective treatment before assembly. Surfaces which will be in contact after site assembly shall receive a coat of paint (in addition to any shop priming) and shall be brought together while the paint is still wet. Damaged or deteriorated paint surfaces shall be first made good with the same type of coat as the shop coat. Where steel has received a metal coating in the shop, this coating shall be completed on site so as to be continuous over any welds, bolts and site rivets. Specified protective treatment shall be completed after erection. 1906.6. Methods of Application The methods of application of all paint coatings shall be in accordance with the manufacturers written recommendation and shall be as approved by the Engineer. Spray painting may be permitted provided it will not cause inconvenience to the public and is appropriate to the type of structure being coated. Areas hard to gain access to for painting and areas shaded for spray application shall be coated first by brushing. Oil based red lead primers must be applied by brush only, taking care to work into all corners and crevices. The primer, intermediate and finishing coats shall all be applied so
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Structural Steel
Section 1900
as to provide smooth coatings of uniform thickness. Wrinkled or blistered coatings or coatings with pinholes, sags, lumps or other blemishes shall not be accepted. Where the Engineer so directs, the coating shall be removed by abrasive blast cleaning and replaced at the Contractors expense. 1906.7. Guideline of Specifications for Protective Coating System in Different Environments Since the seriousness of the problem of corrosion depends upon atmospheric conditions and these vary enormously, there is no single protective system or method of application that is suitable for every situation. However, as a guide, broad recommendations are given in Table 1900-3 for various types of coatings in various environmental conditions which should be complied with, Approximate life to first maintenance is also indicated and can be used as a guide. TABLE 1900.3: RECOMMENDATIONS FOR TYPES OF PROTECTIVE COATINGS
System i) Wire brush to remove all loose rust and scale; 2 coats drying oil type primer, 1 under coat alkyd type paint; I finishing coat alkyd type. Total dry film thickness = 150 pin Wire brush to remove all loose rust and scale 2 coats drying oil type primer~2 under coats micaceous iron oxide (MXO) pigmented phenolic modified drying oil. Total dry film thickness = 170 ~un Blast clean the surface; 2 coats of quick drying primer~ undercoat alkyd type paint; I finishing coat alkyd type. Total dry film thickness: Environment Suitable for mild conditions where appearance is of some importance and where regular maintenance is intended, This system may deteriorate to a marked extent if it is exposed to moderate aggressive atmospheric conditions for lengthy period Similar to (i) but where appearance is not very important provides longer life in mild condition. Will provide upto 5 years life to first maintenance in polluted inland environment Compared to (i), this would provide a longer life in mild conditions arid could be used in less mild situation e.g. inland polluted, where maintenance could easily be canied our at regular intervals Suitable for general structural steel work exposed to ordinary polluted inland environments where appearance is not of primary importance.
ii)
iii)
130
iv)
150 pm
Blast clean the surface; 2 coats of drying type oil primer, 1 undercoat micaceous iron oxide pigmented drying oil type paint. Total dry film thickness : 165 - 190 ~tm
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487
Section 1900 v) Blast clean the surface; 2 coats of metallic lead pigmented chlorinated rubber primer, I undercoat of high build chlorinated rubber. 1 finishing coat of chlorinated rubber. Total dry film thickness 200 pm Blast clean the surface; - 450 pm thickness. coal tar epoxy.
Structural Steel Suitable for structures in reasonably aggressive conditions e.g. near the coast. Will provide long-term protection than (iv) in non-coastal situations. Also suitable for aggressive Interior situations such as industrial areas. Suitable for sea water splash zones or for conditions of occurrence of frequent salt sprays. Suitable for steel work in reasonably mild conditions Life of 15-20 years before first maintenance could be expected in many siwations Provides a longer life than (vii) because of thicker zinc coating Expected to provide long term protection approx 15-20 years in aggressive atmosphere
vi)
350
vii) Pickle; hot dip galvanised (Zinc). Total thickness : 85 pin
viii) Grit blast, hot dip galvanised. (Zinc). Total thickness = 140 pan ix) Grit blast; I coat of sprayed zinc/ aluminum followed by suitable sealer Total thickness = 150 pro
1907. TESTS AND STANDARDS OF ACCEPTANCE The materials .shall be tested itt accordance with relevant IS specifications and necessary test certificates shall be furnished. Additional tests, if required, shall be got carried out by the Contractor at his own cost. The fabrication, furnishing, erecting, painting of structural steel work shall be in accordance with these specifications and shall be checked and accepted by the Engineer. 1908. MEASUREMENTS FOR PAYMENT The measurements of this Item shall be in tonnes based on the net weight of metal in the fabricated structure computed on the basis of nominal weight of materials. The weight of rolled and cast steel and cast iron shall be determined from the dimensions shown on the drawings on the following basis Rolled or cast steel : 7.84 x 1O~ kg/cu. cm.
Cast Iron 7.21 x IO kg/cu. cm.
Weight of structural sections shall be nominal weight Weight of castings shall be computed from the dimensions shown on the drawings with an addition of 5 per cent for fillets and over-runs.
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488
Stnsctural Steel
Section 1900
Weight of weld fillets and the weight of protective coatings shall not be included. Weight of rivet heads shall be computed by taking the weight of 100 snap heads as given in Table 1900-4. When specially agreed upon, allowance for snap heads may be taken as a flat percentage of the total weight. This percentage may be taken as 3 per cent or modified by mutual ~greement.
TABLE
Din
1900-4
WEIGHT OF RIVET
HEADS
or
Rivet as manufactured mm
Weight of 100 snap heads kg
12
14 16
1.3
2.1 3.4
18
20
4.45
6.1 8.1
22
24
27 30 33
10.5
15.0 20.5
27.2
The Contractor shall supply detailed calculation sheets for the weight of the metal in the fabricated structure. No additions shall be made for the weight of protective coating or weld fillets. Where computed weight forms the basis for payment, the weight shall be calculated for exact cut sizes of members used in the structure, deductions being made for all cuts, except for rivet holes. Additions shall be made for the rivet heads as mentioned above. When specially agreed upon, the basis for payment may be the bridge weight complete, according to specifications included in special provisions of the Contract. 1909. RATE The contract unit rate for the completed structural steel work shall include the cost of all materials, labour, tools, plant and equipment required for fabrication, connections, oiling, painting, temporary erection, inspection, tests and complete final erection as shown on the drawings and as specified in these Specifications.
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489
Bearings
2000 Bearings
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Bearings
Section 2000
2001. DESCRIPTION This work shall consist of furnishing and fixing bearings in position in accordance with the details shown on the drawings, to the requirements of these specifications or as directed by the Engineer. 2002. GENERAL
i) ii) Bearing plates, bars, rockers, assemblies andother expansion orfixed devices shall be constructed in accordance with the details shown on the drawings. The beanngs may either be supplied directly to the Engineer by the manufacturer to be installed by the Contractor or the Contractor is to supply and install she bearings as part of the contract. In the former cue, the manufacturer shall be associated with the installation of the bearings to the full satisfaction of the Engineer, whereas in the latter case, the Contractor shall be solely responsible for the satisfactory supply and installation of the bearing, Inthe detailed description of the specification, a general reference shall be made to the Contractor or manufacturer and the interpresarion shall be as per terms of contract. The Contractor shall exercise the utmost care in setting and fixing all bearings in their correct positions and ensuring that uniformity is obtained on all bearing surfaces. Bearings shall be handled with care and stored under cover. When bearing assemblies or plates are shown on the drawings to be placed (not embedded) directly on concrete, the concrete bearing area shall be constructed slightly above grade (not exceeding 12 miss) and shall be finished by grinding. It shall be ensured that the bearings are set truly level and in exact position as indicated on the drawings so as to have full and even bearing on the seats. Thin mortar pads (not exceeding 12 miss) may even be made to meet with this requirement.
iii)
iv) v)
vi)
vii) It shall be ensured that the bottoms of girders to be rtceived on the bearings are plane at the locations of these bearings and care shall be taken thatthe bearings are not displaced while placing the girders. viii) MS. bearings sliding on M.S. Plates shalt not be permitted. For sliding plate bearings stainless, steel surface sliding on stainless steel plate with mild steel matrix shell be used. The other option shall be to provide PTFE surface sliding on stainless steel. ix) Some types of bearings which have been successfully used in various bridges in India have been covered by these Specifications. For innovative types of structures or in special cases, special types of bearings to suit the requirements may have to be provided for which special specifications may be laid down by the Engineer.
2003. STEEL BEARINGS 2003,1. Materials The material for steel bearings shall conform to the requirements
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493
Section 2000
Bearings
of Section 1000. Some additional requirements for materials for steel bearings are indicated below
a) b) Railway axles (R 19) are also acceptable as forged steel for rollers. For the purpose of checking the soundness of cast steel components, castings shall be ultrasonically examined following procedures as per 15:7666 with acceptance standard as per IS:9565. The castings may also be checked by any other accepted method of non..destnsctive testing as specified in 15 1030. Quality level of castings shall be level 3 as per iS:9565.
The grease for bearings shall conform to the requirements of IS:503 (Grade 4). 2003.2. Construction Operations
a) All work shall conform strictly to the drawings and shall be in accordance with the provisions of this section. Care shall he taken to ensure that all parts of an assembly fit accurately together. The workmanship shall satisfy all relevant provisions laid down in Section 1900. Knuckle pins, rolling surfaces of the rollers and bearing surface of the bearing plates shall be machined and all bolt holes shall be drilled. The whole bearings shall be fitted and finished as required for good quality machined work to the satisfaction of the Engineer. However, in case of bearings which are to be groused or bedded on a suitable yielding material on any surface which is to be in permanent contact with the grout or the yielding material may be left unmachined. In prestressed concrete construction where launching of girders is employed, in order to avoid slipping or jumping of rollers due to vibeation or jolts, adequate measures may be taken to ensure that the roller assembly is not disturbed. It is normal practice to provide rocker bearings on the launching end and place Use beam on the rocker end slightly in advance of placing on the roller. During concreting of girders, the bearings shall be held in position securely by providing temporary connection between the top and bottom plates in case of fixed bearings and between top plate, base plate and saddle plate in case of roIler~ cum-rocker bearing or by any other suitable arrangement which prevents the relative displacement of the components. In prestressed precast girders, where recesses are left on the underside of girders to receive the anchor bolts, grout holes extending to the beam sides or to the deck level shall be provided. The cement sand grout shall have a mix of 1:1.
b)
c)
d)
e)
2003.3. Workmanship
a) h) c) Fabrication shall be carried out by an organisation experienced and qualified to undertake precision engineering of this type and be approved by the Engineer. Workmanship shall be of good quality, neatly finished and of good appearance. Castings shall be tnse to the forms and dimensions shown on the drawings and shall be free from pouring faults, sponginess, cracks, blow holes and other defects on position, affecting their appearance or strength. Warped or distorted castings will not be accepted. Exposed surfaces shall be smooth and dense.
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494
Bearings d) e)
Section 2000
All castings shall be cleaned by sand or shot blasting to remove sand or scale and to present a clean uniform surface. All irregularities, fins or risers shall be ground off flush with the adjacent surface. Castings with visible cracks, blow holes or similar blemishes shall be rejected if the imperfections are located in bearing surfaces or cannot be remedied to the approval of the Engineer. imperfections which are not located in bearing surfaces shall be cleaned out, filled with weld metal of the appropriate composition and ground flush. All surfaces of major components like top plates, saddle plates, base plates, rollers of the bearings shall be machined all over for correct alignment, interchangeability, proper fitting, etc.
1) g)
2003.4, Tolerances Tolerances for its individual components or of the assembled bearings shall be as shown on the drawings or subject to the approval of the Engineer. Unless otherwise specified, the following tolerances shall be maintained Diameter of Rollers, Knuckle Pins and Bores Tolerances on diameter of rollers and all convex surfaces shall conform to K7 of IS:919. Tolerances on diameter of a]] concave surfaces shall conform to
D8 of IS:919.
Height of Bearings Tolerances on height of any component casting shall not exceed +0.5mm. No minus tolerance shall be allowed. The edges of all ribs shall be parallel throughout their length. Base Plate Tolerance on length and width of the base plate shall not exceed +1.0 mm, tolerance on the thickness of the plate shall not exceed +0.5 mm. No minus tolerance shall be allowed. All rocking, rolling and sliding surfaces shall have a machine smooth finish to 20 micron maximum mean deviation as per IS:3073. Castings No minus tolerance shall be allowed in the thickness of any part of the castings. The edges of all ribs shall be parallel throughout their length.
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495
Section 2000
Bearings
2003.5. Installation of Steel Bearings 2003.5.1. General

a) b) Bearings shall be placed in the positions as shown on the drawings with all bearing surfaces in full contact and to the tolerances as specified. Roller and rocker bearings shall be placed so that their axles of rotations are horizontal and nomial to the direction of movement of the members they support. Upper and lower bearing plates shall be set horizontal in both directions. During installation the bearings shall be pre.set with respect to the bearing axis to account for the movement due to the following i) ii) d) Temperature variation between the average temperature prevailing at the time of installation and the mean design temperature. Shrinkage, creep and elastic shortening.
c)
For bridges in gradient, the beanng plates shall be placed in a horizontal plane.
2003.5.2. Placing
a) On supporting stmctures, pockets shall be provided to receive anchor bolts; one side of the pocket shall project beyond the bearing plate. The pocket shall be filled with mortar of mix li and the concrete bearing area also shall be finished level by a thin and stiff mortar pad of mix 1:1 (the thickness not exceeding 12 mm) just before placing of bearing assemblies or bottom plate on the concrete seat. in case of precast girders a recess of 6 mm shall be provided on the underside with a level fsnish for housing the beating plate. A thin and stiff mortar pad of mix 1:1 with thickness not exceeding 3 mm shall be provided over the top plate before lowering the precast beam in position in order to ensure full and even pressure on the plate surface. It shall be ensured that while placing the girders, the bearings are in their exact positions as indicated on the approved drawing and not displaced therefrom. All concrete surfaces to be in contact with the mortar shall be thoroughly cleaned and kept saturated with water for a period not less than 24 hours before placing mortar and operations are to be carried out when the surface temperatures of the exposed bearings are the minimum practical. No ntortar that is more than 30 minutes old after completion of mixing, shall be used. After placing and finishing the mortar, the bearing shall be checked for position and shims or other temporary supports removed and the mortar made good. If the bearing has moved, it or the plate shall be lifted, the mortar removed and the whole procedure repeated. Exposed days. faces of the mortar shall be cured under damp Hessian for 7
b)
c) d)
e) f)
g)
h)
Placing of the bearing and mortar shall only be carried out in the presence of the Engineer.
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Bearings
Section 2000
2003.5,3. Checking, cleaning and lubrication : Before erection, each bearing shall be uncrated, disassembled and checked. Any damaged parts shall be made good for approval. All bearings with sliding surfaces shall be cleaned and lightly lubricated with an approved lubricant immediately before erection. 2003,5.4. Testing
i) ii) The materials to be used in the bearings shall laid down in clause 2003.1. conform to the specifications
If inquired, a suitable number of complete bearings as specified by an accepting authority shall be tested to 1.25 times the design load. Recovery should be 100 per ceent. Contact surfaces shall be examined by illumination source for any defects, cracks, etc. Segmental rollers shall be tested for design movements. For large lots (consisting of 12 sets or more), be submitted as detailed below: a) a quality control report shall
iii)
Unless otherwise agreed upon by the Engineer and the manufacturer, the latter shall furnish a complete report on the process of quality control. The Engineer may appoint an authorised inspection agency for inspection purpose on his behalf. Such an inspection agency shall also submit reports to the Engineer regarding various tests performed on the beating or certify the acceptance of the beatings. Test certificates of all raw materials shall be submitted. If manufacturers test certificates are not available for the raw materials, the bearings menu. facturer shall perform the necessary confirmatory tests as per relevant codes of practice and shall furnish the test results. A detailed quality control system induding stage by stage inspection, starting from raw materials upto the finished bearing shall be submitted by the bearing manufacturer. The Engineer shall reserve the right to witness such inspection at manu~ facturers works with or without prior permission of the manufacturer, For this, the beating manufacturer shall have in.plant testing facilities as far as possible and practicable. The bearing manufacturer shall maIntain a list of consumption of raw material for a period of at least previous one year. Test certificates of bearings manufactured during preceding one year shall be made available at the manufacturers works. In case the lot size of similar bearings exceeds 12 sets as per the direction of the Engineer, one extra set of bearings for each 24 sets of beatings or part thereof, shall be manufactured and the cost of such extra bearings shall be borne by the user. The Engineer shall select the extra bearing(s) at random and shall perform various tests including destructive testing on it at his discretion, either at the manufacturers works or at any other approved test laboratory, notwith. standing the test reports submitted.
b)
c)
d)
e)
0
g)
h)
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497
Section 2000 i)
Bearings In case there is a major discrepancy regarding material, the engineer shall declare the whole lot of bearings as unacceptable. In case minor defects in fabrication, like welding or machining, is found in the test bearing before destructive testing and if the test hearing is found to he acceptable after destructive testing, the minor defects in the test bearings shall not he a bar to the acceptance of the entire lot. The opinion of the Engineer in cases (i) and the manufacturer.
j)
k)
(3) above
shall be binding on
2004. SPECIAL BEARINGS 2004.1. Spherical Bearing This bearing only takes care of vertical load and horizontal force due 10 sliding friction. The bearing will permit uniaxial translatory movement along longitudinal axis of the bridge and rotation along all axes. The bearing shall consist of the following pacts Bottom Plate A bottom plate with concave surface is integrally cast on circular! square plate. The bottom plate is connected to the sub-structure by means of tight fitted anchor bolts, which are embedded in concrete. The material of bottom plate shall be cast steel. Pure unfilled quality dimpled PTFE of specified thickness shall be provided on top of concave surface of bottom plate in order to allow smooth rotation. Saddle Plate A saddle plate with square/circular/rectangular top and convex surface at bottom shall be placed in the concave surface of bottom plate. The radius of curvature of the convex bottom of the saddle plate shall he slightly less than that of the concave top surface of the bottom plate to enstire sufficient contact over a small area. Rotation along all axes shall be permitted along the contact surface of the saddle plate and we bottom plate. Pure unfilled quality dimpled PTFE sheet shall be recessed to specified depth of recess over the top of saddle plate. Suitable elastomeric seal shall be provided on the saddle plate to prevent ingress of dirt and moisture. The material of saddle plate shall be cast steel. Top Plate The top plate shall have stainless steel plate welded to its bottom which shall slide over PTFE. The assembly shall be connected to
498
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Bearings
Section 2000
the superstructure by tight fitted anchor bolts. Translatory movements along longitudinal axis of bridge shall be accommodated at the PTFE/ Stainless steel sliding surface. The material of top plate shall be cast steel. Guide Plate Guide Plates shall be welded to saddle plate so as to permit only longitudinal movement. The material of guide plates should be cast steel. 2004.2. Pin Bearing Pin bearing shall ensure fixity by arresting translatory movement. The pin bearing shall not take any vertical load, It will take care of the longitudinal horizontal force of the entire superstructure unit as well as transverse horizontal force developed at the fixed end. A pin bearingshall consist of a short height structural built-up column embedded in pier cap and the protruding length inside soffit of deck shall have rocker plates on all four sides, which permit rotation. Pin bearing shall resist horizontal force from any direction and will permit rotation but will not bear any vertical load. The material of pin bearing including rocker plates shall be high tensile steel conforming to IS:961. 2004.3. In general the sliding spherical and pin bearing shall conform to BS:5400, Parts 9.1 and 9.2 and all relevant clauses of this specification. Bearings shall be guaranteed for design loads and movements. The term bearing shall include the entire assembly covering all the accessories required for operation, erection and dismantling for replacement. All bearings shall be of replaceable type~ These bearings should be based on their design to the specifications mentioned/international specifications. The manufacturer should get their design approved from appropriate authority and the manufacturer should be associated with installation of bearings. 2004.4. Materials All materials, particularly the following, shall be original, unused or non-re-cycled conforming to relevant specifications
Cast Stcel~Mild Steel, Stainless Steel shalt conform to Clause 2003.1.
-
Copolymer Poly Tr~r*Fluora Ethylene (FIFE) unfitted quality shall have required properties as per BS:5400 and thickness shall be as specified. Anchor Bolts shall be as per relevant IS specifications.
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499
Section 2000 2004.5. Seating of Pin Bearing

i) ii)
Bearings
Backing plate with studs welded on the face opposite to the seating of manufacture shill be delivered by the mannfacnner.
This backing plate shall be aecurarety positioned on the reinforcement grid of the pedestal and IevdletL iii) Studs shalt be tack welded/tied so the reinforcement to keep the backing plate inpruper location during casting.
iv) v) vi) Depth of embecknent of the backing plate in relevant drawing.
the
concrete shall be as per
The mund base of the pot (bottom) of the pin beating assembly shall be connected to the backing pLates by anchor screws after concreting of tier cap/pedestal. In order so ensuresuccessful tranth~r large horizontal forces so be resisted of by the Pin bearing, great care shall be taken in desaihng the reinforcement in the sub.stnrcsurc and the super-structure adjacent to the studs in the backing plate.
2004.6. Acceptance Test on Spherical Bearings

1. 2. 3. 4.
ALl bearings shalt be checked for overall dimensions

All bearings shall be load tested to 1.25 limes design vertical load A pair of bearings selected at random shall undergo testing in order to determine coefficient of friction which shall be less than 01)5. Two beatings selected at random shall be tested for pennissible meanon.
2004.7. Acceptance Test on Pin Bearings

1. 2.
All bearings shall be checked for overall dimensions.

ALl bearings shalt be load tested (if required, for design horizontal load only)
2005. ELASTOMERIC BEARINGS The term bearing in this case refers to an elastomeric bearing consisting of one or more internal layers of elastomer bonded to internal steel laminates by the process of vulcanisation. The bearing shall cater for translation and/or rotation of the superstructure by elastic deformation. 2005.1. Raw Material Chloroprene (CR) only shall be used in the manufacture of bearing. Grades of raw elastomer of proven use in elastomeric bearings, with low crystallization rates and adequate shelf life (e.g. Neoprene WRT, Bayprene lit), Skyprene B-5 and Denka S-40V) shall be used. No reclaimed rubber or vulcanized wastes or natural rubber shall be used. The raw elastomer content of the compound shall not be lower than
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500
Bearings
Section 2000
60 per cent by its weight. The ash content shall not exceed 5 per cent. (as per tests conducted in accordance with ASTM D-297, sub-section 10). EPDM and other similar candidate elastomers for bridge bearing use shall not be pennitted. Properties The elastomer shall comform to the properties specified in Table 2000.1
TABLE 200e.l. PROPERTIES Propcrtly
UnIt
OF
ELASTOMER Value of the cbaracteristk
Test Method, IS
spedftcatlcsa reference
Physical Prupesties 1.1. 12. 1.3. Hardness Minimum Tensile Strength Minimum Elongation atbreak Max ~mwn Compression
spedfled
IRHD
Mls Per cent
IS:3400
(Past Ii) IS:3400 (Pan I) IS:3400 (Part!)
60
17 400
2.
Set
Per cent
IS:3400 (PartX)
duration temperature
(h) +Oto
242 3. Accelerated Agemg IS:3400
(deg C) 1001
35
CR
3.1 3.2. 3.3.
duration (h) 70 IRHD Percent Per cent
(Pastry)
temperature (dcgC)
l00~1
Max change in
Hardness Max change in
+15
.15
Tensile Strength
Max change in
Elongation
-40
Shear modulus of the elastother bearing shall neither be less than 0.80 MPa nor greater than 1.20 MPa. The adhesion strength of elastomer to steel plates determined
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501
Section 2000
Bearings
according to IS:3400 (Part XIV) method A shall not be less than 7 kN/m. For elastomeric bearings (CR) used in adverse climatic conditions the following ozone resistance test shall be satisfied The ozone resistance of elastomer shall be proved satisfactory when assessed by test according to IS:3400 (Part XX). The strain, temperature, duration and ozone concentration of the test shall be 20 per cent, 40 ~ I degree Celsius, 96 h and 50 pphm by volume respectively, No cr~ickingdetected by visual observation at the end of the test shall be considered satisfactory. No specific tests forassessment of low temperature resistance may be deemed necessary. NOTE : For use of elastomer in extreme cold climates, the Engineer may specify special grade of low temperature resistant elastomer in conformity with operating ambient temperature conditions. The sped. fications of such special grade elastomer including the tests for low temperature resistance shall be mutually agreed to by the Engineer and the producer supplier and are outside the purview of these specifications. Laminates of mild steel conforming to IS:226 shall only be permitted to be used. Use of any other material like fibre glass or similar fabric as laminates shall not be permitted. The manufacturers of elastomeric bearings shall satisfy the Engineer that they have in-house facilities for testing the elastomer for carrying out the following tests in accordance with the relevant provisions of ASTM D-297.
a) b) c) d)
Identification of polymers
Ash content test
to confirm the usage of Chioroprene (Appendix X-2)

to determine the percentage (sub-section 34) : : (tub-section 15) (sub-section 10)
Specific gravity test

Polymer content test
The Engineer shall invariably get the test (a) performed within his presence or in the presence of his authorised representative to satisfy the requirement. In case of any disputes regarding interpretation of results the Engineer may carry out test as per ASTM S-3452-78 (Chromatography test) at the manufacturers cost in a recognised test house. The elastomer specimen to conduct the Lest shall be obtained from the bearings selected at random for destructive test. Remaining part of the test bearing shall be preserved by the Engineer for any Lest to be done in future, if required. 502
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Bearings
Section 2000
2005.2. Fabrication Bearing with steel laminates shall be cast as a single unit in a mould and vulcanised under heat and pressure. Casting of elements in separate units and subsequent bonding shall not be permitted, nor shall cutting from large size cast be permitted. Bearings of similar size to be used in particular bridge project shall be produced by identical process and in one lot as far as practicable. Phased production may only be resorted to when the total number of bearings is large enough. The moulds used shall have standard surface finish adequate to produce bearings free from any surface blemishes. Steel plates for laminates shall be sand blasted, clean of all mill scales and shall be free form all contaminants prior to bonding by vulcanisation. Rusted plates with pitting shall not be used. All edges of plates shall be rounded. Spacers used in mould to ensure cover and location of laminates shall be of maximum size and number practicable. Any hole at surface or in edge cover shall be filled in subsequently. Care shall be taken to ensure uniform vulcanising conditions and homogeneity of elastomer through the surface and body of bearings. The bearings shall be fabricated with the tolerances specified in Table 2000-2.
TABLE ~.2
ITEMS Overall plan dimensions
TOLERANCES TOLERANCES
-0, + 6 mm
2.
3. a) b) 4&
Total beaiing thickness

Parallelism Of top surface of bearing with respect to the bottom surface as datum Of one side surface with respect to the other as datum Thickness of individual internal layer of elastomer Thickness of individual outer layer Plan dimensions of laminates Thickness of laminates Parallelism of laminate with respect to bearing base as datum
-0,
5 mm
I in 200 1 in 100 20 per cent (max. of 2 mm) .0, + 1 mm -3mrn,+0
b)
5a. b) c)
~l0 per cent

1 in 100
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503
Section 2000
Beatings
The vulcanising equipmen~ressshall be such that between the plattens of press the pressure and temperature are uniform and capable of being maintained at constant values as required for effecting a uniform vulcanisation of the bearing. The moulding dies utilised for manufacturing the bearings shall be so set inside the platten of the press so that the pressure developed during vulcanisation of the product is evenly distributed and the thickness maintained at all places are within acceptable tolerance limits taking into consideration the shrinkage allowance of valcanizate. The raw compound which has been introduced inside the metal dies for vulcanisation shall be accurately weighed each time and it must be ensured that sufficient quantity has been put inside the die for proper flow of material at every place so that a homogeneous and compact bearing is produced without any sign of sponginess or deficiency of material at any place. Before any vulcanizate of any batch of production is used for producing vulcanised bearings, test pieces in the form of standard slab and buttons shall be prepared in accordance with prescribed standards and salient properties tested and recorded regularly against each batch of j~oductionto monitor the quality of the products. 2005.3. Acceptance Specifications The manufacturer shall have all the test facilities required for the process and acceptance control tests installed at his plant to the complete satisfaction of the Engineer. The test facilities and their operation shall be open to inspection by the Engineer on demand. All acceptance and process control tests shall be conducted at the manufacturers plant. Cost of all materials, equipment and labour shall be borne by the manufacturer unless otherwise specified or specially agreed to between the manufacturer and Engineer. Acceptance testing shall be commenced with the prior submittal of testing programme by the manufacturer to the Engineer and after obtaining his approval. Any acceptance testing delayed beyond 180 days of production shall require special approval of the Engineer and mOdified acceptance specification, if deemed necessary by him. All acceptance testing shall be conducted by the inspector with aid of the personnel having adequate expertise and experience in rubber
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504
Bearings
Section 2000
testing provided by the manufacturer, working under the supervision of the Inspector and to his complete satisfaction. Lot by lot inspection and acceptance shall be made. 2005.3.1. Acceptance lot : A lot under acceptance shall comprise all bearings, including the pair of extra test bearings where applicable of equal or near equal size produced under identical conditions of manufacture to be supplied for a particular project. The size and composition of acceptance lot shall be got approved by the Engineer. For the purpose of grading levels of acceptance, testing lots shall be classified as follows
i)
ii)
A lot size of 24 or larger number of bearings shall be defined as a large lot

A lot size of less than
24 bearings
shall be defined as a small tot
When the number of bearings of equal or near equal size for a single bridge project is large and phased production and acceptance is permitted, the number of bearings supplied in any single phase of supply shall comprise a lot under acceptance. When such phased supply is made, each such lot shall be considered as a large lot for the purpose of acceptance testing. 2005.3.2. Levels of acceptance inspection : The level of acceptance testing shall generally be graded into the following two levels depending on lot size Level I acceptance testing Level 2 acceptance testing Acceptance testing Level 1 is a higher level inspection and shall be applicable to large lots only, unless otherwise specified. This shall involve manufacture of two extra bearings for each lot to be used as test bearing and eventually consumed in destructive testing. Acceptance testing Level 2 shall be applicable to small lots only, (i.e. less than 24 lots) for which one extra bearing shall be manufactured. Out of the lot one bearing shall be selecled at random for carrying out material tests. This bearing shall be excluded from the lot accepted. Acceptance inspection level 1 may be specifiedat the sole discretion of the engineer taking into account the special importance of bridge project for small lots also under the purview of special acceptance
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505
Section 2000
Bearings
inspection. The cost of extra bearings, in such cases shall be borne by the user, while the cost of all other materials, equipment and testing shall be borne by the manufacturer. 2005.3.3, Testing : Acceptance testing shalt comprise general inspection, test on specially moulded test pieces and test on complete bearings or sections for measurement of various quality characteristics detailed below 2005.3.3,1. Acceptance testing level I General Inspection
All bearings of the lot shall be visually inspected for any defects in finish, shape or any other discernible superficial defects. 2. 3. surface
All bearings of the lot shall be checked for tolerances specified in Table 2DO0~ 2. All bearings of the lot shall be subjected to axial load to correspond to ~m (i.e. average compressive stress) = 15 MPa applied in steps and held constant while visual examination is made to check for discernible defects like a) b) c) d) e) Misalignment of reinforcing plates Poor bond. at laminate/steel interface Variation in thickness of elastomer layers Any surface defects
Low stiffness
Deflection under loads between om=5 MPa and ~m=l 5 MPa shall be measured and recorded for all bearings with sufficient accuracy (~ 5 per cent), Variation in stiffness of any individual bearing from the mean of the measured values for all such bearings of the lot shall not be larger than 20 per cent (of the mean value). Tests on specially moulded test pieces
1. Test pieces shall be moulded by the manufacturer with identical compound and under identical vulcanising conditions as used in the manufacture of the bearings of the acceptance, lot, The process shall be open to inspection by the Engineer. Test pieces offered for inspection shall be identified by suitable markings and duly certified by the manufacturer.
2. 3.
The quality characteristics to be tested are listed below. The specification

references in parenthesis shall define the corresponding specification for test piece, test method and criterion for acceptance.
Composition (see Note I below) Hardness (Table 2000-1 1.1)

,
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506
Bearings
,
Section 2000
Tensile strength (Table 2000-1 1.2) Elongation at Break (Table 2000-1 1.3) Compression Set (Table 2000-1 2) Accelerated Ageing (Table 2000-1 3) Adhesion Strength (Clause 2005.1) Ozone Resistance (see Note 2 below) Note I. For acceptance testing the properties enumerated in Clause 2005.1 and specific gravity of elastomer of test pieces from test bearing shall be compared with those for corresponding specially moulded test pieces furnished by the manufacturer. The following variations shall be deemed maximum acceptable
, , ,
Specific Gravity 0.2 Ash Content 0.5 per cent Hardness (Table 2000-1 1.1) Tensile strength (Table 2000-1 1.2) Elongation at Break (Table 2000-1 1.3) Compression Set (Table 2000-I 2) Accelerated Ageing (Table 2000-1 3) Adhesion Strength (Clause 2005.1) Note 2.
, , , , ,
Ozone resistance test can be waived by the Engineer for bearings of CR when satisfactory results of ozone resistance tests on similar grade of elastomer may be available from process control records or development test data furnished by the manufacturer. Where such process control data are not available or the frequency of testing~not deemed adequate, ozone resistance test shall be mandatory for acceptance of bearings of CR. However, such tests may not be insisted for bearings not located under adverse conditions of exposure and where the test on accelerated ageing could be considered as adequate. Process and acceptance control tests for ozone resistance by an independent testing agency shall be acceptable. Tests on Complete Bearings or Sections
I. Two bearings thall be selected at random from the lot as test bearings. These bearings shall be excluded from the lot accepted.
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507
Section 2000 2. The following tests shall be conducted on test bearings Test Test Test Test Test for for for for for determination detennination determination determination determination of of of of of shear modulus elastic modulus shear modulus (short teim loading) adhesion strength ultimate compressive strength
Bearings
The test specifications and acceptance criteria shall conform to those~ given in Appendix 2 of IRC:83 (Part II). 2005.3.3.2. Acceptance testing level 2 General Inspection. This shall conform to the provision in Clause
2005.3.3.1 in all respects.
Test on specially moulded test pieces. This shall conform to the provisions in Clause 2005.3.3.1 in all respects. Test on complete bearings. Test for determination of shear modulus shall be conducted using two bearings of the lot selected at random and conforming to relevant provisions of Clause 2005.3.3.1. These bearings shall however be part of the lot accepted. The remaining tests stipulated in aforesaid clause shall be carried out Ofl all bearings selected at random which shall be excluded from the lot accepted. 2005.3.4. Special acceptance inspection : Special acceptance inspection may comprise the following
1. 2. 3. Acceptance testing by an independent external supplemental test facilities provided by it. agency with separate or
Acceptance testing on test pieces prepared from the surface or body of the test bearings instead of specially moulded test pieces. Acceptance tests not covered by these specifications but according to the specifications laid down by the Engineer.
Special acceptance inspection may be specified under the following conditions

a) b) Special contract agreement Unsatisfactory evidence of process or acceptance control
2005.3.5. Inspection certificate : A lot under inspection shall be accepted by the Inspector and so certified, when no defect is found with respect to any of the quality characteristics tested on samples drawn from the lot according to specifications laid down in Clause 2005.3.3 covering general inspection tests on specially moulded test pieces and on complete bearings.
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508
Bearings
Section 2000
In case of any bearing with defect, the lot shall be rejected by the Inspector and so certified. In case any bearing is found to be defective with respect to any quality characteristic, discerned by general inspection tests specified in Clauses 2005.3.3.1 and 2005.3.3.2, tests on specially moulded test pieces and complete bearings as applicable according to Clauses 2005.3.3.1 and 2005.3.3.2 shall nevertheless be completed. If the said lot, rejected by general inspection, satisfies the acceptance criteria in respect of these other tests, the lot and individual bearings found defective shall be learly identified in the inspection certificate, The manufacturer shall obtain from the inspector, authorised by the Engineer, immediately on completion of his inspection, an inspection certificate which shall include the details of a lot or lots accepted/rejected by him and records of all test measurements. 2005.3,6. Quality control certificate: The manufacturer shall certify for each lot of bearing under ac~eptance: That an adequate system of continuous quality control was operated in his plant. That the entire process remained in control during the production of the lot of bearings under acceptance as verified from the quality control records/charts which shall be open to inspection of Engineer/ Inspector on demand. A certified copy of results of process control testing done on samples of elastomer used in the production of the lot shall be appended and shall include at least the following information Composition of compound raw elastomer ahd ash content, the grade of raw elastomer used (including name, source, age on shelf), test results of hardness, tensile strength, elongation at break, compression set, accelerated ageing, etc. A higher level certification of the process quality control shall be called for at the sole discretion of the Engineer in special cases e.g. where adequate inspection of bearings similar to those comprising the lot under inspection produced in the same plant is not available with the Engineer or in case of any evidence of process or acceptance control being deemed unsatisfactory. The higher level certification shall comprise submittal of a complete quality control report as given
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509
Section 2000
Bearings
in Appendix 3 of JRC:83 (Part II) supplementing the quality control certificate, 2005.3.7 Acceptance The manufacturer shall furnish the following to Engineer for the acceptance judgement
Quality control certificate as lain down in Clause 200516. 2. Inspection certificate as laid down in Clause 2O053.5~.
The manufacturer shall furnish any supplementary information on the system of quality control and/or process and acceptance control testing as may be deemed necessary by the Engineer. In case of any evidence of process or acceptai~cecontrol testing being deemed unsatisfactory by him, Engineer at his sole discretion may call for a special acceptance of the lot according to specifications laid down by him, without any prejudice to his right to reject the lot. The entire cost of such supplementary inspection shall be borne by the manufacturer. The Engineer shall be the sole authority for accep~anccof a lot on scrutiny of the certificates alongwith any supplementary evidence and complete satisfaction therewith. In case of rejection of a lot, the Engineer shall reserve the right. to call for special acceptance inspection for the succeeding lots offered for inspection, according to the specifications laid down by him. The enhire cost of such tightened inspection shall be borne by the manufacturer. 2005.4. Cerification and Marking Bearings shall be transported to bridge site after final acceptance by Engineer and shall be accompanied by an authenticated copy of the certificate to that effect. An information card giving the following details for the bearings, duly certified by the manufacturer shall also be appended Name of manufacturer Date of manufacture Elastomer grade used Bearing dimensions Production batch no. Acceptance lot no. Date of testing
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510
Bearings
Section 2000
Specific bridge location, if any Explanation of markings used on the bearing All bearings shall have suitable index markings identifying the information. The markings shall be made in indelible ink or flexible paint and if practicable should be visible after installation. The top of the bearing and direction of installation shall be indicated. 2005.5. Storage and l~andling Each elastomeric bearing shall be clearly labelled or marked. The bearing shall be wrapped in a cover. They shall be packed in timber crates with suitable arrangement to prevent movement and to protect corners and edges. Care shall be taken to avoid mechanical damage, contamination with oil, grease and dirt, undue exposure to sunlight and weather to the bearings during transport and handling prior to and during installation. 2005.6. Installation Installation of multiple bearings one behind the other on a single line of support shall be of identical dimensions. Bearings must be placed between true horizontal surfaces (maximum tolerance 0.2 per cent perpendicular to the load) and at true plan position of their control lines marked on receiving surfaces (maximum tolerance 3 mm). Concrete surfaces shall be free from local irregularities (maximum tolerance i mm in height). Design shall be checked for the actual inclination in seating if larger inaccuracies than those specified are permitted. For cast-in-place concrete construction of superstructure, where bearings are installed prior to its concreting, the forms around the bearings shall be soft enough for easy removal. Forms shall also fit the bearings snugly and prevent any leakage of mortar grout. Any mortar contaminating the bearings during concreting shall be completely removed before setting. For precast concrete or steel superstructure elements, fixing of bearing to them may be done by application of epoxy resin adhesive to interface, after specified surface preparation. The specifications for adhesive material, workmanship and control shall be approved by the Engineer. Care shall be taken to guard against faulty application and consequent behaviour of the adhesive layer as a lubricant. The bonding
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511
Section 2000
Bearings
by the adhesive shall be deemed effective only as a device for installation and shall not be deemed to secure bearings against displacement for the purpose of design. As a measure of ample safety against accidental displacement, the bearings shall be placed in a recess as shown in Fig. 9 of IRC:83 (Part II). 2005.7. Seating of Elastomerk Bearings on a Non-Horizontal Plane Installation of elastomeric bearings on a Non-Horizontal Plane shall be as follows
I) ii) Elastorneric bearings shall be delivered with MS backing plate fastened to the bearing from the manufacturer. Template of 6 mm M.S. plate and of size same as bearing holding base plate with matching holes for the anchor screws shall be used. Anchors shall be fined to the templates with the anchor screws but with MS washers in place of elastomer washers. The above template assembly shall be fitted in the fomtwork at its proper location and in a vertical plane. After casting of the pedestal and removal of the fonnwork, the template is to be removed.
iii)
A. Installation with race plate and without template b-situ casting

I) The sub-assembly of elastomeric bearing wish the MS backing plate shall be fitted to the embedded anchors with anchor screws and elastomeric washers replacing the steel washer. A clearance is required between the stainless steel face of the eleazomenc beating and that of the vertical face of the face plate with stainless steel top installed on the projection below the soffit. This shalt be achieved by inserting removable steel sheeting of thickness as per the drawing, during preparation of the formwork before casting of the superstnremre. The face plate with stainless steel top and pack plate shall be assembled with the anchors with elastomeric washers and anchor screws. The assembly shall be fined in the formwork at its proper location and in a vertical plane. The removable steel shims shall be removed at an appropriate time after the casting of the super-strocture.
ii)
iii)
B, Installation with face plate and with template in-situ casting

i) Template of 6 mm MS plate and of size same as face pimp with stainless steel top and matching holes for the anchor screws shall be used. Anchors shall be fitted to the templates with the anchor screws but with MS washers in place of elastoiner washers. Separate screws may be used in case of inconvenience of in the length of original anchor screws. The above template assembly shall be fitted in the fonnworic for the super-strocture at its proper location and in a vertical plane.
ii)
After removal of the superstructure fonnwosk, the template shall be removed.
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512
Bearings iii)
Section 2000
The face plate with the required thickness of pack plate shall be loosely fitted to the anchors embedded in the projection below the superstmcture, with elastomer washers and anchor screws. The sub-assembly of elastomeric beating with the MS backing plate shall be fined to the embedded anchors in the pedestal with anchor screws and elastomeric washers replaang the steel washer this time. The required clearance between thettainless steel face of the elastosneric bearing and that of the vertical face plate installed on the projection below the soffit shall be checked. After adjustment of the required working clearance the small gap between the vertical face of the prcpection below the soffit and the back of the face plate (with pack plates, if any) shall be grouted with epoxy grout.
iv)
v)
2006. POT BEARINGS 2006.1. General 2006.1.1. Pot type bearings shall consist of a metal piston supported by a disc or unreinforced elastomer confined within a metal cylinder to take care of rotation. Horizontal movement, if required, shall with a system of sealing rings be provided by sliding surfaces of PTFE pads sliding against stainless steel mating surfaces. The pot bearings shall consist of cast steel assemblies or fabricated structural steel assemblies. 2006,1.2. Provisions of IRC-83 (Part I) shall be applicable for all metallic elements. Provisions of IRC:83 (Part II) shall be applicable for all elastomer elements. When any items are not covered by IRC:83 (Parts I and II), the same shall be as per guidelines given hereunder and BS:5400 (Sections 9.1 and 9.2), except that no natural rubber shall be permitted. If there is any conflict between BS on the one hand and IRC on the other, the provisions of IRC will be guiding. 2006.13. Combination bearings using any judicious combination and sliding element shall be permitted. As for example :
Name Pot Ru~atlon Element Sliding Element None Generally for Vertical Load Horizontal Buffer
Pot
Elastomer
Elastomer Pot PTFE Spherical Knuckle PiPE Elastoiner PTFE Elastomer SS~
**
None*
l9?E-SS~
Pot
Spherical Knuckle
Vertical Load and Horizontal Load Vertical Load and

Horizontal Load Transverse Guide
PTFE.SS~ FT?E-SS~ SS.SS
Elastomer Elastomer
Transverse Guide
Etastomer shall permit movement by shear Stainless Steel
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513
Section 2000
Bearings
For special and innovative bridges, new combinations beyond what is shown may be required. The same may be used g1~approval by the Engineer. 200&2. Fabrication
i) The surface mating with the FIFE in the sliding pair shall be corrosion resistant stainless steel, Normally, the stainless steel shall form the upper component. The stainless steel shall overlap the PTFF after full movement on all sid~.If stainless steel sheet is used, it should be bonded by continuous welding tong the edges. Adhesive or any other bonding can be approved by the Engineer. The surrace shall be prepared by thorough cleaning to remove grease, dust or any other foreign substance. PiPE modular sheets of the sliding pair shall be located by confinement assisted by bonding. Confined PTFE shall be recessed into the metal backing plate. The shoulders of the recess shall be sharp and square to restrict the now of PTFE. The thickness of the PTFE shall not be less than 4.5 mm with projection above the recess not exceeding 2.0 mm. When the piston is subjected to tilting, the seal must slide along the wall and alter its shape according to the angle of tilt At the same time, it must be sufficiently rigid to bridge the gap between the piston and the wall of the pot. However, the percentage of plan area of the lubrication cavities to the gross area shall not exceed 25 per cent. The depth of the cavity shall not exceed 2.0 mm. The diameter to thickness ratio of the confined elastomer shall not exceed 15. The surface of the confined elastomer shall be smooth. A seal shall be provided to prevent extrusion ofthe confmed elastomer between the piston and the pot wall, The seal should stay functional under the loads and rotations acting on it. Additional seal shall be provided to prevent entry of dust! into the pot. Sealing rings for .pot bearings shall be fabricated from stainless steel. When the piston is subjected to tilting, the seal must slide along the wall and alter its shape according to the angle of tilt. At the same time, it must be sufficiently rigid to bridge the gap between the piston and the wall of the pot, The hardness of the piston and pot wall at their contact region shall be minimum 350 BHN to reduce wear. The surface finish of the pot base in contact with the confined elastomer shall be very smooth.
ii)
iii)
iv) v)
vi)
vii) All bearings shall be installed with anchor and anchor screws or some similar device such that while replacing, the bearings can be removed with minimum lifting of the supersirueturt viii) The extemal surfaces of the assemblies shall be completely cleaned by sand blasting. After sand blasting, dust shall be removed from the swface using clean and dry compressed air or a clean brush after which suitable coating shall be applied. ix) Pot bearings including all parts as shown on the drawings shall be fully shop assembled at the manufacturers works to ensure proper fitting of all parts.
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514
Bearings
Section 2000
2006.3. Materials
a) Steel i) ii) ii) Structural steel shall conform to 15:226 and 15:2062, as applicable. Cast steel shall conform to Cr 280-520W of 15:1030. 0,3 to 0.5 per cent copper may be added to increase the corrosion resistance properties. Stainless steel shall conform to AlS1:304 or XO4CrISNiIO of 15:6911 for ordinary applications. For applications with adverse/corrosive environment, the stainless steel shall conform to AlSt:316L or O2Crl7Nil2Mo2 of 15:69 11.
b)
PTFE PTFE (poly tetra fluoro ethylene) shall be of unfilled pure virgin quality. It shall be free sintered. The mechanical properties of unfilled PiPE shall comply with Grade A of BS:3784.
c)
Elastomer ftc a) h) c) confined Hardness Mm tensile strength elastonser inside pot IRlID MPa will have the following properties 50
+
1S3400 (Part II) TS:3400 (Part 1) shall be as per Table 2000-1 Properties of Elastomer
15.5
Mm elongation at break,) Max compression set and Accelerated ageing
For other details, refer to Clause 2005.1. 2006.4. Workmanship 2006.4.1. Welding All welding shall conform to IS:9595 with electrodes of suitable grade as per IS:814. Preheating and post weld stress relieving shall be done as per TS:9595. 2006.4.2. Cast steel assemblies Cast steel for pot bearing assemblies shall conform to requirements of relevant IS. Castings shall he true to the forms and dimensions shown on the drawings, and shall be free from pouring faults, sponginess, cracks, blow holes and other defects affecting their appearance or their strength. Warped or distorted castings shall not be accepted. Exposed surfaces shall t;e smooth and dense. All irregularities, fins or risers shall be ground off flush with the adjacent surface. Castings with visible cracks., blow holes, or similar blemishes shall be rejected if the imperfections are located on bearing surfaces or cannot be remedied to the satisfaction of the Engineer.
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515
Section 2000
Bearings
Imperfections which are not located on bearing surfaces shall be cleaned Out, filled with weld metal of the appropriate composilion and ground flush with adjacent surfaces. 2006.4.3. Structural steel assemblies: Defects arising from the fabrication of the steel shall be inspected by the Engineer, who will decide whether the materials may be repaired by the Contractor or will be rejected. The cost of repairs or replacement shall be borne by the Contractor. All steel whether fabricated or not, shall be stored above the ground on platforms, skids, or other supports, and adequately protected against corrosion. Excessively rusted, bent or damaged steel shall be rejected. All plate.s shall be flat and rolled bars and shapes straight before marking out or being worked Straightening shall be done by methods which shall not damage the material. Sharp kinks and bends shalt be the cause for rejection. Steel may be flame cut to shape and length so that a regular surface, free from excessive gouges and striations is obtained. Flame cutting by hand shall be done only with the approval of the Engineer.
.
Exposed corners shalt be machined or ground. 2006.4.4. Tolerances i) Plan dimensions : -o to +5 mm

ii) iii) iv) Overall height Height of elastomer Height of any steel component a) b) v) a) b) Machined Unmachined Flatness Surface Finish : .0 to + I mm Class 2 of lS:4897 0.0004L. where L = length in direction of measurement Ra 0.2.5 pm as per IS:3(Y73 : : -0 to +3 mm 5 per cer~t
Stainless steel sliding surface :
2006.4.5. Painting
i) All non-working surfaces shall be coated with two coats of epoxy primer and one or more coat each of epoxy intermediate and finish, total thickness ~g0.150 p.m or any other painting scheme as approved by the Engineer. Silicon grease shall be applied at the PTFEISS inierface after testing.
ii) iii)
Anchor sleeves shall be cement coated at the manufacturers works.
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516
Bearings
Section 2000
2006.5. Test 2006.5,1. Raw materials Necessary test certificates for all raw materials as in Clause 2006.3 above shall be furnished by manufacturers. Reference may also be made to Clause 2005.1 for tests on elastomers. 2006.5.2. Test on casting : Tests specified in IS:1030 shall be performed. Castings shall be ultrasonically tested and certificates submitted. Quality level of castings shall be level 3 as per IS:9565. 2006,5.3. Test on welding All welding shall be tested by Dye Penetration method. But welding shall be tested by Ultrasonic method. Soundness of welding shall be certified by the manufacturer. 2006.5.4. Acceptance test on bearing
I) ii) iii) All bearings shall be checked for overall dimenuons. All bearings shall be load tested to Li times maximum design capacity including seismic force. Bearing tested at higher loads cannot be used. A pair of bearings arlected at random will undergo testing in oidcr to detennine the coefficient of friction if. The coefficient of fricuon shall be ~ 0.05 at the deMgn load. Two bearings selected at random shall be tested for pemthsible rotation.
iv)
2006.6. Installation of POT-cum-PTFE Bearings 2006.6.1. General

i) ii) iii) Care shall be taken during installation of the bearings to permit their correct functioning in accordance with the design scheme. To prevent contamination, dismantling of the done. bearings at site shall not be
The load shall be transferred onto the bearings only when the bedding material has developed sufficient strength. The props for the forrnwork shall only be removed after lapse of appropriate time. In special cases, this can be ensured by suitable devices like jacks, etc. Temporary damps and shims (introduced to maintain working clearance) shall be removed at ass appropriate time, before the bearing is required to permit movement. Permitted installation tolerance of the bearing from plane of sliding shall be maintained, Cement based non-shrink grout with air releasing additive and epoxy based grout, whichever is specified shall be first tried at the site. For the proprietary grout mixes, appropriate instructions from the manufacturer shall be followed specially with regard to the following
iv)
v) vi)
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517
Section 2000 a) h) c) d) e) Preparauon~>r.oncretecleaning, roughening, pre.soaking, etc.
Bearings
Fonzts->sturdiness, leak proofing, shape, hrader funnel vents, etc. earing Base->cleaning, etc. Plaeernent..>rnircing, consistency!, time period, finishing, etc. Protection->curing, ambient temperature, etc.
2006.6.2. In-situ casting of superstructure

i) ii) iii) Pormwork around the bearing shall be carefully sealed to prevent leakage. Sliding plates shall be fully supported and care taken to prevent tilting, dis. placement or distortion of the bearings under the weight of wet concrete. Bearings shall bc protected during concreting operation. Any snort ar contaminating the bearing shall be completely removed before it sets.
2006.6,3. Seating of bearing

A.
Using Template
i) ii) Template with required rigidity and matching holes corresponding to the base of the bearing shall he used. All the anchors shall be fitted to the tower face of the template using the anchor screws but with steel washer replacing the elastomer washers, Separate screws may be used in case of inconvenience in the length of the original anchor screws. The. template assembly shall be located with regard to level and alignment. It shall be ensured that the sop of the anchors lie in a horizontal plane at the required elevation. Ihe anchors shall be tied/welded so reinforcements to avoid displacement during concreting. Concreting of she pedessallpier cap shall be done to a level leaving a gap of 25~~51) below she template. rnnt The template and steel washers shall be removed prior to placement of she hearing assembly with temporary clamps. The bearing assembly shall he Fitted to the anchors with the help of anchor screws and elastosncr washers. Level at the bearing shalt be checked. The gap below the bearing assembly shall be grouted with cement based grout. Reference may be made to Clause 2006.6.1 (vi).
iii)
is) s)
vi)
B. Without Tempiale with Gap

i) Pockets commensurate with the sizes of the anchors shalt be kept in pedestals during concreting of the same. The pedestal shall be cast approximately 25 mm shon of the required finished level. Anchors shall be fitted to the bearing bettom with elastomer washers and anchor screws. The bearing assembly shalt be seated in the location on steel chairs/packs. flat anchors fitted below the bearing shall go into pockets in the bed block. Level and alignment of the bearing shall he checked. it shalt be ensured that the bearing sits in a horizontal plane.
ii)
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518
Bearings iii)
Section 2000 The gap below the bearing assembly including anchor pockets shall be grouted with cement based grouL Reference may be made so Clause 2006.6.1 (vi).
C. Without Template without Gap Elongated pockets commensurate with the sizes of the anchors shall be kept in pedestals during concreting of the same. The geometry and location of the anchor pockets (with tapered funnel extension, if required) shall be such that after placement of the bearing the pockets can be successfully grouted. The pedestal shall be cast 5 mm 15 tnm short of the required finished level. The required level shall be achieved by chipping before placement of the bearing. Careful control shall be exercised to cast at the exact finished level or 1 mm 3 mm down from the required finished level. D. Seating of bearings shall be as per manufacturers instructions. 2007. INSPECTION AND TESTING Where any patents are used, the manufacturers certificate with test proofs shall be sttbmitted alongwith the design and got approved by the Engineer before their itse in work.
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2008. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The work shall confonn to these specifications and shall meet the prescribed standards of acceptance. 2009. MEASUREMENTS FOR PAYMENT Bearings shall be measured in numbers, according to their capacities and particular specifications given on the drawings. The quantity of elastomeric bearings shall be measured in cubic centimetres of finished dimensions. 2010. RATE The contract unit rate of each type of bearing shall include the cost of supplying and fixing the bearings in position complete as specified on the drawings or as decided by the Engineer. The rate shall also include the cost of samples and their testing when desired by the Engineer. In case of steel bearings the rate shall include the cost of all nuts,
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519
Section 2000
Bearings
bolts, the cost of all tests prescribed in the specifications and shown on the drawings. Where the Department supplies the bearings, the rate for fixing them shall include the cost of anchor bolts, their fixing, transport of bearings from the place of supply to the site, handling and placing them in position as per direction of the Engineer.
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520
Open Foundations
2100 Open Foundations
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Open Foundations 2101. DESCRIPTION
Section 2100
The work shall cover furnishing and providing plain or reinforced concrete Ibundation placed in open excavation, in accordance with the drawings and these specifications or as directed by the Engineer. 2102. MATERIALS Mate~rialsshall conform to Section 1000 of these Specifications. 2103. GENERAL A method statement for construction indicating the following shall he submitted by the Contractor for approval of the Engineer, well in advance of the commencement of open foundation
i) ii) iii) iv) v) vi) Sources of Materials Design, erection and removal of forenwork Prodectior, sraesportation, laying and curing of concrete Persomtct employed for execution and supervision Teats and sampliitg procedures Equipment details
vii) Any other point
Necessary arrangements for execution under water wherever necessary, shall he included in method statement. Dimensions, lines and levels shall be set out and checked with respect to permanent reference lines and permanent bench mark. 2104. WORKMANSHIP 2104.1. Preparation of Foundations Excavation for laying the foundation shall be carried out in accordance with Section 300 of these specifications. The last 300 mm of excavation shall be done just before laying of lean concrete below foundation. in the event of excavation having been made deeper than that shown on the drawing or as ordered by the Engineer, the extra depth shall be made up with MlS concrete in case of foundation resting on soil and foundation grade concrete for foundations in rock, at the cost of the Contractor and shall be considered as incidental work. Special care shall be taken not to disturb the bearing surface. Open fotindations shall be constructed in dry conditions and the Contractor
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523
Section 2100
Open Foundations
shall provide for adequate dewatering arrangements to the satisfaction of the Engineer. 2104.2. Setting Out The plan dimensions of the foundation shall be set out at the bottom of foundation trench and checked with respect to original reference line and axis. It shall be ensured that at no point the bearing surface is higher than the founding level shown on the drawing or as directed by the Engineer. 2104.3. Construction Where the bearing surface is earth, a layer of M15 concrete shall be provided below foundation concrete. The thickness of lean concrete layer shall be 100 mm minimum unless otherwise specified. No formwork is necessary for the lean concrete layer. For foundation concrete work, side formwork shall be used. Formwork for top of the foundation concrete shall also be provided, if its top has slopes steeper than I (vertical) to 3 (horizontal). When concrete is laid in slope without top formwork, the slump of the concrete shall be carefully maintained to ensure that compaction is possible without slippage down the slope of freshly placed concrete. In certain cases it may be necessary to build the top formwork progressively as the concreting proceeds up the slope. Reinforcement shall be laid as shown on the drawing. Before laying of lean concrete layer, the earth surface shall be cleaned of all loose material and wetted, Care shall be taken to avoid muddy surface. If any portion of the surface has been spoiled by overwetting, the same shall be removed. Concrete M15 shall be laid to the thickness as required. No construction joint shall be provided in the lean concrete. Before laying foundation concrete, the lean concrete or hard rock surface shall be cleaned of all loose material and lightly moistened. Foundation concrete of required dimensions and shape shall be laid continuously upto the location of construction joint shown on the drawing or as directed by the Engineer. Formwork and concrete shall conform to Sections 1500 and 1700 respectively of these specifications. Furnishing and providing steel reinforcement shall conform to Section 1600. The concrete surface shall be finished smooth with a trowel. The location of construction joint and its treatment shall be done as per
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524
Open Foundations
Section 2100
requirements of Section 1700. Formwork shall be removed not earlier than 24 hours after placing of concrete. Where formwork has been provided for top surface, the same shall be removed as soon as concrete has hardened. Curing of concrete shall be carried out by wetting of formwork before removal. After its removal, curing shall be done by laying not less than 10 cm of loose moistened sand, free from clod or gravel and shall be kept continuously moist for a period of 7 days. Dewatering, where necessary for laying of concrete, shall be carried out adopting any one of the following procedures or any other method approved by the Engineer:
i) A pit or trench deeper than the foundation level as necessary may be dug beyond the foundation pit ckinng construction so that the water level is kept below the foundation level. Water table is depressed by well point system or other methods. Use of steellconcrese caissons or sheet piling for creating an enclosure for the foundations, which can subsequently be dawatered,
ii) iii)
Before backfihling is commenced, loose sand laid on foundation shall be removed and dispersed as directed by the Engineer. All spaces excavated and not occupied by the foundation or other permanent works shall be refilled with earth upto surface of surrounding ground in accordance with Section 300. In case of excavation in rock, the annular space around foundation shall be filled with Ml 5 concrete upto the top of rock. The protective works, where provided shall be completed before the floods so that the foundation does not get undermined. 2105. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. No point of the surface of the lean concrete in the case of foundation on soil or the surface of hard rock in the case of foundation of hard rock, shalt be higher than the founding level shown on the drawing or as ordered by the Engineer. Levels of the surface shall be taken at intervals of not more than 3 metres centre to centre, subject to a minimum of nine levels on the surface.
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525
Section 2100
Open Foundations
2106. TOLERANCES
a) b) c) ci) Variation in dimensions Misplacement rrom specified position in plan Surface irregularities measured with 3 m straight edge Variation of levcls at the top 50mm 15 mm 5 mm 25mm
-
10 mm
2107. MEASUREMENT FOR PAYMENT Excavation in foundation shall be measured in accordance with Section 300 based on the quantity ordered or as shown on the drawing. Lean concrete shall be measured in cubic metres in accordance with Section 1700, based on the quantity ordered or as shown on the drawing. Concrete in foundation shall be measured in cubic metres in accordance with Section i700, based on the quantity ordered or as shown on l.he drawing. ~einforcement steel shall be measured in tonnes in accordance with Section 1600, based on the quantity ordered or as shown on the drawing. 2108. RATE The contract unit rates for excavation in foundation, lean concrete and concrete in foundation aftd reinforcement steel shall include all works as given in respective sections of these specifications and cover all incidental items for furnishing and providing open foundation as mentioned in this Section,
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526
Sub-structure
2200 Sub-structure
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Sub- structure 2201. DESCRIPTION
Section 2200.
The work shall cover furnishing and providing of masonry or reinforced concrete sub-structure in accordance with the drawings and as per these specifications or as directed by the Engineer. 2202. MATERIALS Materials shall conform to Section 1000 of these Specifications. 2203. GENERAL A method statement for construction indicating the following shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of sub-structure
1) ii) iii) iv) v) vi) Sources of Materials Design, erection and removal of fosmwork Production, transportation, laying and ewing of concrete Personnel employed for execution and supervision Tests and sampling procedures Equipment details
vii) Any other point
Arrangements for execution under water wherever necessary, shall be included in method statement. Dimensions, lines and levels shall be set out and checked with respect to permanent reference lines and permanent bench mark. 2204. PIERS AND ABUTMENTS Masonry, formwork, concrete and reinforcement for piers and abutments shall conform to relevant sections of these specifications. In case of concrete piers, the number of horizontal construction joints shall be kept minimum. Construction joints shall be avoided in splash zones unless specifically permitted by the Engineer and provided they are treated in accordance with special provisions. No vertical construction joint shall be provided. The work shall conform strictly to the drawings or as directed by the Engineer. In case of tall piers and abutments, use of slipform shall be preferred. The design, erection and raising of slipform shall be subject to special specifications which will be furnished by the Contractor. The concrete shall also be subject to additional specifications as necessary. All
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529
Section 2200
Sub- Structure
specifications and arrangements shall be subject to the approval of the Engineer. The surface of foundation/well capflile cap shall be scrapped with wire brush and all loose materials removed. In case reinforcing bars projecting from foundations are coated with cement slurry, the same shall be removed by tapping, hammering or wire brushing. Care shall be taken to remove all loose materials around reinforcements. Just before commencing masonry or concrete work, the surface shall be thoroughly wetted. in case of solid (non-spill through type) abutments, weep holes as shown on the drawings or as directed by the Engineer, shall be provided in conformity with Section 2706. The surface finish shall be smooth, except the earth face of abutments which shall be rough finished. In case of abutments likely to experience considerable movement on account of backfill of approaches and settlement of foundations, the construction of the abutment shall be followed by filling up of embankment in layers to the full height to allow for the anticipated movement during construction period before casting of superstructure. 2205. PIER CAP AND ABUTMENT CAP Formwork, reinforcement and concrete shall conform to relevant sections of these specifications. The locations and levels of pier cap/abutment cap/pedestals and bolts for fixing bearings shall be checked carefully to ensure alignment in accordance with the drawings of the bridge. The surface of cap shall be finished smooth and shall have a slope for draining of water as shown on the drawings or as directed by the Engineer. For short span slab bridges with continuous support on pier caps, the surface shall be cast horizontal. The top surface of the pedestal on which bearings are to be placed shall also be cast horizontal. The surface on which elastomeric bearings are to be placed shall be wood float finished to a level plane which shall not vary more than 1.5 mm from straight edge placed in any direction across the area. The surface on which other bearings (steel bearings, pot bearings) are to be placed shall be cast about 25 mm below the bottom level of bearings and as indicated on the drawings.
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530
Sub- structure
Section 2200
2206. DIRT/ BALLAST WALL, RETURN WALL AND WING WALL Masonry, concrete and reinforcement shall conform sections of these specifications. In case of cantilever return walls, no construction generally be permitted. Wherever feasible, the concreting return walls shall be carried out in continuation of the to relevant joint shall in cantilever ballast wall.
For gravity type masonry and concrete return and wing wall, the st face of foundation shall be prepared in the same manner as prescribed for construction of abutmeni No horizontal construction joint shall be provided. If shown on drawing or directed by the Engineer, vertical construction joint may be provided. Vertical expansion gap of 20 mm shall be provided in return wall/wing wall at every 10 metre intervals or as directed by the Engineer. Weep holes shall be provided as prescribed for abutments or as shown on the drawings. Formwork, reinforcement and concrete in dirt/ballast wall shall conform to relevant sections of these specifications. The finish of the surface on the earth side shall be rough while the front face shall be smooth finished. Architectural coping for wing wall/return wall in brick masonry shall conform to section 1300. 2207, TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The work shall conform to these specifications and shall meet the prescribed standards of acceptance. 2208. TOLERANCES IN CONCRETE ELEMENTS
(a) Variation in cross-sectiohal dimensions
+10 mm, -5 mm 10 mm 10mm

5 snm :
(b) Misplacement from specified position in plan

(c) Variation of levels at the top
(d) Variations of reduced levels of bearing areas

(e) Variations from plumb over fuil beigld Swface irregularities measured with 3 m atraigjn edge All surfaces except bearing areas Bearing areas
10mm
5 mm
(0
3 mm
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531
Section 2200 2209. MEASUREMENTS FOR PAYMENT
Sub- Structure
Masonry in sub-structure shall be measured in cubic metres in accordance with Section 1300 or 1400, based on the quantities ordered or as shown on the drawing. Concrete in sub-structure shall be measured in cubic metres in accordance with Section 1700, based on the quantity ordered or as shown on the drawing. No deduction shall be made for weep holes. Steel in concrete of sub-structures shall be measured in tonnes, in accordance with Section 1600, based on the quantity ordered or as shown on the drawing. Weep holes shall be measured as per Section 2700, based on the quantity ordered or as shown on the drawings.
2210. RATE
The contract unit rates for masonry, concrete, reinforcement and weep holes shall include all works as given in respective sections of these specifications and cover all incidental items for furnishing and providing substructure as mentioned in this Section.
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Concrete Superstructure
2300 Concrete Superstructure
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Section 2300 DESCRIPTION
2301.
The work shall cover furnishing and providing of concrete superstructure in accordance with the drawings as per these specifications or as directed by the Engineer. 2302. MATERIALS Materials shall conform to Section 1000 of these Specifications. 2303. GENERAL 2303.1. A method statement for construction, indicating the following, shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of the construction of superstructure
i) ii) iii) iv) v) vi) Sources of Materials Design, erection and removal of fonnwodc Production, transportation, laying and curing of concrete Prestressing sysiem, if applicable Personnel employed for execution and supervision Testa and sampling procedure
vii) Equipment details viii) Any other point
2303.2. Dimensions, lines and levels shall be set Out and checked with respect to permanent reference lines and permanent bench mark so that the final product is in accordance with the drawings or as directed by the Engineer. 2303.3. The work shall conform to the following sections besides stipulations in this section with regard to specific type of construction:
i) ii) iii) iv) Formwosk Strel Reinforcement Structural Concrete Prestressing Section Section Section Section 1500 1600 1700 1800
Additionally, some of the common types of superstructure construction shall have features as discussed in this Section. 2304. REINFORCED CONCRETE CONSTRUCTION 2304.1. Solid Slabs Where adjacent span of slab has already been cast, the expansion joint and filler board shall be placed abutting the already cast span which
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Section 2300
shall form the shutter on that side of the new span to be cast. The whole of the slab shall be cast with reinforcement embedded for the road kerb and railings. No other construction joint shall be allowed except with the express permission of the Engineer. Where wearing coat is required to be provided, after the deck slab has been cast, the surface of the slab shall be finished rough, but true to lines and levels as shown on the drawings, before the concrete has hardened. The areas of construction joints shall be treated in the prescribed manner. The top of the slab shall be covered with clean moist sand as soon as the top surface has hardened. Curing shall be carried out as per Section 1700. Where the slab is resting on bearings, the same shall be placed in position in accordance with the drawings, before casting of deck slab. 2304.2. RCC 1-Beam and Slab Provision of construction joint shall conform to the drawings or as per directions of the Engineer. No construction joint shall be provided between the bottom bulb and the web. If not indicated on the drawing, construction joint m~aybe provided at the junction of the web and the fillet between the web and the deck slab with the permission of the Engineer. The portions of deck slab near expansion joints shall be cast alongwith reinforcements and embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer. The surface finish of the deck slab shall be finished rough but true to lines and levels as shown on the drawings before the concrete has hardened. Care shall be taken for setting of bearings as indicated on the drawings. 2305. PRESTRESSED CONCRETE CONSTRUCTION
2305.1. PSC Girder and Composite RCC Slab

PSC Girder may be precast or cast-in-situ as mentioned on the drawing or as directed by the Engineer. Girders may be post-tensioned or pre-tensioned. Where precast construction is required to be adopted, selection of casting yard and details of methodology and of equipment for shifting an~J launching of girders shall be included in the method statement.
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Cuncrete Superstructure
Section 2300
In case of cast-in~~situ construction, the sequence of construction including side shifting of girders, if applicable, and placing on bearings shall be in accordance with the drawings. The PSC girder constituting the top flange, web and the bottom flange shall be concreted in a single operation without any construction joint. The portions of deck slab near expansion joints shall be cast alongwith reinforcements and embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer. The surface finish of the deck slab shall be finished rough but true to lines and levels as shown on the drawings before the concrete has hardened, Care shall be taken for setting of bearings as indicated on the drawings. 2305.2. Box Girder Box girders may be simply supported or continuous. Simply supported box girders shall have minimum construction joints as approved by! the Engineer. In the case of continuous box girders the sequence of con~tructionand location of construction joints shall strictly follow the drawings. The box section shall be constructed with a maximum of one construction joint located in the web below the fillet between the deck slab and web. If permitted by the Engineer, one additional construction joint may be permitted and this construction joint shall be! located in the web above the fillet between the soffit slab and web. The portions of deck slab near expansion joints shall be cast alongwith reinfotcements and embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer. The surface finish of the deck slab shall be finished rough but true to lines and levels as shown on the drawings before the concrete has hardened. Care shall be taken for setting of bearings as indicated on the drawings. 2305.3. Cantilever Construction Continuity~of untensioned reinforcement from one segment to the next must be ensured by providing full lap length as necessary.
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Section 2300
The design of the superstructure shall take into account the following aspects which form an integral part of the construction operations
a) b) Stability against overturning for each statical condition through which the assembly passes, shall be checked. Stresses at each preceding segment joint with the addition of evesy segment or change of statical conditions shall be checked, The load of equipment as well as construction live load shall be taken into accotmL Precanibenng of the superstructure during construction shall be done in such a manner that the finally constructed structure under permanent load attains the final profile intended in the drawings.
c)
2306. TOLERANCES 2306.1. Precast Concrete Superstructure Variation in cross-sectional dimensions

a) b) upto and including 2m over 2m Variation in length overall and length between bearings : 5 mm 5 mm shall not exceed 10mm or 0.1per cent of the span length, whichever is lesser
c)
Permissible surface irregularities when measured with a 3 m straight edge or template
5 mm -5 mm to +10 mm
2306.2. Cast-in-Situ Superstructure

a) Variations ir~ thickness of top and bottom slab for box girders, top and bottom flange for T.girders or slabs Variations in web thickness Variations in overall depth or width Variation in length overall and length between bearings
b) c) d)
-5
mm to +10 mm
5 mm shall not exceed +10mm Or 0.1per can of the span length, whichever is lesser 5 mm
e)
Permissible surface irregularities when measured with a 3 m straight edge or template
2307, TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The work shall conform to these specifications and shall meet the prescribed standards of acceptance.
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Section 2300
2308. MEASUREMENTS FOR PAYMENT Concrete in superstructure shall be measured in accordance with Section 1700, based on the quantity ordered or as shown on the drawings. Steel reinforcement (untensioned) in superstructure shall be measured in accordance with Section 1600, based on the quantity ordered or as shown on the drawings. High tensile steel (prestressing) in superstructure shall be measured in accordance with Section 1800, based on the quantity ordered or as shown on the drawings. 2309. RATE The contract unit rates for concrete, steel reinforcement (unten~ sioned) and high tensile steel (prestressing) shall include all works as given in respective sections of these specifications and cover all incidental items for furnishing and providing superstructure as mentioned in this section.
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Surface and Sub-surface Geotechnical Exploration
2400 Surface and Sub-surface Geotechnical Exploration
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Surface and Sub-surface Geotechnical Exporation 2401. GENERAL
Section 2400
2401.1. The objective of sub-surface exploration is to determine the suitability or otherwise of the soil or rock surrounding the foundation and soil parameters and rock characteristics for the design of foundation by in-situ testing or testing of sampIe~coresaken out of exploration. t The sub-surface exploration shall be planned in such a way that different types of soil upto the desired depth and their profile for the full proposed length of the bridge can be recorded and other information such as mechanical and physical properties like grain-size distribution, sensitivity, any existence of deleterious material in soil or ground water, etc., are determined alongwith soil parameters and rock characteristics. The sub-surface exploration shall also throw light on porosity of rock and subsidence due to mining, ground water level, artesian condition, if any, likely sinking and driving effort, likely constructional difficulties, etc. 2401,2, Field Investigation Field investigations of sub-surface has. usually three phases
i) ii) iii) Reconnaissance Preliminary Explorations Detailed Explorations
2401.2.1. Reconnaissance includes a review of available topographic and geological information, aerial photographs and data from previous investigations and site examinatiorr. 2401.2.2. Preliminary investigation shall include the study of existing geological information, previous site reports, geological maps, air photos, etc. and surface geological examination. For large and important structures the information may be supplemented by geophysical methods. In some cases where no previous sub-strata data are available, exploratory geophysical investigation may need to be supplemented by resorting to a few bore-holes. These will help to narrow down the number of sites under consideration and also to locate the most desirable location for detailed sub-surface investigation like bore or drill holes, sounding probes, etc. 2401.2.3. The scope of detailed investigation for bridges may be decided based on data obtained after preliminary investigation. Based on data obtained after preliminary investigations, the bridge site, type of
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Section 2400
structure with span arrangement and the location and type of foundations, shall be tentatively decided. Thereafter, the scope of detailed investigation including the extent of exploration, number of bore-holes, type of soundings, type of tests, number of tests, etc., shall be decided, so that adequate data considered to be necessary for the detailed design and execution, are obtained. 2401.2.4 The width of exploration One purpose of detailed exploration for high embankments is to ascertain the average shear strength of each strata. The other purpose is to ascertain the compressibility of the clayey strata. It is, therefore, necessary that detailed and well illustrated description of the characteristics of stratification should be prepared. After the general shape and trend of the boundaries of the various soil deposits have been determined and rough assessment of their strength has been made by sUb-surface sounding, with or without sampling in exploratory boring, the location of bore-hole(s) for undisturbed sampling shall be decided. At least one representative undisturbed sample should be collected from each strata, When the homogeneous strata is very thick, one representative sample shall be collected for each 3 m thickness of the strata. 2401.3. Soil investigation for foundations shall contain a programme for boring and retrieval of samples. The field work shall consist of excavation, drilling of bore-holes for the purposes of collection of undisturbed and disturbed samples, standard penetration tests, in-situ vane tests, static and dynamic cone penetration tests, other field tests, as specified by the Engineer and preparation of bore-logs. Collection and preservation for testing of disturbed and undisturbed samples from boreholes, borrow pits, etc., as specified by the Engineer shall form a part of the above. All in-situ tests shall be supplemented by laboratory investigations. Relevant Indiab Standards such as 15:1498, IS:1888, IS: 1892, 15:2131, IS:2132, IS:2720, 15:4434 and IS:4968 and Appendix I of IRC:78, etc., shall be followed for guidance. 2401.4. The soundings by dynamic method shall be carried out in bore-holes using a standard sampler as specified in IS:2131. 2402. PRELIMINARY INVESTIGATION 2402.1. Foundations 2402.1.1. Preliminary exploration shall be carried out to determine the soil profile showing the boundaries between the different soil types and between loose and dense parts in the same type of deposits.
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Surface and Sub-surface Geotachnical Exploration
Section 2400
For guidance reference may be made t~LRC:75. For this purpose, as a first step, a suitable type of sub-surface sounding (e.g. static or dynamic cone penetration test) shall be carried out. As many soundings as necessary should be made, until the penetration data is complete enough to leave no doubt concerning the general shape and the trend of boundaries of the various soil deposits. Exploratory drill holes should then be made at one or two locations where average condition prevails and near those few points where the penetration diagrams indicate maximum deviations from the average. 2402.1.2. The exploration shall cover the ~ntire length of the bridge and also extend at either side for a distance about twice the depth below bed of the last main foundations. If there is any necessity for designing investigation for approaches particularly on soft soil or with high embankment or there is a possibility of considering alternatives between via~luctor earthen embankment, the extended length anl location of the borings beyond the proposed .iccation of abutment should be determined and executed. 2402.1.3. The depth of exploration should be at least iV2 times the minimum width of foundation below the proposed foundation level. Where such investigation end in any unsuitable or questionable foundation material the exploration shall be extended to a sufficient depth into firm and stable soils or rock but not less than four times the minimum depth of foundation below the earlier contemplated foundation level. In case of good sound rock the stipulation of minimum depth ma~ be decreased based on difficulty to conduct core drilling and the minimum depth may be resthcted to 3 metres. 2402.2. Guidebund and Embankment
The depth of exploration should include all strata likely to affect stability of the embankment, guide bund and/or cause undesirable settlement. In general, the requirement of settlement governs the depth of exploration for high embankments in particular. However, borings can be terminated at shallower depths when firm strata or bed rock is encountered. Ordinarily, the boring shall be taken to a depth of at least 1.5 times the height of embankment and guidebund. However, where highly compressible strata are encountered, the boring may have to be taken deeper. In order to ensure that farm strata is sufficiently thick, the boring should extend 3 metre into the firm strata.
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Section 2400
Surface and Sub-surface t3coteclmical Exploration
2403. DETAILED EXPLORATION 2403.1. The exploration shall cover the entire length of the bridge and also extend at either end for a distance of about twice the depth below bed of the last main foundation to assess the effect of the approach embankment on the end foundations. Generally the sub-surface investigations (preliminary and detailed) for bridges shall extend to a depth below the anticipated foundation level equal to about one and a half times the width of the foundation. However, where such investigations end in any unsuitable or questionable foundation material, the exploration shall be extended to a sufficient depth into firm and stable soils or to rock. 2403.2. The type and extent of exploration shall be divided into the following groups as per requirement of foundation design and likely method of data collection
i iii) Foundation requiring shallow depth of exploralion Fills behind abutments and protection wo~ts i~) Foundation requiring large depth of exploration
24033. Location Boring Where the data made available by detailed exploration indicates appreciable variation or where variations in a particular foundation are li~el, o appreciably affect the construction (specially in case t of bridge foundations resting on rock), it will be necessary to resort to additional bores/soundings to establish complete profile of the underlying strata, The additional borings /soundings shall be decided depending upon the extent of variation at a particular foundation location and should cover the entire area of the particular foundation. 2403.4. Construction Stage Exploration Whenever a change in the sub-soil strata/rock profile is encountered during construction, explorations shall be resorted to establish the correct data for further decisions. 2403.5. Logging of bore..holes by radio-active methods shall be done for detailed investigations as specified in the contract or in special provisions. 2403.6. For bridge works, the investigations shall be comprehensive enough to, enable the designer to estimate or determine the following
i) the engineering properties of the soit/rod 546
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Surface and Sub-surface Geotechnical Exploration ii) iii) iv) v) vi)
Section 2400
the l~cationand extent of soft layers and gas pockets, if any, under the hard founding strata, the geological condition like type of rock, faults, fissures or sabsidence due to mining, porosity etc., the ground water level, artesian conditions, if any, quality of water in contact with the foundation,
vii) the depth and extent of scour, viii) suitable depth of foundation, ix) a) xi) the bearing capacity of the foundation, probable settlement and probable differtstial settlement of the foundations, likely sinking or driving effort, and
xii) likely coustmction difficulties.
2404. EXPLORATION FOR BRIDGE FOUNDATIONS RESTING ON ROCK 2404.1. Investigation and interpretation of data for rock is a specialised work. To arrive at the characteristic strength of rock mass, reliance shall be placed more on in-situ tests in comparison to laboratory tests. An engineering geologist shall also be associated in the exploration programme. 2404.2. Identification and classification of rock types for engineering purposes may in general be limited to broad, basic geological classes in accordance with accepted practice. Strength of parent rock alone is of limited value because overall characteristics depend considerably on character, spacing and distribution of discontinuities of the rock mass, such as the joints, bedding planes, faults and weathered seams. An important factor affecting the behaviour is the weathered zone at top. 24043. Basic Information Required from Explorations
i) Depth of rock strata and its variation ovdr the site,
ii) iv) v)
vi)
Whether isolated boulder or massive rock formation, Stmcnue of rock. including bedding planes, fauks, fissures, solution cavities etc., Properties of rock m
si-strength, geological formation, etc.,
iii) Extent and character of weathered zone,
Erodibilily of rock to the extent possible.
vii) Colour of water.
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Section 2400
Surface and,Sub-surface Geotechnical Exploration
2404.4. Exploration Programme If preliminary investigations have revealed presence of rock within levels where the foundation is to rest, it is essential to take up detailed investigation to collect necessary information mentio~ied in clause 2404.3. The exploratory bore-hole shall be drilled into the rock to a depth of about 3 metres to distinguish a boulder from a continuous rock formation. 2404.5. The extent of exploration shall be adequate enough to give a complete picture of the rock profile both in depth and across the channel width to assess the constructional difficulties in reaching the foundation levels. 2404.6. The depth of boring in rock depends primarily on local geology, credibility of the rock, extent of structural loads to be transferred to foundation etc. Normally, it shall pass through the upper weathered or otherwise weak zone, well into the sound rock. Minimum depth of boring in sound rock shall be 3 metres. 2404.7. Detailed Investigation for Rock 2404.7.1. This covers sounding, boring and drilling. An adequate investigation programme shall be planned to cover the whole area for genera! characteristics and in particular the foundation location, to obtain definite information regarding rock-depth and its variation over the foundation area. The detailed programme of exploration will depend on the type and depth of over-burden, the size and importance of the structure, etc. To decide this, geophysical methods adopted at the preliminary investigation stage will be helpful, this data being supplemented by sounding, bore-holes and .drill holes. 2404.7.2. Drilling through rock is a very specialised work and every care shall be taken to notice and record any small change during drilling. The time required to drill through a certain depth, amount of core recovery, physical condition, length of pieces of core~.oints, j colour of water residue, weathering and evidence of disturbance and other effects shall be carefully noticed and entered in the drilling log. For guidance, IS:5313 may be referred to. The data shall be presented in accordance with 15:4464. 244)4.7.3. The cores shall be stored properly in accordance with
JS:4078.
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Section 2400
2404.7.4. The rock cores obtained shall be subjected to following laboratory tests:
i)
Visual identification for texture, stmctuie, composition, colour and grain size. Laboratory tests shall be done for specific gravity, porosity and moisture content.
ii)
2404.7.5. In-situ tests shall be made in accordance with IS:7292; IS:73l7; and IS:7746. In addition, laboratory tests can also be made on samples. 2404.7.6. Usc of in-situ tests for measuring strength and deformation characteristics shall be made. Use of bore-hole photography will be desirable to evaluate the presence of faults, fissures or cavities, etc.. 2404.8. Special Cases 2404.8.1. Investigation for conglomerate : A drill hole shall be made same as for rock. The samples collected shall be subjected to suitable tests depending upon the material, special care shall be taken to ascertain erodibility of the matrix. Where possible, specially for shallow foundation, Plate Load Test shall be conducted. 2404.8.2, Investigation for laterites : The investigation shall be generally similar to that required for cohesive soils, use of penetration tests shall be preferred, if suitable correlation charts are available. This may be static or dynamic penetration tests or vane shear tests. In the case of hard laterite, recourse may have to be made to core drilling as for soft rocks. For laterites at shallow depths, use of Plate Load Test may be advantageous. 2404.9. Caution 2404.9.1. The interpretation of laboratory results on rock samples depends upon the relationship of the specimens tested to the overall rock characteristics, enumerated in Appendix 1 of IRC:78. For this purpose, care shall be exercised in the choice of specimen size and its orientation in relation to the joint pattern. 2404,9.2. In some cases, the foundation behaviour will be dominated by a possible mode of failure involving movement along some joint surface, fissures or weak layer within a generally strong rock system and also by possible weathering. In-situ shear tests may be conducted wherever feasible, as such tests are likely to give more representative data than the shear tests conducted on core samples.
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Section 2400
Surface and Sub-surface Geotecimical Exploration
2404.10. Presentation or Data The data shall be given in diagrammatic form in 3 sheets giving the following details Sheet 1: Plan showing the position of bore-holes clearly marked so as to fix the position at a future date. Sheet 2 : This shall contain the bore-log chart and test results of the samples separately for each bore-hole/pit etc. Sheet 3 : This shall contain pictorial representation of the borelog data to get an overall picture of the soil profile at the crosssection of the river. NOTE : For guidance, refer to lRC:78~. 2405. BORING Boring shall be done by any of the following methods depending on the soil type and types of samples required for the investigation:
i) ii)
Auger Boring
Shell and Auger Boring
iii) Percussion Boring

iv)
W.jh Boring
Rotary Boring
v)
For preliminary and detailed sub-surface investigation only rotary drills shall be used. The casing shall also be invariably provided with diameters not less than 150 mm upto the level of rock, if any. However, use of percussion or wash boring equipment shall be permitted only to penetrate through bouldery or gravelly strata for progressing the boring but not for the collection of samples. While conducting detailed borings, the resistance to the speed of drilling i.e. rate of penetration, core loss, etc., as already specified in Appendix 3 of IRC:78 shall be carefully recorded to evaluate the different types of strata and to distinguish specially sand from sandstone, clay from shale, etc. 2406. RECORDS OF BORINGS AND TRIAL PiTS 2406.1. The field records for the preliminary and detaIled exploration shall contain the date when the boring was made, the location of the boring with reference to a permanent system of co-ordinates and the elevation of the ground surface with respect to a permanent bench mark. They shall include elevation at which the water table axtd the upper boundary of each of the successive soil strata were encountered,
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Section 2400
the investigators classification of the layer on the basis of general information obtained from field examination (refer to Appendix 2.1 of IRC:75) and the value of the resistance obtained by means of Standard Penetration Test. The type of tools used for borings shall be recorded. If the tools were changed, the depth at which the change was made and the reason thereof shall also be noted. Incomplete and abandoned borings shall be described with no less care than successfully completed drill holes. The notes shall contain everything of significance observed on the job such as the elevation at which wash water was lost from the hole. 2406.2. For all borings and. trial pits, necessary information as detailed below shall be given. A site plan showing the disposition of the bore holes shall also be attached
a) b)
c) d) e)
Agency Location with reference map

Pit1Bor~-ho1enumber Reduced level (RI.) of ground suiface or other reference point
Dates of starting and completion Name of supervisor Scales of pans and sections
0
g) It)
Dimensions, methods of advancing exploration such as by hand tools, blasting. boring, etc. Generaldescriptionofatratametwith and RLs at which they are met Position and ahitude of contaas, faults, strong joint, slidcen sides, etc. Inflow of water, methods of controlling the water, required capacity of pumps for dewatering Thelevelatwhichthe sub-soil water is met with
Dip and strike of bedding and of cleavage. Visual description of strata
i)
j) k) I)
m)
n) o)
Results of field tests e.g. SPT, in-situ vane shear test etc. Any other information and remarks.
p)
2406.3. Upon removal of sampling tube, the length of the ~imple in the tube and the length between the top of the tube and the top of the sample in the tube shall be measured and recorded. 2407. METHODS OF SAMPLING There are two types of samples viz. (a) Disturbed sample (b)
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Section 2400
Undisturbed sample. The usual methods for sampling conforming to IS:1892 and IS:2132 are given below
Nature of Ground
Soil Type of Sample Disturbed
Method of Sampling
Hand Samples Auger San~ples Shdl Samples
~ Undisturbed
Rock Disturbed
Hand Samples Tube Samples

Wash Samples from percussion or rotary drilling Cores
Undisturbed
2408. PROCEDURE FOR TAKING SAMPLES 2408i. For proper identification of sub-surface material, sample should be recovered containing all the constituents of the materials in their proper proportion. In clayey deposits such samples could be collected by split spoon samplers. In the case of sandy deposits, sampling spoons shall be fitted with suitable devices for retaining samples. All data required for soil identification (Appendix 2.1 of IRC:75) should be collected from the samples so extracted when undisturbed samples, which are more desirable for collection of some of the data, are not available. Penetration test should be carried out with the standard splitspoon sampler or penetrometers if the soil is coarse grained. When it is known in advance that the soil profile is fairly regular, preliminary and detailed investigation may be combined. Tube samplers can be used in place of split spoon samplers for collecting samples in clayey strata. 2408.2. Disturbed Soil Samples 2408.2.1. Disturbed samples of soil shall be obtained in the course of excavation and boring. For procuring samples from below the ground water level, where possible, special type of sampler shall be used. Where Standard Penetration Test is conducted, representative samples shall be obtained from the split spoon. While collecting disturbed samples from borrow areas it shall be ensured that the samples collected represent all types of borrow materials to be used in the construction of embankment and sub-grade. 2408.2.2. The size of sample generally required shall be as given in Table 2400-1.
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Surface and Sub-surfale Geotechnical Exploration TABLE 2400-1 SIZ~ SOIL SAMPLE REQUIRED OF S. I.
Section 2400
No. PURPOSE OF SAMPLE SOIL TYPE

Soil identification, natural moisture content tests, mechanical analysis and index properties,
WEIGW.1 OP SAMPLE REQUIRED Kg 1 3
Cohesive soils
Sands and Gravels
chemical tests Compression testS
2,
3.
Comprehensive examination of construction material and borrow area soil including soil
stabilisaticn
Cohesive soils and sand Cohesive soils and sands Gravelly soil
12.5 25 - 50
50
-
100
2408.2.3, While taking out disturbed soil samples, Standard Penetration Test may also be conducted to find out the bearing capacity of the sub-soils at specified levels. 2408.3. Undisturbed So Samples 24083.1. The location of the bore-hole shall be as indicated on the drawing or given by the Engineer. The depth of the bore-hole shall be as indicated on the drawing or shall be governed by the criteria given therein or as directed by the Engineer. 24083,2. Samples shall be obtained in such a manner that their moisture content and structure do not get altered. This may be ensured by careful protection and packing and by use of correctly designed sampler. 2408.3.3. Standard Penetration Test may have to be conducted in each case to obtain additional data as directed by the Engineer. In soft clay, in-situ vane shear test as per JS:4434 may have to be conducted. Where all the three operations have to be carried out in one layer, the sequence shall be undisturbed soil sampling followed by in-situ vane shear test, followed by Standard Penetration Test. 2408.3.4. For compression test samples, a core of 40 mm diameter and about 150 to 200 mm length may be sufficient, but for other laboratory tests, a core of 100 mm diameter and 300 mm length
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553
Section 2400
shall be taken as far as possible, unless otherwise specified by the Engineer. 2408.3.5. The upper few millimetres of both types of sample shall be rejected as the soil at the bottom of the bore hole usually gets disturbed by the boring tools. 2408.4. Rock Samples 2408,4.1. Disturbed samples: The sludge from percussion borings or from rotary borings which have failed to yield a core, shall be collected for a disturbed sample. It may be recovered from circulating water by settlement in a trough. 2408.4.2. Undisturbed samples Block samples taken from the rock formation shall be dressed to a size of about 90 x 75 x 50 mm. For core samples cores of rock shall be takth by means of rotary drills fitted with a coring bit with core retainer, if warranted. 2408.4.3. In case of rock at shallow depths which can be conveniently reached, test pits or trenches are the most dependable and valuable methods since they permit a direct examination of the surface, the weathered zone and presence of any discontinuities. It is also possible to take representative samples for tests. For guidance, IS:4453 may be referred to. 2409. PROTECTION, HANDLING AND LABELLING OF SAMPLES 2409.1. Care shall be taken in handling and labelling of samples so that they are received in a fit state for examination and testing and can be correctly identified as coming from a specified trial pit or boring. 2409.2. The disturbed material in the upper end of the tube shall be completely removed before applying wax for sealing. The length and type of sample so removed should be recorded. 2409.3. The soil at the lower end of the tube shall be reamed to a distance of about 20 mm. After cleaning, both ends shall be sealed with wax applied in a way that will prevent wax from entering the sample. Wax used for sealing should not be heated to more than a few degrees above its melting temperature. The empty space in the samplers, if any, should be filled with moist soil, saw dust, etc., and the ends covered with tight fitting caps.
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554
Surface and Sub-surface Geotechnical
Exploration
Section 2400
2409.4. Labels giving the following information should be affixed to the tubes
a) Tube number
b)
c) d) e) f)
Job designation
Sample location
Boring number
Sample number Depth
g)
h)
Penetration Gross recoveiy ratio
The tube and boring numbers should be marked in duplicate. Duplicate markings of the boring number and sample number on a sheet which will not be affected by moisture should be enclosed inside the tube. 2410. TESTS FOR EXPLORATION OF SHALLOW FOUNDATIONS OF BRIDGES 2410.1. Test pits or trenches are the most dependable and valuable methods of exploration since they permit direct visual examination and more reliably the type of soil and their stratification. This will also allow in-situ tests like plate bearing tests, shear tests and uni-axial jacking tests, etc. 2410.2. Tests shall be conducted on undisturbed samples, which may be obtained from pen pits. The use of Plate Load Test (as per 15:1888) is considered desirable to ascertain the safe bearing pressure and settlement characteristics. A few exploratory bore holes or soundings shall be made to safeguard against presence of weak strata underlying the foundation. This shall extend to a depth of about P12 times the proposed width of foundation. The laboratory results shall correlate with in-situ tests like Plate Load Tests and Penetration Test results. 2411, TESTS FOR EXPLORATION FOR DE1~PFOUNDATIONS OF BRIDGES 2411.1. The tests to be conducted at various locations for properties of soil, etc., are different for cohesive and cohensionless soils. These are enumerated below and shall be carried out, wherever practicable, according to soil type.
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555
Section 2400
2411.1.1. Cohesionless soil

a) b) aassifkation tests, density, etc. Field tests.
-
Plate Load test as per IS:l88& Dynamic Penetration test as per IS:2l31 and Use of Dynamic Cone penetration test as per 15:4968 (Part I or Pan 2) may be conducted where considered appropriate
c)
Laboratory tests : Sharing strength test - triaxial or box shear test - in case of the possibility of rise of water table, the tests shall be done on sawrated samples.
-
2411.1.2. Cohesive soils

a)
b)
Classification tests, density, etc.

Field tests
-
Plate Load Test. Unconfined Compression Test as per 15:2720 (Part 10). Vane Shear Test as per 15:4434. Static Cone Penetration Test (15:4968 Part 3),
-
c)
Laboratory tests : Shearing strength test dation Test (15:2720 Part 15)
triaxial tests (15:2720 Part 9). Consoli-
Note
: Where dewatering is expected, samples may be tested for permeability (15:2720 Part 17.).
2411.2. The sub-surface exploration for bridge works can be divided into 3 zones
i) ii) iii) between bed level and upto anticipated maximum scour depth (below H.F+L.) from the maximum scour depth to the foundation level. from foundation level to about P4 times the width of the foundation below it.
2411.3. The sub-soil water shall be tested for chemical properties to ascertain the hazard of deterioration to foundations. Where dewatering is expected to be required, permeability characteristics shall be determined. 2411.4. For the different zones categorised in pant 2411.2 the data required, such as soil classification, particle size distribution, shearing strength characteristics, method of sampling disturbed and undisturbed samples, testing, including particle size distribution, shear strength, unconfined compression test, shall be complied with. 2412. TESTING OF MATERIAL FOR GUIDE BUND AND HiGH EMBANKMENT AND ITS FOUNDATIONS 2412.1. The soil properties for the embankment foundation shall be as specified in particular specifications and shall be got verified 556
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Section 2400
prior to construction operation. In case the actual soil properties do not match the particular specification, then embankment design shall be revised. 2412.2. Field investigation for the embankment material should be carried out to collect general information as indicated in IRC:75. For details refer to Clause 305. Field investigatior.s for sub-soil strata shall consist of taking minimum two bore holes for each approach to a bridge along centre line of the alignment at a distance of 50 m and 120 m behind the abutment positions on both sides. The depth of bore holes below the ground level Enay ordinarily be 2.5 times the maximum height of the embankment subject to minimum depth of 20 m. Thin walled sampling tubes of 100 m~n internal diameter and 450 mm minimum length conforming to IS:2132 shall be used for collecting undisturbed samples from bore-holes at an interval of 2.5 to 3.5 m. Standard penetration test should be conducted immediately after undisturbed sample is collected. 2412.3. In addition to the relevant identification tests, mentioned in IRC:75, it shall be necessary to conduct some of the following tests on the undisturbed samples collected from the sub-strata. The choice of test is primarily determined by the type of soil, type of stability analysis (vide Table 2400-2), availability of apparatus and cost of investigation.
TABLE 2400.2 SHEAR STRENGTH TESTS FOR STABILITY ANALYSIS S. Stage in LIfe No. of Embankment 1. (a) Strength Parameters Shear Test Unconsolidated undrained triaxial shear test on undisthibed samples and on compacted embankment material Type of Analysis Total
During construction
or immediate post-construction cuu, ~uU
stress
analysis
(b)
do
S~
Unconlined compression
test in laboratory or
do
vane shear test

I
(c)
During construction or immediate

post-construction
c~
Consolidated undrained Effective test with pore-pressure stress measurement on as analysis compacted soil samples of embankment materials and on undisturbed samples
2.
Long term stability
C~
do
do
557
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Section 24(X)
2412.4. Laboratory Investigations of Embankment Material 2412.4,1. The following tests should be conducted on representative samples of embankment material
S. NO.
I)
TEST
Gradation Test (Sieve Analysis) Aucrberg Limit Test
TEST METHOI)
15:2720 (Part 4) IS:2720 (Part 5)
ii) iii) iv)
Standard Proctor Test

Natural Moisture Content
IS:2720 (Part 7) 15:2720 (Part 2)
2412.4.2 In addition to the above, there is need for shear strength tests on compacted samples of the fill material. For this purpose, the relative compaction should be 95 per cent of the Standard Proctor maximum dry density and moisture content, same as that likely to prevail in the embankment during the period covered by the stability analysis or to be used in the field during construction. Undrained test shall be run on cohesive soils and sheer strength parameters should be ascertained for the ranges of normal pressures which are likely to be experienced in the field. In cases where effective stress analysis is required to be done, pore-pressure measurements should also be made during the undrained tests and effective strength and pore-pressure parameters should be found out. For fill material of cohesionless soils, a direct shear box test (!S:2720-Part 13) may be conducted to ascertain shear strength of soil. 2412.4.3. The results of reconnaissance, field and laboratory investigations for embankments shall be consolidated into a well-knit report. The record of findings and recommendations, if any, may be presented in the form of written test, graphs, figures and tables, as appropriate for different types of data and findings. Information and data to be contained in the report should include general location map, pertinent geological information on reconnaissance observations, sub-soil profile (Fig. 2,1 of IRC:75), boring logs and summary of sub-soil properties (Fig. 2.2 of IRC:75), graphs and tables related to laboratory investigations, results of borrow area investigations (Fig, 2.3 of IRC:75) and recommendations, if any. The undisturbed samples shall be collected from each layer of sub-soil unless the stratum is such that undisturbed samples cannot be collected using ordinary sampler. Where indicated by the Engineer, undisturbed samples shall be collected using piston sampler or corecutter or such special devices. In thick layers undisturbed samples shall be collected at 3 m interval.
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558
Section 2400
2413. MEASUREMENTS FOR PAYMENT In case of bridge and road structures, the work of boring and trial pits shall be considered as incidental to the foundation works and nothing extra shall be paid unless otherwise specified in the contract In cases where it is specified to be paid separately, like contract for soil investigation, the work shall be measured in running metres for boring, in cubic meters for trial pits, in number of samples for collection of disturbed and undisturbed samples and in number of tests for each type of test. 2414. RATE The contract unit rate shall include the cost of all labour, materials, tools and plant an5 equipment required for doing the boring or making pits as per these specifications, taking out and packing the samples, sending and getting them tested in approved laboratories and making available the test report as specified or directed by the Engineer inclusive of all incidental costs to complete the work as per the specifications.
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559
River Training Work and Protection Work
2500 River Training Work and Protection Work
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River. Training Work and Protection work 2501 DESCRIPTION
Section 2500
River training and protection work shall include construction of guide bunds, guide walls, bank protection, flooring and approach embankment protection as required for ensuring safety of the bridge structure and its approaches against damage by flood/flowing water. Construction of various components shall conform to IRC:89 and these specifications or as directed by the Engineer. 2502. GUIDE BUND 2502.1. This work shall consist of construction of embankment of guide bund and provision of pitching/rivetment on slopes, apron, toe protection, curtain walls etc. as indicated on the drawing in accordance with these specitkations or as approved by the Engineer. The provisions given hereunder are applicable only to guide bunds for bridges across alluvial rivers. Guide bonds for bridges across submontane rivers shall call for supplemental specifications. 2502.2. The alignment and layout of guide bund shall be as indicated on the drawing or as approved by the Engineer. The construction of embankment for guide band shall conform to provisions of SecLion 300 of these Specifications. Pitching, filter underneath pitching and turfing, apron, toe protection, curtain walls, etc., shall be as per these specifications. 2502.3. Guide bands shall generally be made of locally available materials from the river bed preferably cohesionless materials. Trial pits shall be taken in borrow holes to examine suitability of soil for construction and also to decide the types of earth moving machinery to be arranged. The borrow pits should be sufficiently away from the location of the launching apron. No borrow pits should be dug on the river side of the guide bunds. Construction of guide band shall be taken in hand alongwith the construction of the bridge. Every effort shall be made to complete the work of the guide bund in one working season. Where there is any doubt about completion of the whole guide bund within one working season, suitable measures shall be planned and executed for protection of completed work. In such cases the construction of guide bund shall be started from abutment towards upstream. 563
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Section 2500
River Training Work & Protection Woat
2502.4, Construction of apron and pitching of the guide bonds shall generally confonu to clause 2503 and 2504 of these Specifications. Sufficient, length of pit along the guide bond shall be ready within one to two months of commencement of work so that the placing of stones in the apron and in the slope pitching can be commenced. As a guideline, earthwork should be completed within 80 per cent of working season and about 70 per cern working season shall be available for laying apron and pitching. No portion o the guide bond should be left below HFL before the onset of monsoon.: Bottom of apron pit shall be as low as permitted by sub-soil waler/lowest water level. Sufficient labour and appropriate earth moving machinery and trained staff shall be deployed in construction. 2502.5. The Contractor shall furnish his planning for approval of the Engineer regarding transport of stones from the quarries to the site of work inking into account the quantities of stone required to be transported every day, train/truck, etc., deployed, available ferry or boats and labour available for loading and unloading and fbr laying within the time frame for construction of guide bond. Adequate reserve of stones should be maintained for major works as decided by the Engineer. Reserve stones shall be stacked far away from the main channel of the river. 2502.6. Where the alignment of guide bond or the approach embankment crosses a brunch channel of the river, the branch channel may be either diverted to the main channel of the river with the help of spurs, etc. or closed by a properly designed closing dyke or closure bund before taking up construction of guide bond. 2503. APRON 2503.1. General This work shall consist of laying boulders directly or in wire crates on the bed of rivers for protection against scour Where the required size of boulders are not available economically, cement concrete blocks of equivalent weight shall be used. The grade of concrete shall be M 15 nominal mix, (This holds good for pitching on slopes and flooring also). Cement concrete blocks shall be preferred where practicable. The stones used in aprOn shall be sound, hard, durable and fairly regular in shape. Stone subject to marked deterioration by water or weather shall not be used.
564
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River Training Wait & Protection Work
Section 2500
Quarry stones are preferable to round boulders as the latter roll off easily. Angular stones fit into each other better and have good interlocking characteristics. Where the required size stones are not economically available, cement concrete blo~ks Ml 5 grade conforming to Section 1700 or in stones in wire crates in combination may be iLsed in place of isolated stones of equivalent weighL Cement concrete blocks will be preferred, wherever practicable. 25032. Laying Boulder Aproth The size of stone should conform to clause 5,3,7,2 of IRC:89. The size of stone shall be as large as possible. In no case any fragment shall weigh less than 40 kg. The specific gravity of stones shall be as high as possible and it shall not be less than 2.65. To ensure regular and orderly disposition of the full intended quantity of stone in the apron, template cross walls in dry masonry shall be built about a metre thick and to the full height of the specified thickness of the apron at intervals of 30 metres aft along the length and width of the apron. Within these wails, the stone then shall be hand packed. The surface on which the apron is to be laid shall be levelled and prepared for the length and width as shown on the drawings. In case the surface on which apron is to be laid is below the low water level, the ground level may be raised upto low water level by dumping earth and the apron laid thereon. The quantity of stone required in the apron shall be re-worked out by taking the toe of pitching at higher level. 2503.3. Laying Wire Crates and Mattresses in the Apron Wire crates shall be made from hot dipped galvanized mild steel wi:re of diameter not less than 4 mm in annealed condition having tensile strength of 300450 ItPa conforming to IS:280. The galvanizing coating shall be heavy coating for soft condition conforming to 15:4826. The mesh of the crate shall not be more than 150 mm, Wire crates for shallow or accessible situations shall be 3 metre x 1.5 metre x 1.25 metre in size. Where these have to be deposited and there is a chance of overturning, the crate shall be divided into ii metre compartments by cross netting.
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ccc
Section 2.5(X)
River Training Work & Proteaion Work
For deep or inaccessible situations, wire crates smaller subject to the approval of the Engineer.
can be made
Wire dates built in~-situ, shall not he larger than 7.5 metres x 3 metres x 0.6 metre, nor smaller than 2 metres x 1 metre x 0.3 metre Sides of large crates shall be securely stayed at intervals of
not more than 1 .50
metres to prevent bulging.
The netting shall be made by fixing a row of spikes on a beam at. a spacing equal to the mesh. The beam must be a little longer than the width of netting required. The wire is to be cut to lengths about three times the length of the net required. Each piece shall be bent at the middle around one of tt~e.~spikesand the weaving commenced IrVin one corner, A double twist shall he given at each intersection. This twisting shall he carefully done by means of a strong iron bar, five and half turns being given to the bar at each splice. The bottom and two ends of the crate or mattress shall he macIc at one time. The. other two sides shall he made separately and shall he secured tn the bottom and the ends by twisting adjacent wires together. The top shall he made separately and shall be fixed in the same manner as the sides after the. crates or mattress have been filled. Wherever possible, crates shall be placed in position before filling with boulders. The. crates shall be filled by carefully hand~packing the boulders as. tightly as possible and not by merely throwing in stones or boulders. For laying of wire crates in aprons of bridges, two situations arise:
i)
ti)
Where the crates arc to be bid in deep water and have to be dumped and then joined together. Where depth of water is tow or dry bed is avaitabte, tn such cases, the crates can be laid at site.
2504. PITCHING / REVETMENT ON SLOPES 2504.1. Description This work shall consist of covering the slopes of guide hunds, training works and road embaukments with stone, boulders, cement concrete blocks or stones in wire crates over a layer of granular material called filter. While river side slopes are given this protection against river action, the rear slopes, not subjected to direct attack of the river,
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River Training Work &
Protection Work
Section 2500
may be. protected against ordinary wave splashing by 0.3M.6 metre thick cover of clayey or silty earth and turfed. 2504.2. Pitching/Filter media 2504.2.1. Pitching : The pitching shall be provided as indicated in the drawings. The thickness and the shape of stone pitching shall he shown on the drawing. The stone shall be sound, hard, durable and fairly regular in shape. Quarry stone should be used. Round ho ulders shall not he. allowed. The stone.s subje.ct to marked deterioration by water or weather shall not he accepted. Thes ize and weight of stone shall conform to clause 5.3.5.1 of l.R,C:89. No stone, weighing les~sthan 40 kg shall, however, he used. The s. izes of spalis ,sha,I I be a minimum of 25 mm and shall he suitable to fill the. voids in the pitching. Where. t.he required size stones are not economically available., cement concrete blocks in MIS grade conforming to Section 17(X) or stone.s in.wire crates may be used in place of isolated stones of equivalent weight. Cement concrete blocks will be preferred wherever practicable.. Use of geosynthetics has been dealt with in Section 700. 2504,2.2, Filter media : lhe material for the filter shall consist of s.and, gravel, stone or coarse sand. To prevent escape of the embankment material through the voids of the stone pitching / cement concrete blocks as well as to allow free movement of water without creating any uplift head on the pitching, one or more layers of graded materials, commonly known as a filter medium, shall be provided underneath the pitching. The gradation of the filter material shall satisfy the following re~ quircme.nts Provision of a suitably designed filter is necessary under the slope pitching to prevent the escape of underlying embanktnent material through the. voids of stone pitching/cement concrete blocks when suh~ jected to the attack of flowing water and wave action, etc. In order to achieve, this requiretnent, the filter may be provided in one or more layers satisfying the following criteria D 15 (Filter) <5 D 85 (Base) (Filter) < 20 D 15 (Base)
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567
Section 25(X)
River Training Work & Protection Work
D 50 (Filter) <25 D 50 (Base)

Notes I. Fitter design may not be required if embankment coon us or cit or Ch soits with liquid timit greater than 30, resistant to nsirrace erosion. to this case, if a tayer of material is used as bedding for pitching, it shall be welt graded and its It) 85 size shatt be at teast twice the nsaximum void size in pitching. tn the foregoing, 0 15 means the size of that sieve which attows 15 per cent by weight of the fitter materiat to pass through it and simitar is the meaning of t) 50 and 1. 85. tf more than one fitter tayer is required, the same requirement as atxsve shalt be fottowed for each tayer. The finer fitter shatt be considered as tsase materiat for selection of coarser fitter. The fitter shatt be cotnpacted to a fimi condition. The thickness of ntter is generally of the order of 200 mm to 300 nun. Where titter is provided in two tayers, thickness of each layer stsatt be 150 mm..
2.
3.
4.
2504.3. Construction Operations Before laying the. pitching, the side.s of banks shall he trimmed to the required slope and profiles put up by means of line and pegs at intervals of 3 metres to ensure regular straight work and a uniform.. slope throughout. Depressions shall be filled and thoroughly compacted. The. filte.r granular material shall he laid over the prepared base and suitably compacted to the thickness .specified on the drawings. The lowest course of pitching shall he started from the toe wall antI built up in courses upwards. The toe wail shall he in dry mhhle. masonry (uncoursed) confonning to Clause 1405.3, in case of dry rubble pitching and shall be in nominal mix cement concrete (M 15) conforming to Clause. 1704.3. in case. of cement concrete block pitching. The stone pitching shall commence in a trench below the toe of the slope. Stone shall he placed by derrick or by hand to the required length, thickness and depth conforming to the drawings. Stones shall he set normal to the. slope, and placed so that the largest dimension is: perpendicular to the face of the slope, unless such dimension is i.,,reater than the specified thickness of pitching. The largest stones shall be placed in th,e bottom courses and for use as: headers for subsequent courses. in ha.nd placed pitching, the stone of flat stratified nature should he placed with the principal bedding plane normal to the slope. The pattern of laying shall be such that the joints are broken and voids
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568
River Tfaining Work & Protection Work
Section 2500
are minimum by packing with spalls, wherever necessary, and the top surface is as smooth as possible. When full depth of pitching can be formed with a single stone, the stones shall be laid breaking joints and all interstices between adjncent stones shall be filled in with spalis of the proper size and wedged in with hammers to ensure tight packing.. When two or more layers of stones must be laid to obtain the design thickness of pitching, dry masonry shall be use.d and stone.s shall he well bonded. To ensure regular and orderly disposition of the full intended quantity of stone as shown, template cross walls in dry masonry shall be built about a metre wide and. to the full he.ight of the specified thickness at suitable intervals and all along the length and width of. the pitching. Within these walls the stones: shall he hand packed us specified. 2504.4. Toe Protection
.
in conformity with clause 5.3.7. of IRC:89, a toe wall shall he provided at the junction of slope pitching and launching apron of a guide hund so as to protect the slope pitching from falling even when the apron is not laid at low water level. The toe wall shall he in dry rubble masonry (uncoursed) conforming to Clause 1405.3 in case of dry rubble pitching or pitching! revetment with stones in wire crates and in nominal mix cement concrete (M 15) conforming to Clause 1704.3 in case ce.ntent concrete blocks have been used in pitching. For protection of toes of hank slopes terminating either in short aprons at bed levels or anchored in flooring / rocky bed, the provisions of clause 8.2.2 of 1RC:89 may he complied with, The relevant specifications of the protective works br individual components will be followed. 2505. RUBBLE STONE/CEMENT C ONCRETE BLOCK FLOORING OVER CEMENT CONCRETE BEDDING 2505,1. This work shall consist of constructing ntbble stone / c.c. block flooring laid over a cement concrete (M 15) bedding. The floor protection will comprise rigid flooring stated above with curtain walls .and flex ible apron. 2505.2. Construction Operations Excavations for laying the bedding and floor protection works shall he carried out as per specifications un.der proper supervision. BefOre laying the foundation and protection walls, the excavated trenches shall he. t.horoug,hly inspected by the Engineerin..Charge to ensure that
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569
.Sc.ctiots 250t)
River Training Work & Protection Worrk
a)ihe.re are no too.se t~cketsand unfitted depressions teft in the stench. h) c) The soit at the founding tevct is property compacted to tnie tines and level so as to have an even bedding.. Att concrete and oiher ete.rnents are taid in dry bed.
Cement concrete nominal mix (grade M 15) of 300 mm thickness shall then be laid in accordance with provisions given in Section 1700 c~.xeeptthat the surface of the concrete. shall not be given a smooth finish, The p.aving work shall he embedded in green concrete. 1lcioring shall consist of 150 nim thick flat stone/cement concrete blocks (Nominal mix Grade. M 15 conforming to Section 1700). it shall he bedded on a layer of ceme.nt mortar (1:3) prepared to Clause I 3&4. Spalls shall be used to fill in the voids. The joints shall then be. filled with cement mortar and finished neat. The stone shall hre..ak joints and the joints shall not excee.d 20 mm in thickness. Spacing of joints may he 20 m or so. The top of flooring shall be kept to 3.00 mm below the. lowest bed level. 2506, I)RY RUBBLE FLOORING This work shall consist of constructing dry rubble flooring at cross drainage works for relatively less important works. The. base for the flooring shall be prepared to the specified levels and slopes and compacted suitably with hand rammers or other ;neans to have an even bedding. The thickness ol flooring shall be made with one stone only. The stones shall then be laid closely on the prepared base in one or more layers as specified and the bond used shall be. as specified by the Engineer. 2507, CURTAIN WALL AND FLEXIBLE APRON 2507.1. Curtain Wall The. rigid flooring shall be enclosed by curtain walls (tied to the. wing walls) with a minimum depth below floor level of 2 in on upstream side and 2.5 m on downstrea.m side.. The curtain wall will be in cement concrete. M 15/stone masonry in cement mortar 1:3. The rigid flooring shall he continued over the top width of curtain wall. 2507.2. Flexible Apron Flexible. apron 1 m thick comprising lose stone boulders (weighing not less than 40 kg) shall be. provided beyond curtain walls for a minimum distance of 3 m on upstream side. and 6 m on downstream side. The
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570
River Training Work
&.
Protection Work
Section 2500
work of floor protection shall be simultaneously completed alongwith the
work on bridge, foundations. 2598. TESTS AND STANDARDS OF ACCEPTANCE the materials shall. he tested in accordance with. these Specifications
and shall mee.t the prescribedl criteria.
the work shall conform to these Specificatkns and shall meet the p~e.ser ihed standards of acceptance. 2509. MEASUREMENTS FOR PAYMENT
The protection works shall he measured as se.t forth be.!ow. if
directed by the. Engineer for me.asure.ntent, the materials may have to best.ack.e.d at site before laying and nothing extra will he paid to
the Contractor for this stacking.
The earth work in construction of embankment for guide hued shall he measured in cubic me.tre.s unless otherwise specified. The boulders/cement concrete blocks and wire crates in a.pron shall be measured in cubic metres. The filter arid stone pitching shall be measured separately in cuhie nie.ue.s unless otherwise specified. Rubble stone/ee.me.nt concrete blocks, flooring and cement con. crete bedding shall be mea.stired in cubic metres for each class of material. Preparation of base for laying the f.ooring shall be deemed incidental to the work, For laying apron, e.xcavation upto an average depth of 150 mm shall he deemed to he included in the main item and shall not be measured separately unless otherwise specified, Excavation more t.han 150 mm shall he measured in cubic metres as given in Clause 304. 2510. RATE
The. contract unit rate for the construction of embankment for guide bund shall cover the cost of all materials including transportation, laying, compacting, all labour, toEs, equipment, sampling and testing, supervision and all incidentals necessary for completing the work according to these specifications. The contract unit rate for one cubic metre of finished work of apron shall include the cost of all material, labour, tools and plant fo~ completing the work according to above specifications. Fxeavation upto an average depth of 150 mum shall also be deemed to be included in the rate. its
.571
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Section 2500
River Training
Work & Protection Work
dressing of the bed, Excavation beyond this depth shall be paid for separately unless otherwise specified. The contract unit rate for one ctibic metre of filter or sto.e/cement concrete block pitching on slopes shall include the cost of preparing the b:ases, putting to the profiles, laying and compacting the filter and s.tone pitching of dry rubble/cement concrete block rivetment for embankment slopes to the specified thickness, lines, curves, slopes and ieve.is and all labour and materials as well as tools and plant required for the work, The contract unit rate for rubble stone/cement concrete b~ock flooring shall include the cost of all material, labour and tools and plant for completing the work as per these specifications.
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Expansion Joints
2600
Expansion Joints
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Expansion Joints 260!. DESCRIPTiON
Section 2690
This work shall consist of fabrication and placing of expansion mints as indicated on the drawing and conforming to these speci~ fica.tions or as directed by the Engineer. 2602. GENERAL
a) The expansion ~omu shalt be designed and duty got approved try the Engineer. It ehalI cater for expected movement and rotation of the ssmcture at the ~ and provide smooth riding surface, It shatt atso be easy for inspection, snaintcnance and replacement. hxpans~ossjoints shalt be robust, durabte, water~might and reptaceable. Site fabricated expansion joints shall be prohibited. Expansion joints shatt be obtained by the Engineer either directly or through the Contractor from approved manufacturers and beof proven type. For bridges with prestreesed concrete superstructure, with individual span length snore than 2.0 m or built with innovative designfeonstruceion etastomeric e spansion joints of slab seat or strip seat type shatt be provided.. Foe slab type of bridges of spans less than tO metres continuous surfacing may tat provided across the expansion gaps, suppo:rted on a 20 mm thick plate placed and fised at the level of the deck stab, c) For brid,gcs other than ttsose ntentioned in (c) abeve with spares atseve 1 an alternative specification of stiding steet plate joint or filled joints with copper plates may at so he adopted if approveat by the Engineer, apan 1mm elastosneric expansion joint of stab seal or strip seat type. Vctticular traffic shatt not he allowed over expansion joints after its constmc.tion for such period as may be detemsirsed by the Engineer. Proprietary type deck joints offered by the Contractor in tieu of the type speciliect shall cossepty irs alt respects with the manufacturers specifications and meet the required range of movements and rotations and be fit for the purpose of ensur.ing satisfactory long tersrs performance its the bridge.
h)
c)
1) i
Where alternative type proprietary deck joints are proposed hy the Contractor, the following information shall be provided.
i) ii) iii) Name and location of itse proposed manufacturer. Dimensions and general details of mite joint including material tpeci fication.s, ltotding down belt or anchorage details and instttation procedures. [ividence .of satisfactory perfomsanm under similar envirormsenmal conditions of similar joints being produced by the manufacturer.
.Any acceptance of alternative types will be at the sole discretion
of the Engineer, Such deck joints shall be installed in accordance with the manu~ 575
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Section 2600
Expansion Joints
facturers recommendations and to the general requirements of this Speciflcation. No expansion joint shall be provided only for the width of the carriageway. It shall follow the profile including the kerb and the footway and facia., if provided. The type of expansion joint for the latter may he made different from that used for the carriageway expansion joint. 2603. REQUIREMENTS
2603.!. The requirement criterion will be separately applicable for the expansion joint proper and the transition zone of attachment to the
deck, 2603.2. There are two types of performance requirements for the cx. pansion joint proper viz, from the necessity of the bridge and from the road users e.g. man, animal and vehicle. 2603.3, Performance Requirement with Respect to Bridges
The expansion joint shall
a) h) c) d) Withstand the imposesi toad inclusling the impact load frotn live toami anti other sources. Allow expansion and contraction movement due to temperatstre, creep, shrinkage, preatretting and structural deformations. Permit relative rotation in elevation and plan due to the causes as noted akove, Be waterproof. Bridge deck expansion joint seals play a critical role in preventing the degradation of the stmctsaral components of the bridge system. Without effective joint seals, water passes through the bridge deck and works harmfully to corrode steel components and cause deterioration of the concrete. Rain water gathers various corroding additives from the atmosphere and also from the carriageway. Ensure seating. In case bridge deck joints are not seafed, apart from tots of waterproofing, grit and other forms of road debria may enter the joint Debris, when unpacted with the joint can seriously restrict the moventent instead of facilitating the same, In the case of proprietary joint.s being accepted for adoption, the sealing shall be as specified by them, Ensure long life by being resistant to corrosion Be easy so install, Be easy to maintain. Replaceability of expantion joint shall be one of the basic criteria for selection of type of expansion joint, Be resistant to the materialt likely to collect/spill over the deck in its normal service. 1
e)
I) g) h) i)
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576
Expansion Joints The expansion joint shall

a) 5) c) d) e) t) g)
Section 2600
2603.4. Performance Requirement with Respect to User

Provide smooth continuity at the top of the deck for riding comfort, Be of skid resistant surface, Be non-damaging to the rubber tyre, Make minimusn noise during vehicular crosaing, Ensure that animal paws and hooves should not gee entangled where bridges are used by animal drawn traffic, Permit passing of bullock cart steel tyre for bridges Look good aesthetically. where bullock carts ply,
2603.5. Performance Requirement for Transition Zone It is the zone of connection of joint a.ssernbly and the adjoining deck. The expansion joint shall
a) Permit transfer of generated forces without distress, i.e,, without getting uprooted. The puwoae will not be served if the bonding is with the wearing coat only. Anchorage must he provided with the deck atnicwral element, Ensure that surface in the transition zone stays undisturbed during long term service,
b)
2604. STEEL PLATE SLIDING EXPANSION JOINTS

a) In this type of buried joint, the wearing coat shall be made continuous over the joint. The other altemative shall be to keep a gap in the wearing coat which is filled up with a seal and filler, to be provided in extremely hot areas, Materials for steel plates shall conform to Section 1900. The exposed metallic components ~hall be galvanised or coated with approved anti-corrosive painL The thickness shall be 20 mm or so for obtaining satiafactory perfonnance. Plates shall be placed to the line, grade and expansion gap shewrs on the drawings with any adjustment required for temperature, particular care being taken ~ith the top of the plates. Plates shall be firmly held in place during concreting by methods approved by the Engineer. Any temporary bolts or other fixings which prevent relative movement of the adjacent pasts of the joint shall be removed as soon as the concrete has set sufficiently so hold the expansion plates in their correct positions. In any case, temporary bolts or other fittings shall be removed within 6 hours of placing concrete unless otherwise directed by the Engineer. Care shall be taken to prevent damage to expansion joint plates or its coating. if any damage occurs, the plates and coatings shall he restored by the Contractor to the satisfaction of the Engineer. Plates shall be free ofoil, nan, loose paint or other similar material before coating.
b)
c)
d) e)
Q
g) h)
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577
Section 26(X)
Expansion Joints
2605,
a)
FILLER JOINTS
The components of this type of joint shall be at least 2 rem thick corrugated copper plate placed slightly below the wearing coat, 20 mm thick compressible fibre board to protect she edges, 20 mm thick pre-moulded joins filler filling the gap upto the top level of the wearing coat, sealed with a joint sealing compound. The material used for filling expansion joins shall be bitumen impregnated felt. elastotner or any other suitable material, as specified on the drawings.! impregnated felt shall conform to the requirements of iS~ 1838, and shall be got approved front the Engineer. The joint filler shall consist of large pieces and assembly of small pieces to make up the required size shall be avoided, Expansion joins mttteriais shall be handled with care and stored under cover by the Contractor to prevent damage. Any damage occurring after delivery shall be made good to the satisfaction of the Engineer and at the expente of the Contractor. Joint gaps shall be constructed as shown on the drawings. Surfaces of ~oinr grooves shall be thoroughly cleaned with a wire brush to remove all loose materials and dirt and debris, then washed or jetted out.. Pte.mnoulded expansion joint filler shalt not be placed in position until immediately prior to the placing of the abtrtting material. If the two adjacent surfaces of the joint are to be placed at different times, this type of joint filler shall not be placed until the second face is about so be placed. Sealants shall b. installed in accordance with the manufacturers dastons and all appropriate requirements for joins face priming. recommen-
h)
c) d) e)
f)
g)
h~i Sealants shall be finished approximately 3 runt below the upp.r surfaces of the !joint. i) Joint materials spilt or splashed oito finished surfaces of the bridge during joint filling operations shall be removed and the surfaces made good so the Engineers approval. No joins shall be sealed until inspected by the Engineer and approval is given to proceed wish the work,
2606. ELASTOMERIC SLAB SEAL EXPANSION JOINT 2606.1. MateriaLs

a) b) Steel inserts shall conform to IS ~226.Use of any other materials like fibre-glass or similar material shall not he permitted. Elastomer for elastosnerie slab unit (11513) shall conform to clause 915.1 of IRC:83 (Part Ii), compounded to give hardness IRIID 60 ~5, subject to the following additional stipulations i) Chloroprene (CR) only shall be used in the manufacture of elastomeric expansion joints. No reclaimed/natural rubber or vulcsnised wastes shall be used. The chloroprene material ttsed in the manufacture of elassomeric (expansion joints) shall be Neoprene WRT, Rayprene 110, Skyprene 85 or Derrka 540V.
ii)
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578
Expansion Jotnts iii)
Section 2600
Chioroprene content of the compound shall tsot be lower than 6111 per cent by weighs. The ash content shall not exceed 5 pr cent (as per tests cortducsed in accordance with ASTM D.297 fin (1) and (ii) above. EPDM, and other similar candidate etastoroers for etpansion joints shall not be permitted.
iv) c) d) e) 11)
Elastomeric plugs. Spacer hers, marked with centre

to
centre distance of fixing holes.
Fixing bolts and nuts ntade of stainless steel. Anchor bars comprising hooked anchor stiffenert welded !with lower steel inserts and sinusoidal anchor bars welded with horizontal leg of the edge steel inserts!, ihe elaborate anchoring arrangements of steel inserts shall be pennanently welded] tied witlt the steel reinforcetnenL
2606.2. Fabricatkyn
a) b) c) Steel inserts shall be grit blasted and provided with epoxy paint. Edges of reinforcing steel sections shall be rounded, Expansion joints shalt be fully moulded to the required size in one single vulcanising operation including the encasing layers! ~t integral and homogeneous part Tolerances of fabrication shall be at follows i) ii) Plan dimension Total height
->
st)
.>
5 mm
3 mm
2606.3. Supply and Handling

i) The Contractor shall supply all steel-reinforced elastomeric expa:os!iort joints including bolts, nuts, sealant, plugs and all other accessories for the effective installation of the joints including angled jointing sections for kerbs. Expansion joins material shall be handled wish care and stored under cover by the Consractor to prevent damage. Any damage occurring after delivery shall be made good at site expense of the Contractor so the satisfaction of the Iin!gineer.
ii)
2606.4. Installation
2606.4.1, Expansion joints shall be installed as per approved drawhtg. Steel inserts, spacer bars, concreting of pockets, fixing of eiaslonie,r slab unit and presetting!, etc., shall be done as per the following:
a) Steel inserts i) ii) iii) iv) Deck casting shall be done leaving pockets or recess For steel inserts and anchors of the expansion joint as per drawing. Steel insetis shall be towered as the appropriate locasion inside !the pocket. The sop of the inseti shall be flush with the finished level of wearing course maintaining the camber, Spacer bars, duly set appropriately to the month of installation!~!shalthe fisted under proper supervision.
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579
Section 2600 v) vi)
Expansion Joints Anchor rods shall be tied/welded with the existing deck main reinforcement, mainsaining level and alignment Welding between anchor rods and deck reinforcement is preferable. If welding is not possible, strong steel sie wires shall be used for fastening, under proper supervision.
b)
Spacer Bar i) Spacer bars shalt be used to ensure proper positioning of bolts and also levelling of the steel inserts during fixing of the same with the deck reinforeemens and catting second stage concreting in the pocket thereafter, The 2nd stage concreting operation shall preferably he started within 24 hours of firing the steel inserts. In such cases, spacer bars should be removed just after concreting is finished. If there is a substantial time lag between fixing of inserts and concreting, then any one of the following methods shall be adopted, depending on the support condition a) For simply supported bridge resting on simple elastomeric bearings, (with no dowel pins), insert shall be placed in position with spacer bars at every altemasejoinis. Such joints shall be called restrained joints hereafter. in other words, mserts shall not he fixed simnulsarseously at swo ends of one span. If the above condition is satisfied, interts with spacer bars shall he kept in position for a substantially longer period at such restrained joints. Spacer bars shall he removed after concreting of such restrained joints and inserts placed in position with spacer hems at the other unrestrained joints thereafter. For bridges resting on other than elassomeric bearings (including hearings with dowel pins at one end), after placing and aligning the inserts and securing the same, the spacer bars shall he removed, Concreting shall be done with great care so that inserts are not dislocated or distorted.
ii)
h)
iii)
While removing the spacer bar after concreting, one must take care so see that the concrete is not datnaged during withdrawal of spacer bar. If the spacer bar happens to be snugly fisted, it shall not be pulled by any means; it shall he gas cut in two pieces and then removed. Concreting of pocket shall be done with greas care using proper mix conforming so grade similar to that of the deck casting besides ensuring efficient bonding besween deck and steel insert. Also proper r.are shalt be given for ensuring efficient bonding with the already cast concrete. Needle vibrasors shall be used. Care shall be saken so thas the position of steel insert is not disturbed during vibration. Spacer bar shall he resnoved within an appropriate time before the joint is required to pennis nsovenaent
c)
Concreting of Pocket i)
ii) iii) d)
Fixing of Elastosnerie Slab Unit (ESIJ) i) ii) Special jig shall be used to preset the ESU during installation. ESU (mounted on the jig, if preses) shall be lowered to position.
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580
Expansion Joints iii) iv) v) vi) vi) The line and level on the ESU should he adjusted. ESU shall be removed and coated with special adhesive ESU shalt he placed in position again, ensuring required faees.
Section 2600
waterproof joining at
ESU shall he tightened with stainless steel nuts and lock washers in position. Tightened nuts shall be locked with lock washers, Special sealant shall be poured inside the plug holes.
vii) The etastotneric plugs shall be pressed in position after applying adhesive on the appropriate surface. viii) ESU shall he fined in position after completion of wearing course. While completing this part of the wearing course, adequate care shall be taken to ensure a waterproof joining with she already existing wearing course. e) [re-Setting i) The main purpose of presetting of the steel insens as the time nf its installation is to ensure as closely as possible the condition that in the long nsn as the mean average annusl temperature, the ESU remains at its nominal stare. Major factors responsible for changing bridge superstructure are indicated below a) b) c) d) the longitudinal length of the
Temperasure variation from annual mean, Changes due

to
shrinkage of concrete~
Changes due to elastic shortening and creep of the prestressed bridge superstrucsure. Deformation of superstructure and substructure, if any.
Resultant changes in expansion gap due to first factor can occur in both directions from any pre-selected mean position whereas changes due to creep and shrinkage are unidirectional such that the expansion gap continuously increases with passage of time,
The steel insert unit of expansion joint can be fixed in any month of the year, As stated earlier, the expansion gap betwen bridge superstructure may vary from time to time; hence the initial fixing distance between fixing points will obviously depend on the month of installation of steel insert. The c/c distance between stainless steel fixing of bolts as indicated in the drawing can be taken as only nominal. The same shall be modified by presetting depending on
i) ii) The difference hesween the mean temperature of she month of fixing of steel insert and the annual average temperasure. The elapsed period besween the casting and/or prestresaing steel insert for calculating the remnant creep and shrinkage. and fixing of
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581
Section 261X1
Expansion Joints
2606.4.2. Special requirements for installation

i) [nor to csnistnction of bridge deck area adjacent to the joint, the supplier shall provide detailed working drawings showing the location of all bolts, recesses and holes necessary for the installation of the joint. Reinforcing bars in .supenstntcsume shall be amended as required to ensure that there will be no interference in the installation of she joint. All bearing surfaces and recesses which are in contact with the joint assembly shall he checkesl with a straight edge to ensure flatness of profile. No boles shall he sIn lIed for firing bolts within 7 days of concreting Holes for the bolts shall he drilled to the size and depth shown on the drawitigs 5ecttons of the jointing making she completed line. joint shall follow a straight
ii) ins) iv) s)
lhe. fi sing, hulLs shall not lxi placed in a position sntil at least 4 weeks after stressing is completed in pose-tensioned box or beam and slab stmctures. Prior to placing sections of joinsing, contact surfaces shall he cleaned to remove all grease, tar, paint, oil, mud or any other foreign material that may affcos adhesion of the sealant. Sealsnt shall only he applied to dry contact surfaces. Sufficient sealant shall he applied to the contact surfaces so cause extrusion of sealant when the jointing is fised in position. Final scaling of the finished expansion joint shall be completed immediately after completion of installation All exposed ends, joints between units and other areas of possible leakage shalt be tilled with sealant. All voids between she sides of she jointing and concrete or plates shall he filled with sealant.
ci)
vii)
sin) Bolt cavities shall he cleaned and plugged wish neoprene cavity plugs Prior to placing the plugs sufficient sealant shall he placed in the cavities to cause extrusion of the sealant by the plugs. ix) All escess sealant shall be removed from the jointing and adjacent areas.
2606.5. Acceptance Test 2606.5.1, As per clause 918,7 of IRC-83 (Part II), necessary quality control certification by the manufacturer in regard to properties of Elastomer and steel will be furnished. For severe environmefit, ozone resistance test as per clause 915.2.3 of IRC:83 (Part El), shall be carried out for elastomer, The properties of the elastomer shall conform to Table I of clause 915.2 of IRC:83 (Part II). The acceptance testing for elastomer material shall conform to clause 91&4,l,2 of IRC:83 (Part II) with additional criteria as stated in Clause 2005.
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582
Expansion Joints
Section 2600
2606.5.2. The fabricated expansion joint shall he subjected to the frsflowing accepiance tests
i) Routine test.. Each expansion joint shall be tested for at least 100 cycles for a teas movesnent which shall be 10 per cent more than the design expansion) contradion mowesnent. In addition to routine test, one out of every 20 expansion joints shall he subjected to the teat movement for 40(X) cycles. The. lot shalt be rejected if the elastomer material shows signs of fatigue or pesananent set or distress in the teat. The test piece shall not be used in the bridge. iii) The type test for abrasion resistance shall be carried out for one joint out of every 20 not. as per 15:34(X) (Part 3) and the standard deviation shall be within 20 per cent
ii)
NJ3. The manufacturer shall preferably have in-house testing facility. Otherwise, the testing shall be got done by him at his expen e. at any testing establishment selected by the Engineer. A manufacttjrer who cannot carry out the acceptance test shall not be entitled to supply elastomeric slab seal joint... 2607. STRIP SEAL EXPANSION JOINT 26071. Components
Strip seal expansion joint shall comprise the following items

a) b) Edge beams This special claw leg profiled member shall be of extruded roiled steel section combining good weldability with notch toughness. Strip seal This shall be of dhloroprene with high tear strength, insensitive to oil, gasoline, and ozone. It shall have high resistance to aging. This component, provided to ensure water tightness, shalt have bulbous shape of the pan of the seal which is inserted into the groove, provided in the edge beam, The seal shotsld be vulc.anised in single operation for minimum full length of joint.. Rigid Anchorage - This shall be welded to the edge beam at staggered distance,. toops - This shall be made of weldable steel connecting the rigid Anchor anchorage with deck reinforcement.
c) ct)
2607,2. Material
a) Edge beams of this special section are at present being directly imported in India. The steel shall conform to steel grade Rst 37-2 of German Standard or eqtaivalenL Chloroprene of strip seal shalt conform to clause 915.1 of D.C:83 (Past Ii). The propertiea of chtoroprene ahait conform to Table 26OO~i. Anchosage steel shall conform to 15:2062, Anchor loop shall confonn to 15:2062,
h) c) d)
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583
Section 2600
Expansion Joints
TABLE 2600-1. STRIP SEAL ELEMENT SPECIFICATION Sealing element is made of chloropmne and must be a extruded section. The working movement range of the sealing element shall bc at least 80 mm with a maximum of 100 mm at right angles to the joint and 40mm parallel to the joint .
PROPERTY Hardness Tensile Strength Elongation at fracture Tear Propagation Strength Longitudinal Transverse Shock Elasticity Abrasion Residual Costpressive Strain (22 hT7O deg C /30 per cent strain) Ageing in hot air (14 day s/TO deg C) Change in hardness Change in tensile strength Change in elongation at fracture Ageittg in ozone (24 h/5~phxttt25deg C/20 per cent strain) Swelling behaviour in Oil (116 h/25 per cern C) ASTM Oil no. Volume Change (hange in hardness ASTM Oil no.3 Volunte Change Change in hardness Cold Hardening Poirtt a) SPECIFIED VALUE 63 5 Shore A Mm Mm Mm Mm Mm Mm Ii MPa 350 per cent
10 N/rnnt 10 N/mm 25 per cent 3 220 mm
Max 28 per cent
Max 5Shore A Max -20 per cent Max -20 per cent No cntcks
Max 5 per cent Max 10 Shore A Max 25 per cent Max 20 Shore A Mm -35 deg C
2607.3. Fabrication (Pre-installation)

Rolled steel profiles for edge beams shall be long enough so cater for a 2-lane carriageway. These shall be cut to size of actssal requirements by means of a mitre box saw~Alignment of the cut-to-size steel profiles shall then be made in accordance with the actual bridge cross~sectionon work tables. For this purpose, the contour of bridge cross-section shall be sketched onto these tables. After the steel profiles are aligned, they will be chucked to the tables by means of screw clamps and tacked by arc welding. Anchor plates shall be cut to the required be welded to the edge beams. size by gas cutting. These shall
h) c) d)
Anchor loops shall be bent to the required shape and welded to anchor plates!! The finally assembled joints shall then be clamped and transported to the work site.
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584
Expansion Joints
Section 2600
2607.4. Handling and Storage

a) h) For transportation and storage, auxiliary brackets shall be provided to hold the joint assembly together. the manufacturer allshall materials of stripdirectly to incltading sealants and the Bridge Contractor the supply either seal joints the Ergmeer or to all other accessories for the effective installation of the jointing. c) Expansion joint, material shall be handled with care. It shall be stored under cover on suitable lumber padding by the Contractor to prevent damage. Any damage occurring after delivery shall be made good at the Bridge Contractors expense to the satisfaction of the Engineer.
2607.5. Installation 26073.1. The width of the gap to cater for movement due to thermal effect, prestress, shrinkage and creep, superstructure deformations (if any) and sub-structure deformations (if any) shall he determined and intimated to the manufacturer. Depending upon the temperature at wttich the joint is likely to be installed, the gap dimension shall be preset. 26073.2. Taking the width of gap for movement of the joint into account, the dimensions of the recess in the decking shall be established in accordance with the drawings or design data of the manufacturer. The surfaces of the recess shall he thoroughly cleaned and all dirt and debris removed. The exposed reinforcement shall be suitably adjusted to permit unobstructed lowering of the joint into the recess. 2607,5.3. The recess shall be shuttered in such a way that dimensions in the joint drawing are maintained, The formwork shall he tight. 2607,5.4, Immediately prior to placing the joint, the presetting shall be inspected. Should the actual temperature of the structure be different from the temperature provided for presetting, correction of the presetling shall be done. After adjustment, the brackets shall be tightened again. 2607.5.5. The joint shall be lowered in a pre-determined position. Following placement of the joint in the prepared recess, the joint shall be levelled and finally aligned and the anchor loops on one side of the joint welded to the exposed reinforcement bars of the structure. Upon completion, the same procedure shall be followed for the other side of the joint. With the expansion joint finally held at both sides, the auxiliary brackets shall be released, allowing the joint to take up the movement of the structure. 2607,5.6. High quality concrete shall then be filled into the recess. The packing concrete must feature low shrinkage and have the same
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585
Section 2600
Expansion Joints
slrengl.h as that of the superstrnctnre, hut in any case not less than M 35 grade. (kxxl compaction and earefttl curing of concrete is particularly irnportanl.. After the cnncrete has cured, the movable installation brackets slill in place shall be removed. 2.607,5,7, Rolled up neoprene strip seal shall he cut into the required length and inserted between the edge beams by using a crow bar pttshing the bulb of the seal into the steel grooves of the edge beams. A landing to a bead shall he formed in the thickened end of the edges of the seal which would force the thickened end against the steel beam due to wedge effect when the strip seal is buttoned in place. 26073.8. As soon as the concrete in the recess has become inttially sel., a sturdy ramp shall be placed over the joint to protect the exp..sed steel beams and neoprene seals from site traffic. Expansion joint shall not he expose.d to traffic loading before the carriageway surfacing, is placed. 26073.9. The carriageway surfacing shall he finished flush with the top of the steel sections. The actual junction of the surfacing/wearing coat with the steel edge section shall be formed by a wedge shaped joint with a sealing compound. The horizontal leg of the edge beam shall he cleaned beforehand. It is particularly important to ensure thorough and careful compaction of the surfacing in order to prevent any pretnature depression forming in it, Acceptance Test
i)
All steel elements shall be finished
with corrosion protection system.
ii)
For neoprene seal, the acceptance test shall conform to the requirements stipulated srs Table 2600-1. It shall also be stretch tested, If a manufac.tnrer ia to supply this type ofjoint, they will have to produce a test certificate accordingly conducted in a recognised laboratory in India or abroad. In view of the imporlaasce of the built up edge beams, special investigation of fatigue at.rengtla of this section wish anchorages to withstand 2 x 10 load change cyclea without showing signs of damage, will be required. The supplier shall have to produce a test certificate in this regard, conducted in a recognised laboratory, in India or abroad. The manufacturer shall produce test certificates indicating that anchorage system had beers seated in a recognised laboratory to detennine optimum configuraSn of anchorage assembty under dynamic loading. lhe manufacturer shall satisfy the Engineer that water tightness test for the type of joint has been carried out in a recognired laboratory so check the water tightness under a water pressure of 4 bars. As strip seal type ofjoint is specialisal in nature, generally of the proprietary
iii)
iv)
s)
vi)
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586
Expansion joLrtt.~ ty ~ the manufacturer
Section 2600 shall he rrei uired to produce cvidcncr 1:f stir tactry
perfonnance of this type of joint
2608.
i ions
TES1S AND STANDARDS OF ACCEPTAN(.F
The tnaterials shall be. tested in accordance web these spL,:citira.. and shall meet the prescribed criteria. The work shall conform to these spec ifications and shall meet the prescribed standards of acceptance. 2609. MEASUREM ENTS FOR PAYMENT The. expansion joinl. shall be measured in rtinning metres. l::ctr iii led joints., the rate per running metre shall include the. cost of .sea Ian br the depth provided in this drawing. 2610. RATE the. contract unit rate shall include the cost of all material, lahous, equipment and other incidental charges for fixing the joints complete in all respects as per these specifications in the case of Bridge. Contractor supplyin~~, expansion joint. If the. manufacturer supplies the expansion the joint dtreclly to the Engineer, the cost of installatton, handling and fixing, shall he borne by the Bridge Contractor.
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587
Wearing Coat and Appurtenances
2700 Wearing Coat and Appurtenances
<<
Wearing Coat and Appurtenances 2701. DESCRIPTION
Section 2700
lhis work shall include wearing coat and bridge appurtenances. such as railing, approach slab, drainage spouts, weep holes in conformity with details shown on the drawing and these peciftcations or as approved by the Engineer. 2702. WEARING COAT 2702.1. Bituminous Wearing Coat Specifications for bituminous concrete/bitumen mastic in wearing coat shall conform to Section 500 except for the special require.mnents as stated hereinafter. .2702.1.1. Principles of bituminous wearing coat shall comprise. the. following
i) A layer of mastic asphalt, 6 mm thick after applying a prime coat over the top of the deck before the wearing coat is laid. The prime coat and the layer of mastic asphalt shalt be laid as per Clauses 503 and 515 respectively. 50 mm thick asrthaltic concrete wearing coat in two layers per Clause 512. of 25 rum each as
ii)
in cas.e of high rainfall intensity areas, the thickness of mastic asphall layer mnay be increased to i2 mm, 2702.1.2. For high traffic density, an alternative specification br wearing course comprising 40 mm bituminous concre..te.. overi.aid with 2.5 mm thick bitumen mastic layer can he adopted. The work shall be done in conformity with Section 500. 270 2. Cement Concrete Wearing Coat Cement concrete wearing coat may be provided in case of isolated hri.dg.e construction or bridges located in remote. areas. It shall not he laid monolithic witll the deck. The. l.hickness of wearing coat shall be 75 mm. The minimtum grade of concrete shall he M 30 with water cement ratio as 0.4. Curing of wearing coat earlier than what is generally required may be resorted to, so as to avoid formation of shrinkage cracks in hot weather, All carriageway and fo..tpath surfaces shall have non-skid characteristics.
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591
Section 2700
Wearing Coat & Appurtenances
The cross slope in the deck shall be. kept as 2.5 per cent for decks, level in longitudinal profile. 2702.3. For providing cross camber no variation in thickness of wearing coat shall be permitted. 2703. RAILINGS 2703.1. General
a) h) Bridge railing includes the portion of the structure erected on and above the kerb for the protection of pedestrians and traffic. Railings shall not be cortstnicted until the centering falsewonlc for the span has been released and the span is self-supporting. For concrete with steel re:inforcenient, specifications of the items ofcontrolled concrete and reinforcement mentioned under relevant sections of this specifications shall be applicable. The type of railing shall be carefully erected true to line and grade. Posts shall be vertical with a tolerance not to exceed 6 mm in 3 metres. The pockets left for posts shall be filled up with non-shrinkable mortar The type of railing to be constructed shall be as shown on the drawings.. Care shall be exercised in assembling expansion joints in the tailings to ensure that they function properly. The bridge railings shall be amenable to quick repairs. Railing materials, particularly metal railings, shall be handled and stored with care, so that the material and parts are kept clean and free from damage. Railing materials shall be stored above the ground on plstfonns, skids, or other supports and kept free from grease, dirt and other contaminants.
c)
d) e)
0
g)
Any material which is lost, stolen or damaged after delivery shall be replaced or repaired by the Contractor. Methods of repair shall not damage the material or protective coating. 2703.2. Metal Railings Materials, fabrication, transportation, erection and painting for bridge railings shall conform to the requirements of section 1900. All complete steel rail elements, pipe terminal sections, posts, bolts, nuts, hardware and other steel fittings shall be galvanised or painted with an approved paint. If galvanised, all elements of the railing shall be free from abrasions, rough or sharp edges, and shall not be kinked, twisted or bent. If straightening is necessary, it shall be done by methods approved by the Engineer. Damaged galvanised surfaces, edges of holes and ends of steel railing cut after galvanising shall be cleaned and re-galvanised.
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592
Wearing Cost & Appurtenances
Section 2700
The railing shall be carefully adjusted prior to fixing in place to ensure proper matching at abutting joints and correct alignment and camber throughout their length. Holes for field connections shall be drilled with the railing in place in the structure at proper grade and alignment. Unless otherwise specified on the drawings, meta.l railing shall be given on..e shop coat of paint and three coats of paint after erection if sections are not galva.nised. Railings shall not follow any irregularity in the alignment of the deck, When shown on the drawings, the rail elements shall be curved before erection. 2703.3. Cast-in-Situ Concrete Railings The portion of the railing or parapet which is to he cast in place. shall be constructed in accordance with the requirements for Stntctural Concrete in Section 1700. The reinforcement shall conform to Section 1600. Forms shall either be of single width hoards or shall be. lined with suitable material duly approved by the Engineer. Form joints in plane surfaces will not be permitted. All mouldings, panel work and bevel strips shall be constructed according to the details shown on the drawings.... All corners in the finished work shall be true, sharp and clean-cut and shall be free from cracks, spalls or other defects. Casting of posts shall be done in single pour, 2703.4.. Precast Concrete Railings Precast members for railings shall be of reinforced cement concrete and shall conform to the specifications given in Seelions 1600 and 1700. The maximum size of the aggregate shall be limited to 12 mm and the concrete grade shall be M 30. The precast members shall be removed from the moulds as soon as practicable and shall be kept damp for a period of at least 10 days. During this period they shall be protected from sun and wind. Any precast member that becomes chipped, marred or cracked before or during the process of placing shall be rejected, Special care shall be taken to watch the surface of the cast-in-situ portion of the deck. 2704. APPROACH SLAB Reinforced concrete approach slab covering the entire width of the
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593
Section 2700
roadway shall he. provide..d as per details given on the drawings or as approved by the Engineer. Minimum length of approach slab shall be 3.5 m and minimum thickness 300 mm, The cement concrete and reinforcement shall conform to Sections 1700 and 1600 respectively. The base for the approach slab shall he as shown on l.he. drawings or as directed hy the Engineer. 2705.. DRAINAGE SPOUTS 2705, I. this work shall consist of furnishing and fixing in position
of drainage spouts a.~ddrainage pipes for bridge decks.
l)s am tv& don g km ~ ludt n il cIt ftt tson shall lx n suet ci by .suUicicnt number of drainage fixtures embedded in the deck slab, The spouts shall he of not Ie.s.s than 100 mm in diameter and shall he of corrosive resistant material such as galvanise.d steel with suitable. cleanout fi,x owes. The spacing of drainage spouts shall not exceed 10 m. the. discharge from drainage s-pout shall he kept away from the deck structure, In case. of viaduco in urban areas, the drainage spouts should be connected with suitably located pipelines to clischarge the surface run -off to drains provided at ground level. 2705.2. Fabrication The. drainage assemh]y shall be fabricated 1.0 the dimensions shown on the drawings; all rn ateri ~Js shall he corrosion resistant; stee components shall he. of mild stee conforming to IS:226, The drairtage. asse.mhly shall be. seam welded for uate.r tightness and then hofidip
galvanised. 2705.3. Placement

The galvanised assembly shall be given two coats painting befOre placenient. The whole assembly shall he position, lines and. levels as shown in the drawing cut-out i.n the shuttering for deck slab and held in Where the reinforcements of the deck are required to be of bituminous placed in true wit.h.oece.s.sary place Firmly.
cut, equivalent. reinforcements shall be placed at the corners of the assembly. 2705.4. Finishing Aflersetling of the deck slab concrete, the shrinkage cr.acks
around the. .asscmhly shall he totally sealed with polysulphide sealant
or bituminous sealant as pe.r IS: 1834 and the excess sealant trimmed to receive the wearing coat. After the wearing coat is completed, similar
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594
.1] 1115.
c(11d1 & Appurtenances
Section l7tX)
.;eriftnt shall he firtishecl to cover at leasl 50 mm ccut surface all round the drainage assembly. 2706. WEEP HOLE
Weep u holes shall he provided in solid plain
on the wearing
concrcte(retnli.irced
ctslcrciL, hrick/slnne masonry, ahutmenl, wing wall and return walls w~
on lhe ci rawing or directed by the Engineer to drive moisture the luck filling. Weep holes shall he provided with 100 mm d C pipe or 51 rt,tctttres in plo in/reinforced concrete, or brick mason rv. I iti slone masonry, weep holes shall be 80 mm wide, 15(1 turn Ii ph or circular with I 50mm diameter. Weep holes shall extend through full w ith of concrete/masonry wtth slope of about 1 verlical 211 lit tttttiiil towards the draining face The spacing of weep holes shall aenerall~he Ira in either direction or as showrt tn the drawing ss jIb Ii, t u est at about I 50 mm above the low w ater level or a rotsn d level ss h iche.~ cr is higher or as directed by the Engineer. 2707, TIre iESTS ANt) SiANDARDS OF ACCEPTAN(F: materia.ls shall be tested in accordance with these Spec itrca-
arid shall meet the prescrihed criteria,

lhe work shall conforni to these Specification.s and shall meet die prcsc ri bed standards of acceptance. 270$. MEASUREMENTS FOR PAYMENT lhe tneasurcment for payment for wearing coat, railings and approach slab shall be made as given below
Cement concrete wearing coat shall he measured in cubic met rr.s concrete wearing coat shalt be measured in square metres. .1 Railings shalt he measured in running metres. Approach is I stab and its base shalt be encasurrd separately in cubic metres. Asphalt Ic
Orain rye spouts shall he measured in numbers, Weep holes in conc:reseThric:k masonry structure shall he measured in rs.trriFs.:ss For structures in stone masonry, weep holes shall be deezimd to be included En the itrm of stone masonry wortc and shalt not be measured separately.
2709. RATE The contract tinit rate for wearing coat shall include the cost of all labour, material, tools and plant and other cost necessary for completion of the work as per these Specifications. Ihe contract unit rate of railings shall include the cost of all labour,
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595
Section 2700
material, tools and plant required for completing the work as per these Specifications.. the contract unit rate for approach slab shall include the cost ol all labour, tnate.rial, tools and plant required for completing the work as per these Specifications. The rate for base shall include cost of all labour, material, tools and plant required, including preparation of surface and consolidation complete in all respects. the contract unit rate for each drainage spout. shall include the cosl of all labour, material, tools and plant required for completing the,: work as per these Specifications. It shall also include the cost of providing flow drain pipes with all fixtures upto the point of ground drains wherever shown on the drawings.
The contract unit rate for weep hole shall include the cost of all labour, material, tools and plant required for completing the work as per these Specifications.
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596
Repair ofStructures
2800 Repair of Structures
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Repair of Structures
Section 2800
2801. DESCRIPTiON Repair of structures shall be carried out in accordance with the repair plans and these specifications or as directed by the Engineer. Where repair work is not covered by these specifications, special specifica~ tion may he framed. Implementation of repair schenes shall also conform to provisions of IRC:SP:40. 2802. GENERAL 2802.1, Environmental Aspect Care shall be taken to ensure suitable mitigation measures against noise and dust, pollution and damages to the environs whether temporary or permanent and shall be taken as incidental to work. 2802,2. Phasing The sequence of work shall be in accordance with the drawings or as directed by the F.~~ngineer. 2802.3. Traffic Management Traffic management, signage, signalling arrangement, barricading, and lighting arrangement shall be in accordance with Section 100 and with t.hese specifications and shall be considered as incidentals to work. 2802.4. Safety Precautions Adequate precautions shall be taken for safety .of personnel, road users and existing services, which, during execution, shall be considered as incidentals to work. Persons working should wear safety helmets and rubber gloves. 2802,5, Dismantling and Removal of Material t)is.mantling of any bridge component and removal of materials shall conform to Section 200 and this section and as shown on the drawings or as directed by the Engineer. 2803. SEALING OF CRACKS BY INJECTION OF EPOXY RESIN 2803,1. General The work of epoxy adhesive utilising the Structural Concrete Bonding Process shall conform to these specifications.
599
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Section 2800
2803.2. The Contractor shall furnish detailed methodology of constntction including sotirces of supply of material, tools, equipment and appliances to be used on work, details of personnel and supervision. 2803.3. Personnel
The Contractors personnel shall be qualified and experienced in epoxy injection process. 2803.4. Material
The material for injection shall be suitable two-component low viscosity epoxy resin, having the required characteristics of bonding with concrete and resistance to moisture penetration. Epoxy mortar or poly.sulphide resin may he used for sealing the surface. The material for epoxy injection shall conform to the following
I)
ii)
The mixing ratio of resin and hardener shall generally be between I to I and 2 to I by volume subject to manuracturers recommendation. Neither the mixed epoxy adhesives nor their individual components shall contain solvents and thinners, components shatl be free of lumps or foreign material, The viscosity of the individual components shall not change more than 15per cent when kept in closed containers at 2.5 degrees ~etsius after two weeks. Consistency requiremeni Standard VersIon cpa Low Viscosity Version cpa
iii) The
iv)
Viscosity of Mixed Adhesive at 25 degrees Celsius v)

Si)
(200-300)
(t0O-t90)
Pot Life of mixed adhesive at 25 degrees Celsius
1 hour 15minutes
Set time of miscrl adhesive 3 6 hours at 25 degrees Celsius *ln the case of two component injection system where resin and hardener get mixed at point of injection pot life at 25 degrees Celsius shaH be not greater than 15 rain ~lO minutes.
2803.5. Equipment for injection The equipment shall be portable, positive displacement type pur ~ with interlock to provide positive ratio control of exact propori ons of ihe two components at nozzle. The pumps shall be generally electr:.aliy powered and shall provide in-line metering and mixing. The tolerance. on mix ratio shall be 5 per cent by volume, The injection equipment
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600
Repair of Stnictures
Section
2800
shall have automatic pressure control capable of discharging mixed adhesive at any pre.set pressure within the prescribed limits and shall be additionally equipped with a manual pressure control. The injection equipment shall be equipped with sensors on both the components A and B reservoirs, that will automatically stop the machine when only one component is being pumped to the mixing head. if considered appropriate, suitable compressed air operated epoxy injection gun can be used with prior approval of the Engineer for manual injection of mix when resin and hardener had been mixed in a separ.ate unit, 2803.6. Preparation Surfaces adjacent to cracks or other areas of application shall be cleaned of dirt., dust, grease, oil .efflorescence or other foreign matle.r by brushingJwater jetting/sand blasting. Actds and corrosives shall not be permitted for cleaning. Entry ports shall he provided along the crack at intervals of not more than the thickness of concrete at the location. Surface seal material shall he applied to the face of the crack between the entry ports, For through cracks, surface seal shall be applied to both faces, Before proceeding with the inject.ion, the surface seal material must gain adequate strength with respect to concrete strength of the member! injection pressure. 2803.7. Epoxy Injection Injection of epoxy adhesive shall begin at lowest entry por and continue until there is an appearance of epoxy adhesive ~at the next entry pOrt adjacent to the entry port being pumped. When epoxy adhesive travel is indicated by appearance at the next acUacent port, injection shall be discontinued on the entry port being pumped a.nd entry port shall be sealed. Thereafter, epoxy injection shall he. transferred to next adjacent port where epoxy adhesive has appeared. Epoxy adhesive injection shall be performed continuously until cracks are completely filled. If port to port travel of epoxy adhesive is not indicated, the work shall immediately be stopped. In case the volume of the injected tnate,rial
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601
Section 28(X)
exceeds 2 litres for a particular entry port, the work shall be stopped
and the specifications may be reviewed. 2803.8. Precautions for Application

a) t.Jntess otherwise. specified, components A and B, i.e., resin and hardener, shall be at a temperature between tO degrees Celsius and 35 degrees Celsius at the time of mixing. Temperautre ot structural nsemhee during epoxy injection shall he between 10 degrees C.elsics and 35 degree.s Celsius unless otherwise specified. Inssnediately prior to use, each cotnponent shslt he thoroughly mixed with a clean paddle. The paddle shall be of a type that does not induce air into the material, Separate dean paddle must he used for each component Any heating of the adhesive components shall he. done by application of instirect heat in case the work is to he done in cold climate, Just before use, the two components shall be thoroughly mixed in. the ratios specified by the manufacturer, The length of mixing time shall he in strict accordance with manufacturers recommendations, When mixed, all ad.i.csives with different coloured components shall have a uniform colour without streaks. The use of sulvents and thinners will not he permitted except for cleaning of equipment.
is) c.)
d) c)
~fl
2803.9. Testing 2803.91, Mateilal Testing. Prior to approval of the material, the following tests shall be carried out at site or in an authorised laboratory for each batch of resin and hardener and each combination thereof at the. co:st of the Contractor.
i) ti) iii) is) Viscosity test for resin and hardener and the mix - three specimens each. Pot life test - thre.e specimens each. Bond test
-
three specimens each.
Shear test - six specimens each, 3 after 24 hours and the other three aftet 72 hours of curing
Suhsc.quent~testsshall be. carried out as directed by the Engineer.

a) Pot t,ife Tests
i)
500
gm of resin formulation shall be prepared by thoroughly raising the resin and hardener/accelerator/catalyst component in proposed proportion in a I kg capacity hernispheral porcelain bowl by means of a spatula or any other agitating device and nose down the time and the ambient temperature.
ii)
With
a clean dry 25 mm size painters brush, the resin formulation shall be applied on a clean dry surface such as cement concrete over iS20 cm length, starting immediately after mixing the fonnulation and repeating operation every five minutes. When it becomes just difficult to spread the resin property with the hmsh, the time is notett The
602
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Ret:tais csf Structures
Section
2800
time elapsed since corrspletion csf tnixing of resin fomtulation is taken as its pot life, iii) iv) One pot life test shalt he performed on commencement of work and the sattte shalt be repeated even four hostrs.. In case the material fails to satisfy the Pot life test for injectton. it shall not lx. used
Wttese the resin and hardener get mixed at point of injection, the pot life is r.oi irrtportant and no teats may be required. Ls,t Bond Test .A standard ISO snm diameter and 300 mm long concrete cylinder shalt he east in 2. pieces by providing a separating media at an axis of 45 degrees Celsius to tlse longer axis of the cylinder (refer to Fig. 2.800/1). Ihree sets of such split cylinders shall he prepared in advance, Two pieces of each set shall be joined wir.h epexy rnorear at four p. mrs to give a clear gap of shout 0.2 mnns, which will be injected with epoxy resin at site, After epoxy has been cured, load test is esrried out on the cylinder which shall not he test than Sf) per cent of the cube strength of the concrete mix and the failure shalt not take place at she ,joint injected with epoxy resin, ~e) Sttear Tests Two steel plates, minimssm 3mm thick, shall be bonded with epoxy at site using the same resin mix as used/proposed to he used for injection. The assembly shalt he kept in mechanical clamp till epoxy is cured, A total of six specimens shall be prepared for each hatch of materials. Three test specimens shalt then he subjected to a shear force along the axis after 24 hours and the minimunt shear strength before failure shalt nut be less than 1 MPa, (refer Fig. 2800/2).
The. remaining test specimens shall be similarly tested after 72 hours of curing. The shear strength before failure shall not be less than 2.,5 MPa,
2803.9,2, Core test : If directed by the Engineer, core tests shall be. con.ducted for the acceptance of the work. The selection of the location of cores shall be made under the direction of the Engineer in such a way that damage in critical/stressed areas .of the structure is avoided, The procedure for the test shall be as under. The. Contractor shall ohtain 5 cm diameter initial core samples in
the first 50 linear metres, Thereafter, frequency of core sampling
shall he as specified or as agreed by the Engineer. The depth of the core shall generally be less than 20 cm. lests and Acceptance Criteria shall be as follows
s) Penetration/Visual Examination be full of epoxy adhesive,
-
a minimum of 90 per cent of the crack shall
603
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Section 2800
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604
<<
Repair of Structures b) of either co~xcreLeor adhesive
Section 2800
Bond Strength : Concrete failure before adhesive failure or 40 MPa with no failure
If the cores taken in first 50 m length pass tests as specified above, epoxy adhesive injection work at area represented by cores will be accepted. If cores fail either by lack of penetration or bond strength, work shall not proceed further until the areas represented by the cores are re~ injected and retested for acceptance. Filling of Field Control Testing Core Holes This procedure consists of using two~component bonding agent applied to surfaces of cored holes followed by application of NonShrink cement grout mix placed by hand trowel, thoroughly rodded and tamped in place, and finished to match finish and texture of existing concrete to the satisfaction of the Engineer. Materials and procedures for filling testing core holes shall be submitted to and approved by the Engineer before proceeding with core testing work. 2803.9.3. Test br injection equipment At all times during the course of the work the Contractor shall keep complete and accurate records and make available to the Engineer of the pressure and ratio tests specified above so that the efficacy and accuracy of the injection equipment is verified. In addition, the Engineer at any time without prior intimation of the Contractor may request the Contractor to conduct the tests specified below, in the presence of the Engineer.
a) Pres~areTest The mixing head of the injection equipment shall be disconnected and the two adhesive component delivery lines shall be attached to the pressure check device, which shall consist of two independent vatved nozzles capable of sensing the pressure. The cheek device shall be closed and equipment operated until the gauge pressure in each tine reads 5 MPa, The. pumps shall be stopped and the gauge pressure shall not drop below 4 MPa within 2 minutes.
The
b)
preasure test shall be run for each injection unit at the beginning and after break of every shift. Ratio Test The mixing head of the injection equipment shall be disconnected and the two adhesive components shall be pumped simultaneously through the ratio check device, which shall consist of two independent valved nozzles. There shall be a pressure gauge capable of controlling back pressure by opening or closing valved nozzles capable of sensing the back pressure behind each valve. The discharge pressure shall be adjusted to read 5 bar for both adhesive components,
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605
Section 2800
which shall be simultaneously discharged into separate calibrated containers during the same time period and the amounts discharged into the calibrated containers simultaneously during the same period shall be compared to determine that the volume/discharge conforms to themanufacturers recommended ra.tio for applicable material.
2804. EPOXY MORTAR FOR REPLACEMENT OF SPALLED CONCRETE 2804.1. Material 2804.1.1. Formulation The epoxy resins for use in the mortar shall be obtained from a reputed manufacturer and the mortar shall be prepared in conformi ty with the manufacturers recommendations. They shalt generally conform to the following: Pot Life : 90 minutes at 25 degrees Celsius 60 minutes at 30 degrees Celsius 45 minutes at 35 degrees Celsius
Bond Strength : 12 MPa Tensile Strength : 16 MPa The Contractor shall carry out tests on the samples made out or requirements indicated above. The sand content in the mortar shall be in accordance with the desired consistency. 2804.2. Proportioning and Mixing The resin and hardener shall be mixed before adding the dry filler. The mixed ready to use mortar should not contain lumps of unwetted filler and should be uniform in colour. For a total weight f 1 kg or less, hand mixing will be sufficient. For quantities in excess of 1 kg, the component shall be mixed for 3 minutes with a slow speed 400-600 rpm - electric drill with a Jiffy mixer, The stirrer shall be moved up and down and along the sides until an even streak free colour is obtained. Whipping in an excessive amount of air shall be avoided. If no power is available, a flat putty knife may be used to reach into the corners of the can and hand mixing done for at least 5 minutes. 2804.3. Surface Preparation Surface upon which epoxy is to be placed shall be free of rust,
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606
Repair of
Structures
Section 2800
grease, oil, paint, asphalt, loose material, unsound concrete, dust or any other deleterious material. Since cured epoxy does not provide adequate bond with any material, all overlay, whether epoxy or cement based, shall be done within pot life of the base epoxy layer. 2804.4. Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds or surface impregnants like linseed oil or silicons, including laitance and weak or loose concrete shall be removed. When bonding to asphalt, the surface should be roughened so that clean aggregate is exposed. Epoxy bonding agents shall not be applied when ii rains, or in standing water. The surface must be dry. Two general methods of surface preparation shall be followed
a) b) Mechanical that includes grinding, grit blasting, water blasting and scarification. Chemical that includes acid etching with 15 per cent by weight of hydrochloric solution, followed by repeated flushing with high pressure stream of water.
2804.5. Application Epoxy primer coat shall be applied with the help of stiff nylon bristle brushes or hard rubber rollers or spray gun depending upon the nature of surface and extent of work area. As far as possible, the coating shall be uniformly thick. Before the primer coat is fully cured, epoxy mortar shall be applied by means of !rowels and floats. The interval between the application of primer coat 3nd epoxy mortar shall be approximately 15/30 minutes depending upon the ambient temperature. Seat Coat shall be applied after 24 hours curing, after mild roughening of the surface of the mortar, 2804.6. Coverage The coverage of resin mix would depend on the system of resin However, as a general guideline the coverage area shall be as under
used. a) b) c) Primer Coat. One kg of resin-hardener mix covers an area of 3-6 square metres per coal depending on the fmish of the concrete. Epoxy Mortar. One square metre of surface requires approximately 2024 kg of epoxy mortar when laid to a thicknest of 10mm. Seal Coal. 4 to 6 square metres per kg of mix depending on the temperanire of application.
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607
Section 2800
2804.7. Cleaning and Maintenance of Equipment Tools and equipment are best cleaned immediately after use since the removal of cured resin is difficult and time consuming. The bulk of resin shall be removed using a scraper and remainder washed away completely using solvents such as toluene, xylene or acetone. Equipments used for epoxy shall always be cleaned before it hardens. Solvents used for this purpose may be Acetone (flammable), Methyl Ethyl Kethone (flammable), Methyl Chloride (non-flammable). Cured epoxies may be removed using Methylene Chloride. 2804.8. Testing Epoxy used for making mortar shall conform to all requirements and testing procedures as laid down in Clause 2803.9. 2804.9. Handling Precautions Epoxy resins can cause irritation of skin in sensitive persons if in~
correctly handled. The resin and hardener should not be allowed to come into direct contact with skin. The most effective protection is achieved by wearing rubber or polythene gloves.
2804.10. Personnel and Environment ,Safety

Any skin contact with epOxy materials, solvents and epoxy strippers should be avoided. Epoxy resins and particularly epoxy hardeners (B component) may cause a rash on the skin. The official toxicity classification on the container labels may be looked for before starting work. Rubber gloves, with a cloth liner, and protective clothing shall be worn. Bather creams are recommended but are not substitutes for protective clothing. Eyes shall be protected where splashing could occur while spraying or mixing. Good ventilation shall be ensured and inhalation of vapours avoided. If materials are sprayed, a respirator shall be used. If skin contact occurs, it shall be immediately washed with a cleaner, followed by soap and water. Should eye contact occur, it shall be flushed immediately with plenty of water for 15 minutes and a doctor called for. If contact occurs with the clothing, it shall be immediately changed to prevent further skin contact, and if the contact occurs with components A or B, the clothing shall be thrown away. Hardened epoxy is not harmful but will break the clothing.
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608
Section 2800
All emptied, used buckets, rags and containers shall be removed from site. These shall be stored in waste disposal bags and suitably disposed. 2805. EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE 2805.1. Epoxy resin used for bonding shall be obtained from a reputed manufacturer. The pot life of such bonding epoxy shall not be less than 60-90 minutes at normal temperature. 2805.2. The entire surface of the existing concrete member should be thoroughly cleaned by wire brush and then with compressed air to remove dust and loose particles from the surface. Any crack or spalling of concrete shalt be sealed by epoxy injection/epoxy mortar/grouting as decided by the Engineer. A coating of suitable epoxy resin at the rate of 0.8 kg/sq.m. (minimum) should then be applied on the surface of the existing cOncrete members. Fresh concrete shall then be placed within the pot life of the resin system. 2805.3. Testing 2805.3.1. Epoxy used for bonding work Shall satisfy the criteria mentioned in Clause 28019. 2805.3.2. Two concrete cubes 150 mm size cast as per approved design mix shall be placed, as shown in Fig. 2800/3 at a distance of 150 mm from each other. Epoxy resin system suggested for bonding new to old concrete shall be applied on the opposite faces of the cubes. Fresh cement concrete cube of grade as per approved design mix shall be cast with water cement ratio of 0.4 or less in the manner shown in Fig. 2800/3. The assembly shall be cured in water for 28 days and steel spacer removed thereafter. The cube assembly shall .be subjected to compression load after 28 days of curing, thereby subjecting the bond to shearing load. Failure must not occur at this joint. 2806. CEMENT GROUTING 2806.1. Material Grouting shall normally be performed with a mixture of neat Portland Cement and water. Other additives and admixtures may be added to improve the Impermeability, strength, etc. on the approval of the Engineer. The size of the particles and the consistency of the grout must be suited to the passageways it must follow. Neat grout will not 609
<<
Section 2800
Repair ofStrucuires
LU
LU >
LU
0
4
LU
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0 (%4 L I-
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<<
Section 2800
flow freely into holes smaller than about three times the largest cement particle. Except in large cavities where thick mortar can be placed, the sand should all pass the 28-mesh sieve and have a large portion passing the 50- and the 100- mesh sieves. The proportions of Ordinary Portland Cement to sand Will depend upon the size of the spaces to be filled and will vary from a neat grout to about 1:1 mix. The amount of water to be added depends upon the consistency required. Orouts with as little as 16 litres of water per bag of cement could be handled and it shouldseldom be necessary to use more than 35 to 40 litres of water per bag of cement. Where necessary and approved by the Engineer, admixtures to Portland Cement grout mixtures may be added for delaying the setting time, increasing flow ability, minimising segregation~andshrinkage. 2806.2. Preparation The surface shall be cleaned with wire brush and compressed air. 15 mm din and 150 to 200 mm deep hoLes along the length of the cracks at a spacing of 500 mm may be drifted by wet drilling using rotary percussion drills and nipples. inserted in these boles. 2806.3. Proportioning, MixIng, and Equipment for Grouting The cement grout shall be mechanically mixed using a system of power-driven paddles of high speed centrifugal pump. The grout pump to be used shall permit close control of pressures to allow a flexible rate of injection with minimum clogging of valves and ports The most satisfactory equipment for injecting grout is a pump of the double-acting flexible reciprocating type giving a steady flow. The grout pump shall be so placed as to reduce the waste in cleaning lines. It is preferable to add 50 per cent or mOre of the mixing water into the mixer before adding the dry ingredients and then the remaining water. A continuous supply of grout is preferable to an intermittent one. Consistency of the grout may be determined by trials starting with thin grout i.e. about 40 litres of water per bag of cement and progressively decreasing the water content to about 15 litres per bag of cemenL Where the mixer and pump are combined in one unit1 the dry material shall be screened before mixing. if the mixer and pump are in separate uwis, the grout shall pass through a screen before it enters the pump.
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611
Section 2800
2806.4. Application Highest practical pressure within the limits 100-400 kPa should be used in order to force the surplus water from the grout. As thb pressure may be distributed hydraulically over considerable areas, vigilance must be exercised to prevent damage or, the needless waste of grout. Orouting is ~o be done by attaching a pscker (consisting of expansible tube of rubber) to the end of the grout supply pump through the holes and nipples. Pressure shall be steady to ensure a continuous flow of grout. Grouting shall not be continued till the hole consumes mix at the rate of not less than 30 litres in 20 minutes or until refusal at the grouting pressure of 400 kPa at any hole until iefhsaL Should the grout escape from an adjacent nipple,it should be plugged or capped. Any seam, crack or joint through which grout escapes shall be caulked with epoxy ffiortar as soon as thick grout appears. 2806.& Cleaning o~ Equipment
After completion of each grouting operation or temporary shutdown, it is advisable to force dear water through the pump until the discharge line shows no colour, aflCr which the pump covers shall be removed and the valve chambers thoroughly cleaned.
2S06.6~Testing Percolation test done at the end of grouting operation shall give a value of less than 2 lugions.
NOTE: For specialised trea~ntentike polymer modified cemenu*iour grom injection. l
manufactumrs htemune and specification shall be followed.
2807. GUNIT1NG/SHOTCRETE 2807.1. The gunite is a mixture of cement, sand and water. It comprises 100 parts by weight of cement, 300 parts by weight quartz sand, 35-50 parts by weight water and 2 parts by weight approved quick setting compound. In general, dry mix shotcrete shall be used. 2807.2. Ordinary Poilland cement conforming to IS:269 shaft be used in guniting. 28073. Sand for guniting shall comply with the requirements stipulated in IS:383. In general, sand should neither be zoo coarse to increase the rebound nor too fine to increase the slump. Sand should preferably have a moisture content between 3 to 6 per cent.
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612
Repair of Stmctures
IS Sieve
Designation 4.75mm 2.36mm 1,18mm 600 microns 300 microns 150 microns
Scc~ion2800
The grading of sand shall lie within the limits given below
per cent Passing the sieve
95. 100
65.90
45.75
30 10 2
- 50 - 22
2807.4. For thick sections it may be advantageous to incorporate coarse aggregate in the mix provided adequate guniting equipment is available. Coarse aggregate, when used, shall conform to grading given in Table I of IS:9012. The percentage of coarse aggregate may normally be kept as 20 to 40 per cent of the total aggregate and the mix shall be suitably designed. 2807.5. Water/cement ratio for guniting shall fall within the range 0.35 to 0.50 by mass, wet enough to reduce the rebound. Drying shrinkage may be between 0.06 per cent to 0.10 per cent. The quick setting compound shall be added at the nozzle with water just before guniting. 2807.6. Workrnansh~p The cement and sand shall be batched and mixed and conveyed through a hose pipe with the help of compressed air. A separate line shall bring the water under pressure. The cement, sand and water mix shall be passed through and intimately mixed in a special manifold and then projected at high velocity to the surface being repaired. The density of gunite shall not be less than 2000 kg/cu.m. The strength of gunite shall not be less than 25 MPa. For effective guniting, the nozzle shall be kept 60 to l50~ away from the surface, preferably cm normal to that surface. While enclosing reinforcement bars during repairs the nozzle shall be held~closer at a slight angle and the mix shall be wetter than the normal. 2807.7. Test panels simulating actual field conditions shall be fabricated for conducting preconstruction testing. The procedure for testing the cubes or cylinders taken from the panels stipulated in clause 6 of lS:90l2 shall be followed. 2807.8. It should be ensured from tests that a strength of about 25 MPa at 28 days is available for the mortar/concrete mix. 2807.9. The defective concrete shall be cut out to the full depth
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Section 2800
till sound concrete surface is reached. Under no circumstances should the thickness of concrete to be removed be less than clear cover to the main reinforcement. No square shoulders shall be left at the perimeter of the cut-off portion and all edges shall be tapered. Thereafter, all loose and foreign materials should be removed and the surface be sand~ blasted to make it rough to receive shotcrete after applying a coat of bonding epoxy as per recommendation of the manufacturer @ 1.0 kg per 1.5 sq.m. of surface area. 2807.10. The exposed reinforcement shall be thoroughly cleaned free of rust, scales etc. by wire brushing. Wherever the reinforcements have been corroded, the same shall be removed and replaced by additional reinforcement. Before application of gunite, a coat of near cement slurry should be applied on the surface of the reinforcement. 2807.11. Sufficient clearance shall be provided around the reinforcement to permit encasement with sound gunite. Care shall be taken to avoid sand pockets behind the reinforcement. 2807.12. A thickness of 25 to 40 mm of gunite can normally be deposited in one operation. If, for some reason, the total thickness is to be built up in successive operations, the previous layer should be allowed to set but not become hard before the applicati&n of the subsequent layer. It would always be necessary to apply guniting on a damp concrete surface. 2807.13. Where required, welded wire fabrics Scm x 5 cm x No. 10 gauge shall be provided in the first layer of guniting. The fabric shall be tied properly. In case the damage to the concrete member is too deep, the specifications for guniting as well as requirement of placement of wire mesh has to be decided as per field conditions. 2807.14. The stipulations given in IS:9012 regarding application of gunite should be followed so as to keep the rebound to the minimum. The quality of guniting and workmanship shall be such that the percentage of rebound mentioned in IS:9012 can be adhered to. In no circumstances shall the rebound material be re-used in the work. 2807.15. It would be desirsble that green gunite is moistened for at least 7 days. Guniting work shall not be done during windy or rainy conditions. 2808. REPLACEMENT/RECTIFICATION OF BEARINGS 2808.1. The replacement/rectification of bearings shall be carried out in accordance .with approved repair plan or as approved by the Engineer.
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Section 2800
2808.2. Lifting of superstructure spans may be carried out by jacking up from below or by lifting the span from top. Where jacks are employed, their location/number and size shall be selected in such a manner so that there are no undue stresses created in the structure. Jacks may be placed on piers/pier caps or specially erected trestles in accordance with the approved methodology for lifting of superstruc. ture. All jacks shall be operated from one control panel by a single control lever. The system will have provision for manual over ride to control the loads of any particular jack. The jacks should be so synchronised that differential lift between individual jacks shall not exceed 1 mm 2808.3. Necessary repair/replacement of bearings shall be carried out as indicated in the repair plan or as directed by the Engineer. Care shall be taken to plan the execution of repair in the shortest possible period. 2808.4. Precautions during Lifting of Girders for Rectification of Bearings Walkie talkies system .or similar audio arrangements should be available for communicating instructions regarding lifting, stopping, starting etc. The operator shall have a clear view of the jacks and the lifting of each girder controlled by reading the dial gauges. 2809. DISMANTLING OF CONCRETE WEARING COAT 2809.1. Commencement of Dismantling
i) Before commencing dismantling, the nature and condition of concrete, the condition and position of reinforcement should be ascestained. The Contractor shall familiarise himself with the structural design and ensure that the overall stability of the bridge is not affected, The existing expansion joint assemblies shall be removed carefully along the entire width of the carriageway. The deck slab for a width of 400 mm on either side should be removed for placing of reinforcement., anchor rods, anchor bolts and other fixing assemblies for the new expansion joints and pouring of fresh concrete. The gap between the girders over the piers should be cleared of all debris. A temporary platform in the gap at the end of girders shall be erected to collect the materials falling down during concreting and fixing of expansion joints The service lines, if any, shall be disconnected/ diverted before the dismantling work starts.
ii).
iii)
2809.2. Dismantling of concrete wearing coat shall be carried out using jack hammers or suitable manual methods as approved by the Engineer. Care should be taken to avoid any damage to the existing structure including reinforcement or prestressing anchorages for cables,
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Section 2800
Rcpair of Structures
if any, located in the deck slab. 2809,3. Precautions During Dismantling Work For general guidelines, reference may be made to Section 100. Dismantling work shall not be carried out at night, or during storm or heavy rain. A warning device shall be installed in the area to be used to warn the workers in case of mishaplemergency. Safety helmets conforming to IS:2925 shall be used by the workmen engaged in dismantling work, The sheds and tool boxes should be located away from the work site. Goggles preferably made up of celluloids and gas masks shall be worn at the time of dismantling, especially where tools like jack hammers are deployed to protect eyes from injuries from flying pieces, dirt, dust etc. Leather or rubber gloves shall be worn by the workers during the demolition of RCC work. Screens made up of GI sheets shall be placed wherever necessary to prevent the flying pieces from injuring the workers. Water should be sprayed to reduce the dust while removing concrete wearing course with jack hammer. No work shall be taken up under the span when dismantling work is in progress. 2810. EXTERNAL PRESTRESSING 2810.1. Various components constituting the system of external prestressing are as follows H.T. Strands/Wires, HDPE Sheathing, Deviator Blocks, Anchor Plates, Anchorages and grouting material. 2810.2. Material H,T. Strands / Wires H.T.Strands wires shall conform to Section 1000. HDPE Sheathing HDPE Sheathing shall conform to IS:4984 suitable for a working pressure of 6 bars. Its density shall be 955 kg/cum, shore hardness D63, yield stress 24 MPa and ultimate tensile strength 35 MPa. Deviator Blocks As necessitated by the profile of the external cable, suitable stranW wire deviator block fabricated from M.S.Sections shall be provided. The deviator block shall be given a coat of suitable paint (preferably epoxy based) after sand blasting.
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Section 2800
Anchorages Depending upon the prestressing force, suitable anchorages and wedges shall be used conforming to relevant codes and section 1800. 28103, Workmanship
a) b) Stressing of cables shalt be earned out as per instructions given in the drawing, and conforming to Section 1800. Care should be taken to avoid any damage to the existing sisucture, by way of stress concentration orany other reason during fixing of the deviator blocks and after stressing of cable. The deviator blocks shall be so fixed as not to allow any movement due to prestressing forces. Radius of corvature of the surface of the deviator block interfacing with the cable shall be minimum one metre. The anchorages shall be sealed with suitable epoxy mortar system after the stressing of cables, A minimum cover of 50mm shall be provided for the anchor plates and anchorages. Suitable grouting inlet points and vent points shall be provided by way of HDPE 1 vent connections to the sheathing. Grouting of cables shall be carried out as per provisions made in Section 1800.
c)
d) e)
2810.4. It shall be ensured that no part of the existing structure is damaged/distressed due to the external prestressing. The behaviour of the girder shall be monitored by measurement of deflection so that only required amount of external presiressing is imparted to the girder. Care shall be taken to avoid excess prestressing and impairment to the girders. 2811. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of accepthnce. 2812, MEASUREMENTS FOR PAYMENT
a) Measurement for sealing of cracks and injection shalt be made by weighs of epoxy consumed in kg for epoxy grouting. For provision of nipples required for grouting, the payment shalt be for number of nipples inserted. Measurement for sealing of cracks and injection shall be made by weight of cement consumed in kg for cement grouting. Measurement for application of epoxy mortar for specified thickness shalt be per square metre of surface area of application. Measurement for bonding of old and new concrete by epoxy mortar be measured in square metre surface area of interface. shall
b) c) d)
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Section 2800 e) f) g) h)
Measurement for guniting/shoicreting, shall be per square metre of surface area of application. Payment for replacemenUrectification of bearings shall be for each number of bearing assembl~replaced/rectified. Dismantling of wearing coat shall be measured in square metre of area of wearing course dismantled. Provision of external prestressing shall be measured in tonnes of FIT. ste& strand/wire measured from anchorage to anchorage before stressing.
2813. RATE The contract unit rate for sealing of cracks and injection of cement grout shall include cost of all materials, labour, toots and plant, placing in position, testing, curing and other incidental expenses for the satisfactory completion of the work as per these specifications. The contract unit rate for application of epoxy mortar for specified thickness shall include cost of all materials, labour, tools and plant, placing in position, testing and other incidental expenses including surface preparation for the satisfactQry completion of the work as per these specifications and as shown on the drawings. The contract unit rate for gunitinglshotcreting shall include cost of all materials, labour, tools and plant, placing in position, testing, curing, surface preparation and other incidental expenses including the provision of nipples for the satisfactory completion of the work as per these specifications. The contract unit rate for replacement/rectification of bearings shall include cost of all materials, labour, tools and plant, placing in position, site welding/riveting/bolt connections, operation of jacks and other incidental expenses for the satisfactory completion of the work as per these specifications and as shown on the drawings. The contract unit rate for dismantling of wearing coat shall include cost of all jirnterials, labour, tools and plant, traffic management, signages, safety precautions and other incidental expenses including removal of existing expansion joints for the satisfactory completion of the work as per these specifications. The contract unit rate for external prest.ressing shall include cost of all materials, labour, tools and plant, temporary works, testing, curing and other incidental expenses including the careful monitoring of the deflection of girders being externally prestressed for the satisfactory completion of the work as per these specifications and as shown on the drawings.
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618
Pipe Culverts
2900 Pipe Culverts
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Pipe Culverts
Section 2900.
2901. SCOPE This work shall consist of furnishing and installing reinforced cement concrete pipes, of the type, diameter and length required at the locations shownon the drawings or as ordered by the Engineer and in accordance with the requirements of these Specifications, 2902. MATERIALS All materials used in the construction of pipe culverts shall conform to the requirements of Section 1000. Each consignment ofcement concrete pipes shall be inspected, tested, ifnecessary, and approved by the Engineer either at the place ofmanufacture or at the site before their incorporation in the works. 2903. EXCAVATION FOR PIPE The foundation bed for pipe culverts shall be excavated true to the lines and grades shown on the drawings or as directed by the Engineer, The pipes shall be placed in shallow excavation of the natural ground or in open trenches cut in existing enibankments, taken down to levels as shown on the drawings. In case of high embankments where the height of fill is more than three times the external diameter of the pipe, the embankment shall first be built to an elevation above the top of the pipe equal to the external diameter of the pipe, and to width on each side of the pipe of not less than five times the diameter of pipe, after which a trench shall be excavated and the pipe shall be laid. Where trenching is involved, its width on either side of the pipe shall be a minimum of 150mm orone~fourth ofthediameterbf the ~ipe whichever is more and shall not be more than one-third the diameter of the pipe. The sides of the trench shall be as nearly vertical as possible. The pipe shall be placed where the ground for the foundation is reasonably firm. Installation of pipes under existing bridges or culverts shall be avoided as far as possible. When during excavation the material encountered is soft, spongy or other unstable soil, and unless other special construction methods are called for on the drawings or in special provisions, such unsuitable material shall be removed to such depth, width and length as directed by the Engineer. The excavation shall then be backlilled with approved granular material which shall be properly shaped and thoroughly compacted upto the specified level. Where bed-rock or boulder strata are encountered, excavation shall be
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Section 2900
Pipe Culverts
taken down to atleast 200 mm below the bottom level of the pipe with prior permission of the Engineer and all rock/boulders in this area be removed and the space filled with approved earth, free from stone or fragmented material, shaped to the requirements and thoroughly compacted to provide adequate support for the pipe. Trenches shall be kept free from water until the pipes are installed and the joints have hardened. 2904. BEDDING FOR PIPE The bedding surface shall provide a firm foundation of uniform density throughout the length of the culvert, shall conform to the specified levels and grade, and shall be of one of the following two types as specified on the drawings:
(i) First Class bedding: Under first class bedding, the pipe shall be evenly bedded on a continuous layer of well compacted approved granular material, shaped concentrically to fit the lower part ofthe pipe exterior for atleast ten per cent of i t.s overall heightor as otherwise shown on the drawings. The bedding material shall be well graded sand or another granular material passing 5,6 mm sieve suitably compacted/rammed. The compacted thickness of the bedding ~ yer shall be as shown on the drawings and in no case shall it be less than 75 mm,
~ii) Concrete cradle bedding: When indicated on the drawings or directed t~,the Engineer, the pipe shall be bedded in a cradle constructed of concrete having a mix not leaner than M 15 confomiing to Section 1700, The shape and dimensions of the cradle shall be as indicated on the drawings. The pipes thafi be laid on the conere~e bedding before the conrete has set,
2905. LAYING OF PIPE No pipe shall be laid in position until the foundation has been approved by the Engineer. Where two or more pipes are to be laid adjacent to each other, they shall be separated by adistance equal to at least half the diameter of the pipe subject to a minimum of 450 mm. The arrangement for lifting, loading and unloading concrete pipes from factory/yard and at site shall be such that the pipes do not suffer any undue structural strain, any damage due to fall or impact. The arrangement may be got approved by the Engineer. Similarly, the arrangement for lowering the pipe in the bed shall be got approved by the Engineer. Tt, may be with tripod-pulley arrangement or simply by manual labour in a manner that the pipe is placed in the proper position without damage. The laying of pipes on the prepared foundation shall start from the outlet and proceed towards the inlet and be completed to the specified lines and grades. In case of use of pipes with bell-mouth, the belied end shall face 622
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Pipe Culverts
Section 2900
upstream. The pipes shall be fitted and matched so that when laid in work, they form aculvert with a smooth uniform invert. Any pipe found defective or damaged during laying shall be removed at the cost of the Contractor. 290t JOINTING The pipes shall bejointed either by collarjoint or by flushjoint. In the former case, the collars shall be of RCC 150 to 200 mm wide and having the same strength as the pipesto be jointed. Caulking space shall be between 13 and 20 mm according to the diameter of the pipe. Caulking material shall be slightly wet mix ofcement and sand in the ratio of 1:2 rammed with caulking irons. Before caulking, the collar shall be so placed that its centre coincides with thejointand an even annularspace is leftbetween the collarand the pipe. flush joint may be internal flush joint or external flush joint. In either case, the ends of the pipes shall be specially shaped to form a self centering jointwith ajointing space 13 mm wide. The jointing space shall be filled with cement mortar, 1 cement to 2 sand, mixed sufficiently dry to remain in position when forced with a trowel or rammer. Care shall be taken to fill all voids and excess mortar shall be removed. For jointing pipe lines under light hydraulic pressure, the recess at the end of the pipe shall be filled with jute braiding dipped in hot bitumen or other suitable approved compound.Pipes shall be so jointed that the bitumen ring of one pipe shall set into the recess ofthe next pipe. The ring shall be thoroughly compressed by jacking or by any other suitable method. All joints shall be made with care so that their interior surface is smooth andconsistent with the interior surface of the pipes. After finishing, the joint shall be kept covered and damp for at least four days. 2907. BACKFILLING Trenches shall be backfilled immediately after the pipes have been laid and thejointing material has hardened. The backfill soil shall be clean, free from boulders, large roots, excessive amounts of sods or other vegetable matter, and lumps and shall be approved by the Engineer. Backfilling upto 300 mm above the top of the pipe shall be carefully done and the soil thoroughly rammed, tamped or vthrated in layers not exceeding 150 mm, particular care being taken to thordughly consolidate the materials under the haunches of the pipe. Approved pneumatic or light mechanical tamping equipment can be used.
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Section 2900
Pipe Culverts
Filling of the trench shall be carried out simultaneously on both sides of the pipein such a manner that unequal pressures do not occur. In caseofhigh emba*rnent, after filling the trench upto the top of the pipe in the above said manner, a loose fill of a depth equal to external diameter of the pipe shall be placed over the pipe before further layers are added and compacted. 2908. HEADWALLS AND OTHER ANCILLARY WORKS Headwalls, wing walls, aprons and other ancillary works shall be constructed in accordance with the details shown on the drawings or as directed by the Engineer. Masonry for the walls shall conform to Section 1300, 1400 or 1700 as applicable. Aprons shalt conform to Section 2500. 2909. OPENING TO TRAFFIC No traffic shall be permitted to cross the pipe line unless height of filling above the top of the pipe line is atleast 600 mm. 2910. MEASUREMENTS FOR PAYMENT R.C.C. pipe culverts shall be measured along their centre between the inlet and outlet ends in linear metres. Selected granular material and cement concrete for pipe bedding shall be measured as laid in cubic metres. Ancillary works like headwalls, etc., shall be measured as provided for under the respective Sections. 2911. RATE The Contract unit rate for the pipes shall include the cost of pipes including loading, unloading, hauling, handling, storing, laying in position and jointing complete and all incidental costs to complete the work as per these Specifications. Ancillary works such as excavation including backfiiling, concrete arid masonry shall be paid for separately, as provided under the respective Clauses.
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Maintenance of Road
3000 Maintenance of Road
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Maintenance of Road
Section 3000
3001. GENERAL The Specificationsshall apply to all itemsofroad maintenance works as required to be carried out under the Contract or as directed by the Engineer. The works shall be carried out in conformity with therelevant Specifications to the required level, grade and lines using approvM materials. The works shall be carried out using light duty machinery or manual means provided the quality of the end product does not suffer. In execution of maintenance works, areference is made tothe IRC publications: Manual for Maintenance of Roads and Code of Practice for Maintenance for Bituminous Surfaces of Highways, IRC 82-1982 for guidance and compliance wherever applicable. Wherever the Specification is not clear, good engineering practice shall be adopted in the construction to the satisfaction of the Engineer. 3002. RESTORATION OF RAIN CUTS 3002.1. Scope The work shall consist of earthwork for restoration of rain cuts in the embankment and shoulders, using suitable material, and compacting the same. 3002,2. Materials The material used for restoration of rain cuts shall consist of soil conforming to Clause 305.2. 3002.3. Construction Operation The area affected by rain cuts shall be cleared of all loose soil and benched. The width of the benches shall be at least 300 mm and they shall extend continuouslyfora sufficient length. Theheight of thebenches shall be in the range of 150-300 mm. Fresh material shall be deposited in layers notexceeding 250 mm loose thickness and compacted so as to match with the benching at a moisture content close to the optimum. Compaction shall be carried out using suitable equipment such as platecompactors andrammers or by suitable implements handled manually. The finished work shall conform to aligmnent, levels and slopes as indicated in the drawing. 3002.4. Measurements for Payment The earthwork foi~ restoration of rain cuts shalt be measured in cubic metres.
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Section 3000
Maintenance of Road
3002.5. Rate The Contract rate for the item of earthwork for restoration of rain cuts shall be payment in full for carrying out the required operation including full compensation for: (i) Supply ofmaterial including all leads and lifu and the costof arrangement of land;
(ii) Setling out; (iii) Removal ofloose material from the cain cuts; (iv) Benching ofold earthwork; and (v) Compacting after adding required quantity of water.
3003. MAINTENANCE OF EARTHEN SHOULDER 3003.1. Scope The work of maintenance ofearthen shouldershall include making up the irregularities/loss of material on shoulder to the design level by adding fresh approved soil and compacting it with appropriate equipments or to strip excess soil from the shoulder surface as per the requirement of this Specification. 3003.2. Material The material to be added to the shoulder, ifrequired, shall be a select soil conforming to Clause 305. 3003.3. Construction Procedure This work shall involve:
-
(i)
Making up ofthe earthen thoulderby adding extra soil and compacting rhesame; andl or,
(ii) Stripping a layer of soil to achieve the required grade and level.
Wherever extra earth is required to be added, the earthen shoulder shall be stripped and loosened to receive fresh soil. The deficiency of thickness shall be made up in layers of loose thickness not exceeding 250 mm. Water shall be added, if required, to attain the optimum amount and the layercompacted by 80 to lOOkN smooth wheelroller, vibratory roller, hand roller, plate vibrator or hand rammer to obtain atleast 94 per cent of the maximum dry density in accordance with IS: 2720 (Part 8). The finished surface shall have the specified cross. slope and line in accordance with the drawing.The side slopes shall be trimmed to therequired slope with the help of grader or manual methods using hand tools. Wherever the earth is required to be excavated from the shoulder, this shall be done either using equipment like grader or by inanual means using
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Maintenance
of Road
Section 3000
hand tools. The resulting surface shall be uniform and have a field density of atleast 94 per Cent of maximum density obtained in accorthnce with IS : 2720 (Part 8). If the surface is not uniformly compacted, it shall be excavated to a depth of 150 mm and the soil mixed with water if required and compacted at a moisture content close to the optimum to achieve 94 per cent of maximum density as stated above. 3003,4. Measurements for Payment Maintenance of earthen shouldershall be measured in sq. metres. 3003.5. Rate The Contract unit rate for maintenance of earthen shoulder shall be payment in full compensation for:
(i) (ii) furnishing earth required formaking up of shoulders including all leads and lifts,cost of land and compaction; excavation of earth as required and disposal of the earth at the location approved; and
(iii) all tools, equipments and incidentals to complete the work in accordance with the above Specification.
3004. BiTUMINOUS WORK IN CONNECTION WITH MAINTENANCE AND REPAIRS 3004.1. Filling Pot-holes and Patch Repairs 3004.1.!. Scope : This work shall include repair of pot-holes and patching of all types of bituminous surfaces with a bituminous mix either produced atplant site or atthe site itself with manual method of mixing and placed at site in the pot holes or in patches after trimming the pot-hole or depression to proper shape and depth, side painting with tack coat and compacting the layer to the levels specified in the drawing. 3004.1.2. Materials The materials used for the pot-hole and patch repair of bituminous surface shall be as per the Contract and shall be of the same type as used for the existing bituminous surface. Amix superior to the one on existing surface can also be considered appropriate for repair work. An emulsified bitumen mix compatiblewith the existing layerShall also be considered appropriate. The grading ofaggregates and bitumen content of the mix used for such patch repair shall be in accordance with Clause 501. 3004.13. Preparation ofthe area for pot-hole and patch repair Each pot-hole and patch repair area shall be inspected and all loose material removed. The area shall be cut/trimmed either with jack hammer or hand tools like chisels, pick-axes etc., such that the area is in the shape of a
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Section 3000
Maintenance of Road
rectangle or square. The edges shall be cut vertically uptothe level where the lowerlayer is stable without any loose material, The area shall be thoroughly cleaned with compressed air or any appropriate method approved by the Engineer to remove all dust and loS particles. The area shall be tacked or primed with cutback or emulsion depending upon whether the lower layer is bituminous or granular in nature. The sides, however, are to be painted with hot tack coat material using a brush. The primecoal and tack coat shall conform to Clauses 502 and 503 of these Specifications, respectively. 3004.1.4. Backfilling operation : The mix to be filled shall be either ahot mix or a cold storable mix (using bituminous emulsion). Mixing shall be done in a plant of suitable capacity. It shall be placed in thicknesses not more than 100 mm (loose). It shall be compacted in layers with roller/plate compactor/hand roller/ rammer. While placing the final layer, the mix shall be spread slightly proud of the surface so that after rolling, the surface shall be flush with the adjoining surface. If the area is large, the spreading and levelling shall be done using hand shovel and wooden straight edge. During the processof compaction with roller or other means, the surface level shall be checked using a 3 m straight edge. 3004.1.5. Measurements for payment: Filling of pot-holes and patch repair shall be measured in sq.m. 3004.1.6. Rate: The Contractunit rate for filling of pot-holes and patch repair shall be in full compensation for
(i) (ii) fumi thing all materials required; works involved in trimming, tacking, priming with cutback or emulsion;
(iii) all labour, tools, equipments and incidentals to complete the work inaccordancewith the Specifications.
3004.2. Sealing of Cracks with Fog Seal 3004.2.1. Scope: Fog seal shall consist of an application of emulsified bitumen, withoul any aggregate cover for sealing fine hair-cracks like shrinkage cracks and alligator cracks or rejuvenating oxidised bituminous surfaces. Areas having cracks with less than 3 mm width shall be considered for this treatment. 3004.2.2. Material : Bituminous emulsion for Fog Seal shall be of a slow setting type. 3004.2.3. Application : The area to be applied with fog seal shall be thoroughly cleaned with compressed air, scrubbers, etc. The cracksshall be cleaned with pressure airjet to remove all dirt, dust, etc. The fog seal shall be applied at the rate of 0.5-1.0 litre/sq.m. using equipment like a pressure
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Maintenance of Road
Section 3000
tank, flexible hose and spraying bar or lance. Traffic shall be allowed on the surface after the seal has set to a non-tacky and firm condition so that if is not picked up by the traffic. 3004.2.4. Measurements for payment: The fog seal work shall be measured in sq.metres. 3004.2.5. Rate : The Contract unit rate for application of fog seal shall be in full compensation for:
(i) (ii) supplying of fog seal material and all the operations for applying it; and all the labour, tools,equipments and incidentals to complete the work in accordance with this Specification.
3004.3. Slurry Seals Clause 516 shall apply, with the modification that simple implements and tools amenable to manual methods shall be used. 3004.4. Premix Carpetfor Renewal of Surface The work shall consist of laying a 20 mm thick open-graded premix carpet for renewal of surface. The stipulations contained in Clause 509 shall govern as regards scope and materials. A tack coat shall be applied conforming to Clause 503, but manual methods or use of relatively small capacity equipment shallbe permitted. The premix shall be prepared in hotmix plants of suitable capacity or small portable mixers, approved by the Engineer. Rolling shall be done as per Clause 509.1.3.5. A seal coat conforming to Clause 513 shall be applied after laying the carpet. The work shall be measured in sq.rnetres and the Contract unit rate shall cover supply of all materials, labour and equipment and carrying out the work to Specifications. 3004.5. Surface Dressing for Maintenance Work The work shall be done in conformity with Clause 508, except that the use of small and portable equipment shall be permitted. 3005. MAINTENANCE OF CEMENT CONCRETE ROAD 3005.1. Repair of Joint (hooves with Epoxy Mortar or Epoxy Concrete 3005,1.1. Scope : The work shall consist of repair of spalled joint grooves of contraction joints, longitudinal joints and expansion joints in a concrete pavement using epoxy mortar or epoxy concrete. 3005.1.2. Materials: The type/grade of epoxy compatible with the coefficient of thermal expansion of concrete shall be used with either
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631
Section 3000
Maintenance of Road
processed fine aggregate or fine stone chips to produce a dry mix forrepairing spalled or damaged edges. 3005.1.3. Repairing Procedure: Spalled or broken edges shall be shaped neatly with a vertical cut with chisels into the shape of rectangle. Small pneumatic chisels also may be used, provided the cutting depth can be controlled. The depth of the cut shall be the minimum to effect repair. After shaping the spalled area, it shall be cleaned and primed. The epoxy mortar/concrete is then applied using hand tools like trowels, straight edges, brushes etc. The repaired edge shall be in line with the joint groove and shall be flush with the concrete slabs. During the repair work, any damagenoticed to the joint sealant shall be made good by raking Out the affected portion and resealiag. 3005.1,4. Traffic: Although the epoxy mixes set in 2-3 hours time, it is desirable to divert the traffic for 12 hours or as per the recommendation ofthe manufacturers. 3005,1.5. Measurements for payment: Repair of joint grooves shall be measured in linear metres. 3005.1.6. Rate: The Contractunit rate for repair of joint grooves with epoxy mortar or epoxy concrete shall be in full compensation for~ (i) supply and application of epoxy primer, epoxy mortar or epoxy concrete; (ii) all tools, equipment and incidentals to complete the work in accordance with the above Specification. 3005.2. Repair InvolvingRemoval of OldJoint Sealant and Sealing with Fresh Sealant in Cement Concrete Pavements 3005.2.1. Scope: The repair of sealant of contraction, longitudinal or expansion joints shall include removal of the existing sealant and resealing the joint with fresh sealant material. 3005,2,2. Material: Sealant material to be replaced shall be either hot poured rubberised bitumen or polysulphide type of sealant as per Clause 602.2.8. As per the recommendation of the manufacturer, appropriate type of primer also shall be applied. 3005.2,3. Repairing procedure: The existing sealant shall be raked out with the help of a metal raker such that most of the sealant is removed. Subsequently, the sealant stuck to the sides of the grooves shall be removed thoroughly either by using saw cutting machine so that grooves may be widened by one mm or by sand blasting. In no case the old sealant shall be
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632
Maintenance of Road
Section 3000
present during resealing operation, If joint grooves are found inadequate in depth, they shall be deepened as directed by the Engineer. Before commencing the sealing operation, compressed air shall be used to clean the joint grooves to clean the joint groove. A heat resistant, paper backed compressible debonding strip or tape should be inserted in accordance with the requirement of Clause 602.11.2. Sealant may be poured either using hand held pourer or using mechanised sealing machines. Sealants should not be heated directly but in double jacketed machine. All precautions and arrangements shall be taken not to spill the sealant on the concrete pavement. The sealant may be poured to a depth of 5 mm 2 from the pavement surface. 3005,2,4. Measurements for payment: Repair ofjoint sealant shall be measured in linear metres. 3005.2.5. Rate: Contract unit rate for repair~ joint sealant shall be in of full compensation for~
(i) (ii) removal of old sealant, regrooving or sand blasting the sealinggroove and placing of debondmg strip or tape. all tools, equipments and incidentals to compkte the work in accordance with the above Specification.
<<
633
Appendices
Appendices
<<
Appendices
Appendsxl LIST OF IRC PUBLICATIONS REFERRED TO IN THE SPECIFICATIONS, CODES & STANDARDS
NumbeT Designation TItle Route MaskqSigns forNanonal Highways (FiratRevision) Standard Specifications & Code of Practice for Road Bridges, Section 1-General Feawres ofDesign (Sixth Revisiou) Standard Specifications &Codeof Practice forRoad Bridges, Section H-Loads and Stresses (Third Reviston) Type Designs for Highway Kilometre Stones (Second Revision) Recommended Practice for Borrowpiis for Road F.mbankments ConstnKted by Manual Operation RecommendedPractice for2an Thick Bitumen and TarCarpets (Third Revision) Tentative Specification for Printing of Base Course with Bituminous Primers Tentative Specification for Single Coat BituminoqsSurface Dressing Design Criteria for Prestiessed Concrete Road Bridges Tensioned Concrete) (Second Revision) (Post-
IRC : 21965
IRC : 5-1985 [RC :6-1966 IRC : 8-1980 IRC 10-1961
LRC : 14-1977 IRC : 16-1989 IRC : 17-1965 IRC : 18-1985 IRC : 19-1977 IRC : 20-1966 IRC : 21-1987 [RC : 22-1986 1RC : 23-1966 IRC : 24-1967 IRC : 25-1967 [RC :26-1967
Standard Specifications and Code of Practice for Water Bound Macadam (Second Revision) Recommended Practice for Bituminous Penetration Macadam (Full Gan~) Standard Specifications and Code ofPractice forRoad Bridges, Section HI-Cement Concrete (PLain and Reinforcec~(First Revision) StandardSpecifications and CodeofPractice for Road Bridges, Section VI- Composite Construction for Road Bridges (First Revision) Tentative Specification for Two Coat Bituminous Surface Dressing Standard Specifications and CodeofPracticeforRoad Bridges, Section V-Steel Road Bridges Type Designs for Boundary Stones Type Designs for 200-metre Stones Tentative Specification for Bituminous Macadam (Base & Binder Course) Tentative Specification for 4 cm Asphaltic Concrete Surface Course Standard Letters and Numerals of Highway Signs Different Heights for Use on
mc
: 27-1967
IRC : 29-1968 IRC :30-1968
<<
637
Appendices Number Designation IRC : 35-1970 IRC :36-1970 IRC : 37-1984 IRC : 40-1970 IRC : 45-1972 IRC : 47-1972 IRC 48-1972 Title Code ofPractice for Road Markings (withPaints) Recommended Practice for the Construction ofEarth Embankments for Road Works Guidelines forthe Design ofFlexible Pavements (FirstRevision) Standard Specifications andCode of Practice forRoad Bridges, Section 1V-(Brick, Stone and Block Masonry) Recommendations for Estimating the Resistance of Soil below the Maximum Scour Level in the Design ofWell Foundations of Bridges. Tentative Specification for Built-up Spray Grout Tentative Specification for Bituminous Surface Dressing using Precoated Aggregates Recommended Practice for the Pulverixation ofBlack Cotton Soils for Lime &abilisation Recommended Design Criteria for the Use ofCement Modified Soil in Road Construction Re~ommendedDesIgnCritcria forthe LJseof Sol LimeMixesin Road Construction Recommended Practice for Treatment of Embankment Slopes for Erosion Control Tentative Guidelines for the Use of Law Grade Aggregates and Soil Aggregate Mixtures in Road Pavement Construction Codeof Practice for Road Signs Recommended Practice for Use and Upkeep ofEquipment, Tools and Appliances for Bituminous Pavement Construction Guidelines for the Design of High Embankments StandardSpecifications and CodeofPractice forRoad Bridges, Section VII -Eoundation ofSubstructure (First Revision) RecommendedPractice for Road Delineators Code of Practice for Maintenance of Bituminous Surfaceof Highways Standard Specifications and Code ofPractice for Road Bridges, Section IX-Bearings, Part I: Metallic Bearings Standard Specification andCode ofPractice for Road Bridges, Section LX, Bearings,Part IhElattomeric Boarings Guidelines for the Design & Erection of False Work forRoad Bridges Guidelines for Design and Construction of River Training and Control Works for Road Bridges Guidelines for Selectim, Operation and Maintenance of Bituminous Hot Mix Plant Guidelines on Design amid Installation of Road Traffic Signals
IRC : 49-1973 1RC : 50-1970 IRC :51-1973 IRC : 56-1974 IRC : 63-1976 IRC :67-1977 IRC 72-1978
IRC : 75-1979 IRC : 78-1983 IRC : 79-1981 IRC : 82-1982 IRC : 83-1982 IRC : 83-1987 IRC : 87-1981 1RC : 89-1985 IRC : 90-1985 IRC : 93-1985
<<
638
Appendices Number Designation IRC :94-1986 IRC:SP:1l-1977 IRC : SP :31-1986 Title Specifications for Dense Bituminous Macadam Handbook ofQuality Control for Coesuuction.ofRoads and Runways (First Revision) New Traffic Signs Miniatty of Shipping & Transport (Roads Wing) Handbook on goad Construction Machinery(1985) IRC Highway Research Board, State ofthe Art: Granular and Bound Bases and Sub-Bases
IRC : Special Report 11, 1992
<<
639
Appendices
Appendix 2 LIST OF INDIAN AND FOREIGN STANDARDS REFERRED TO IN THE SPECIFICATIONS (A) INDIAN STANDARDS
Number Designation IS : 5-1978 IS : 73-1992 IS : 164-1981 IS : 210-1978 IS : 215-1961 IS : 217-1988 IS : 226-1975 IS 269-1989 IS : 278-1978 IS : 280-1978 IS : 334-1982 IS : 383-1970 IS : 432-1982 (Part I) (Part 11) IS : 443-1975 IS = 454-1961 IS : 455-1989 IS : 456-1978 IS : 458-1988 IS : 460-1985 IS : 508-1973 IS : 516-1959 IS : 702-1988 IS ~:736 -1986 IS : 814-1974 Title Colour for ready mixed paints and enamels Paving bitumen Ready mixed paints, brushing, for road masking, to Indian Standard Colour No. 356 Golden yellow, white and black Grey iron castings Road tar CUtbaCkbitumen Structural steel (standard quality) 33 grade ordinary portland cement (fourth revision) Galvanized steel barbed wire for fencing Mild steel wire for general engineering purposes Glossary of terms relating to bitumen and tar Coarse and fine aggregates from natural sources for concrete Mild steel and medium tensile steel bars andhard-drawn steel wire for concrete reinforcement Mild steel and medium tensile steel bars Hard-drawn steel wire Methods of sampling and test for rubber hoses Digboi typecutback bitumen Portland stag cement (fourth revision) Code of practice for plain and reinforced concrete (third revision) Concrete pipes (with and without reinforcement) Test sieves Specification grease graphited (second revision) Methods oftest for strength of concrete Industrial bitumen (second revision) Wrought aluminium and aluminium alloys, plate~ general engineerfor i:ng purposes Covered electrodes for metal arc welding of miki steel 640
<<
Appendices
Number Designation
IS : 823-1964 IS : 961-1975 Title
Code ofprocedure for manual metal arc weldtug ofmild steel Stnmctural steel (High tensile)
Multipurpose grease No. 1, No.2and No.3 Steel castings for general engineering purposes
IS : 1002-1956
IS : 1030-1974
IS :1077-1976 IS :1124-1974 IS :1129-1972 IS :1139-1966 IS : 1148-1973 IS :1149-1973 IS :1195-1968 IS: 1199-1959 IS : 1201 to 1220- 1978 iS : 1239-1979 (Part I)
IS : 1239-1979 (Part II)
Common burnt day building brides

Method oftest for water *bsosptiovs ci natural building stones Dressing ofnatural building stones Hot rolled mild steel and medium tensile sleet deformed bars for concrete reinforcement Rivet bars for structural purposes High tensile rivet ban for structural purposes Procedure for resting for hardness number of bitumen mastic
Method of sampling and analysis of concrete

indian standard methods for resting tar and bituminous materials Mild steel tubes (fourth revision)
IS : 1364-1967 IS : 1367-1984 IS : 1387-1967 IS : 1398-1960 15: 1442-1964 1St: 1448 IS : 1477

(Pan I)-1971
Mild steel tubular and other wrought steel pipe fittings (second revision) Precision and semi-precision hesagon boks,sctnwa,nutsandlocknsts
(diameter range 6 to S9tnm) (first revision) Technical supply conditions for threaded steel farmers
General requirements for the supply of metallurgical materials Packing paper, waterproof, bitumen-laminated Covered electrodes for metal arc welding ofhigh tensile structural steel Method of tests for petroleum and its products Code of practice for finishing of it-on and steeWferious metal in buildings : painting and allied finishes Operationsand workmanship Portland-pozzolana cement
Qassification and identification of soils for general engineering
IS : 1489-1991 IS : 1498-1970
IS : 1514-1959
purposes
Methods of sampling and test forquick lime and hydrated lime
IS : 1732-1971
IS :1785 (Part I)-1966
Dimensions for round and square steel bars for structural and general
engineering pwposes Plain hard-drawn steel wire for pretuessed concrete Cold-twisted steel bars for concrete reinforcement
641
<<
Appendices Number Designation IS : 1786-1985 IS : 1838

(Part 1)- 1983 IS : 1888-1982 IS :2004-1978 15 :2062-1980 IS :2116-1980
Title
High ttrength deformed steelbars andwires for concrete reinforcement Prefonned fillerforexpansion jointin concretepavement and structures (non extntding and resilient type)
Bitumen impregnated fibre (first revision)

Method of load tests on soils
Carbon steel forgingfor general engineering purposes

Stnicturai steel (fusion welding quality)
Sand for masonry mortars

Methods for standard penetration test for soils
IS 2131-1981 IS :2250-1965 15 :2386-1963 (Paul) (Part 2) (Part 3) (Part 4)

(Part 5)
Code of practice for preparation and use of masonry mortars Methods of test for aggregates for concrete
Particle size and shape Estimation of deleterious materials and organic impurities
Specific gravity, density, voids, absorption and bullring

Mechanical properties Soundness Measuriig mortar making properties of fine aggregates
(Past 6) (Part 7)
(Part 8) IS : 2720
Alkali - Aggregate reactivity Petrographic examination Methods of test for soils

Determination of water content
(Part 2)4973 (Part 3)-I980 Section 1 Section Il

(Past 4)-1985 (Part 5)-1985 (Part 7)4980 (Pan 8)-I983 (Part 10)-1973 (Part 13)-1985 (Part I4)-l983 (Part 16)-1987
Detennination ofspecific gravity Pine grained soils Medium and coarse grained soils
Grain size analysis Determination ofliquid and plastic limits Determination of moisture content/dry density relation using light compaction Determination of water content-dry density relation using heavy compaction
Determination ofunconfined compressive strength Direct shear test Determination of density index (relativedensity)ofcobesionless soils
Laboratory determination of CBR De~rmination total soluble suliihates of
<<
(Part 27)-1977
642
Appendices Number Designation (Part 28)-1974 (Part 29)-1975 (Part 37)- 1976 (Part 40)- 1977 IS :3117-1965 IS : 3466-1967 iS : 3764-1992 IS : 4138-1977 ES : 4332 (Part 1)4967 (Part 3)4967 (Part 4)4968 (Part 5)-I 970 (Part 7)4973 (Part 8)-1969 IS 4434-1978 Title Determination ofdry density of soils in-place by the sand replacement method Determination ofdiy density of soils in-place by core cutter method Determination of sand equivalent values of soils and fine aggregates Determination of free swell index of soils Specification for bitumen emulsion for roads (cationic type) Masonry cement Code of safesy for excavation work Safety code for working in compressed air Method oftest for stabilized s#iLs Method ofsampling andpreparation of stabilized soils for testing Test for detemnnarion of moisture content-dry density relation for stabilized soil mixtures Wetting and dryingand,freezing and thawingtestsforcosnpactedsoilcement mixtures Detemiination ofunconfsned compressive strength of stabilized soil Determination of cement content of cement stabilized soils Determination oflime content of lime stabilized soils
Code of practice for in-situ vane shear test for soils

Hotdipped galvaniaed coatingon sound scaled wires Specification for bitumen mastic for bridge decking and roads General requirements for old asphaltmacadam mixing plant Method for determining the aggregate impact value of soft coarse aggregate
IS 4826 IS :5317-1969 IS : 5435 (Revised) IS : 5640-1970 IS :6006-1970 IS :6241-1971 IS :6909-1991 IS :6925-1973 IS : 7537-1974
IJncoaxed stress relieved strands for prestrcs~cdconcrete

Method often for determination of stripping value ofroad aggregates Supersulpbated cement Methods of test for determination of concrete admixtures Road traffic signals Rapid hardening portland cement waxer soluble chlorides in
IS :8041-1978 IS :8112-1989 ES : 8887-1978 IS :9103-1979

IS : 10262-1982
43 grade ordinary portland cement

Specification for bitumen emulsion for roads (cationic type) Admixtures for concrete Guidelines for concrete mix design 643
<<
Appendices Number DesIgnation
TItle
Specification for 53 grade ordinary poilland cement Specification for sulphate resisting pon~heid cement Glossary of terms for geosynthesics pats 1: lenna used in materials and propetties Determination of tensile properties of extruded polymer geogrids using the wide strip-test method
iS: 12269-1987 IS: 12330-1988

IS : 13321 (Part 1)-1992 IS: 13325-1992
iS : 13326
(Part l)-l992 IS: SP23-1982
Evaluation of interface friction between geo-synthetics and soilmethod of test part 1: Modified threct shear technique Handbook on concrete mixes (based on indian standards) (B) FOREIGN STANDARDS
Thennoplastie material Compression set of vulcanized rubber
ASTM :D-36
ASTM : D-395
ASTM :D-412 ASTM : D-429 ASTM : D-573

ASTM : D-624
Tension testing of vulcanized tubber

Adhesion of vulcanized rubber to metal Accelerated aging of vulcanized robber by the oven method
Tear resistance of vulcanized rubber

Test method for neutralisation numberfor potentiomerric titration
ASTM : D-664 ASTM : D-797

ASTM 1075
Youngs modulus in flexure of elastomer at normal and subnormal temperature Effect of water on cohesion of compacted bituminous mixtures
Accelerated ozone cracking of vulcanized rubber Test for resistance to plastic flow of bituminous mixtures using Marshall apparatus
ASThI D-1149 ASTM D-1559 ASThI D-2172

ASTM D-2240
Extraction, quantitative of bitumen from bituminous paving mixtures

indentation hardness of rubber and plastic by means of a Durometer Test method for effect of water on bitumen coated aggregate using
ASTM D-3625 ASTM : D-4533

ASTM : fl-li ASTM:E-S10
boiling water,
Test method for trapezoid tearing strength ofgeolextiles. Specification for wire cloth sieves for testing purposes Test method for coefficientofretro-reflectin or retro-reflection sheeting.
AASFETO: DM283
Coarse aggregate for highway and aixport construction
AASHTO: DM 294-70 Fine aggregate for bituminous paving mixtures AASHTO : DM 288-82 Geotextiles used for subsurface drainage pu~oses AASI-ITO : DM 17-77
AASHTO: DR 5-80 Mineral filler for bituminous paving mixtures Selection and use ofemulsified asphaits
<<
644
Appendices Number Designation

AASHTO: DM 81-75 AASHTO : Dlv! 82-75
Title Cut-back asphalt (rapid-curing type) Cut-back asphalt (medium~curing type)

Materials for embankments and subgrades
AASHTO: DM 140-80 Emulsified asphalt
AASHTO: DM 7-10
AASHTO : DM147-65 Materials for aggregate and soil-aggregate (1980) sub-base, base and surface courses AASIITO : OM 216-68 Lime for soil stabilisation AASHTO : DM 249-79 White andyeliow reflectivethermoplasticstripingmaterials(solid form)
AASHTO : DM 268-77 Weatherometer
AASHTO: DM282.80 Joint sealants,hot poured, elastometic type. (or ASTM : D3406) for portlandcement concrete pavements BS ~~10-1969 Test sieves BS 729-1971 Hot dip galvanized coatings on iron and steel articles
ES 812-1975 Part 2Testing aggregates
Methods for determination of physical properties Methods for determination ofmechanical properties
-
Part 3 Part lii

Part 114BS : 1047.1952 BS 1154-1970
Method for determination often per cent fines value (TFV)
MethOd for detennination of the polished-stone value Air-cooled blastfumace slag coarse aggregate for concrete Vulcanized natural rubber compounds
Methods of rest for soils for civil engineering pur~p~scs
BS : 1377-1975 ES : 1447-1973 BS : 1449-1956
Mastic asphah (limestone fine aggregates) for roads and footways

Steel plate, sheet and strip
Part 1-1972
Part 2-1967 BS : 1470-1972 IS :2630 BS : 2870 BS : 3262 Part-i
Carbon steel plate, sheet and strip

Stainless and heat resisting plate, sheet and strip Wrought alinninimn and aluminium alloys for general engineering purposes - plate, sheet and strip
Preformedjoint filler Rolled copper and copper alloys : sheet, strip and foil
Hot-applied thermoplastic road marking materials
Specification for constituent materials and mi,uuses Specification for mad performance Specification for application of material to road surface Cold poured joint sealants for concrete pavements
Part-2
Part-3 BS : 5212 Part 2-1975
<<
645
Appendices
Number Designation BS : 6044 B.S : 6088 ES : 6906
Past I Part 2
Title
Specification for pavement marking paints Specificationforsolid glassbeadaforuse with roadmaikingcompounds and for other industrial uses
Methods of teatfor geotextiles Determination of the tensile properties using a wide width strip Determination of the apparent pore size distribution by dry sieving Determination of waterfiow normalto theplane ofthegeotearile under a constant head Determination ofthe puncture resistance (CBR puncture teat) Determination of in-plane waterfiow Method at test for curing compound forconcrete Bituminous Road Construction Hand Book The asphalt han&took, manual series No.4 (MS-4) 1989 edition Geogrid rib tensile strength Geogrid junction strength Tensile creep testing ofGeogrids
Pail 3 Part 4 Part 7 ES : 7542 CR111 and ICC, New Delhi Asphalt institute
GRI-GGI
GRI-GG2 GRU3G3
(GRI denotes standards for test prepared by Geosynthetic Research Institute at Drexel University Philaddphia, USA)
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646
Appendices
Appendix 3 (Clause 4023.2 and 403.3.2) METHOD OF SIEVING FOR WET SOILS TO DETERMINETHE DEGREE OF PULVERISATION
I. 2.. A sample of pulverised soil approximately 1kg in weight should be taken and weighed(W
1).
3. 4.
It should be spread on the sieve and shaken gently, care being taken to break the lumps of soils as little as possible. Weight of soil retained on the sieve should be recorded (Wi). Lumps offiner soils in the retained material should be broken until all the individual particulars finer than the aperture size of the sieve are separated. The soil should again be placed on the sieve and shaken until sieving is complete. The retained material should be weighed (W,).
WeIght of roil by per cent passing the sieve can than he calculated from the expression: (W1W2)x 100
(W1-W,)
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647
Appendices Appendix 4 GUIDELINES ON SELECTiON OF THE GRADE OF BITUMEN

(Source Bituminous Road Construction Handbook, Indian OilCotporation and Central Road
Research Institute) A For bituminous premix carpet, choice is governed by climatic conditions and intensity of traffic. (I) Grade 30/40 for areas where difference between maxtrnutn and minimum airnospheric temperatures is less than 25 C and traffic intensity is greater than 150(1 commercialvehicles per day. For traffic intensityteas than 1500 commercial vehicles per day, Grade 50/60 is preferred. Where the difference between maximum and minimum atmospheric temperature ismorethan25~C and trafficintensity is greaterthanl500conmrercial vehicles per day, Grade 50/60 maybe used. For traffic intensity of less than 1500 commercial vehiclesperday,Grade 8OflOOmay beused. Forroads withvery heavy traffic greater than 4500 commercial vehicles per clay, such asmetropolitan city roads, Grade 30/40 is preferred.
(ii)
(iii) Grade 80/100 may be used in high altitude and snow-bound regions, irrespective of traffic intensity cotlaideration. B C For bituminous macadam and penetration macadam as also built-up spray grout, Grade 30/40 (for hot climates) and 60/70 or 801100 for other climates are suggested. For a dense-graded bituminous concrete, a more viscous grade like 60170 can withstand stresses of heavier wheel loads better than a less viscous grade of 80/100. Similarly pavingbitumen grade 60/70 isrnore advantageous for roadswith largenumberofrepetitions ofwheel loads like expressways, urban roads, factoryroads etc. High stability requirement cannot be meteffectively by less viscous bitumen. A more viscous grade of bitumen is advantageous inreducing stripping ofbitumen film from aggregates in the presence of water.~ With rounded river shingles,amore viscous grade ofbitumen compensates tosomeextent for poor mechanical interlock. A comparison of penetration grades andviscosity grades (AC-23to AC-40)ofasphalt cement and AR grades (basedonRolling Thin Film Oven Test residue) is shown below.
D E
<<
648
Appendices
tt~
AR. 100 AR. SO AC. LU
C, 0
>4
t 10
2000
;c. 2.5 ~1ooo
Coniparision of per~etration grades grades of bitumert
and
viscosity
<<
649
Appendices
Appendix 5 ANTI-STRIPPING AGENTS USED FOR BITUMINOUS MATERIALSAND MIXES

I. Scope 1.1. Anti-stripping agents are used for bituminous materials and mixes to ensure adhesion between aggregates (hydrophilic in nature) and bitumen, even under submergence in water. Prior approval of the Engineer shall be taken in respect of both qualitative and quantitative use of a particular product. 2. MaterIals 2.1. The anti-stripping agents shall be fatty acid amines having a long hydrocarbon chain. 2.2. PhysIcal and Chemical Requirements : The anri.stripping agents shall conform to the physical and chemical requirements as detailed in Table AS-I. 2.3, Storage and Handling : Anti-stripping agents shall be properly stored in closed containers made of steel or aluminium. Containers made of zinc, copper, polythene PVC and most types ofrubber are not suitable for use. A~ most of the anti-stripping agents cause irritation when in contact with human skin and are also irritating to the eyes, protective gloves for hands and goggles forthe eyes shall be used while handlingthem, specially in caseof liquid antistripping agents. 3. Use in Sprayed Work 3.1. AdditIve Dosage: The dosage shall be determined depending on the nature (stripping value) of the aggregate and the size of aggregate. While the recommended minimum dose of anti-stripping agent for sprayed work is given in Table A5-2, the actual dosage shall be determined in the laboratory as directed by the Engineer. 3.2. MixIng Procedure During Construction: The anti-stripping agent supplied in liquid, solid or concentrate form shall be thoroughly mixedwith liquid bituminous material or with straight rim bitumen. Whenused with straight run bitumen, the correct dose of anristripping agent shall be mixed in a hot bitumen tank boiler. The two constituents shall be agitatedtill the anti-stripping agent is thoroughly mixed. The doseofanti-stripping agenishall suitably be increased ifthe binderis to remain in bitumen boiler tots longerperiod. 4. Use in Premix Work 4.1. Additive Dosage: The dosage shall be determined depending on the nature (stripping value) ofthe aggregate and the percent voids in the mix~Whilethe recommended minimum doses fordifferent types of bituminous premix materials in terms of voids content are given in Table A5-3, the actual dosage shall be determined irs the laboratory as directed by the Engineer.
<<
650
Appendices
TABLE A5.1,SPECIFICATION FOR ANTISTRIPPING COMPOUND S~No. Test 1. 2. 3. 4. 5.

6. Appearance Method
-
Litelt
Liquid/Solid
Visual Smelling IS: 1202-1978 IS: 1448 IS 1448 IS: 1448

As given at
Odour
Specific gravity 27C
Agreeable 0.860-1.03 42 150 1.0

Complete
Pour point C Maximum

Flash point (COC~ Minimum Water Content per cent Vol. Maximum Solubility in diesel
7.
oil (HDOorLDO) in
theraiioof298at
end of
Appendix
50C 8.
9. Total base value mg KOHIg minimum Nitrogen content per cent ASTM 1)664
200 7,0 No stripping
Wt. minimum 10. Strippingvalue with

bitumen containing lpercentWLantiatripping compound at 40 C
Elemental Analyser
IS : 6241 As given at
theendof Appendix
24 hours 11. 12. 13. 14. Under water coating

test
-
do do -
Complete
Coating
-
Thermal stability at 163C 5 hours Boiling water lest percent minimum coating
Retained Marshall Stability per cent minimum
Should not lose its efficacy
ASTM D 3625
As given at the end of appendix
95 75
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651
Appendices
TABLE A5.2. TENTATIVE RECOMMENDED MINIMUM DOSE OF ANTISTRIPPING AGENT FOR SPRAYED WORK Aggregate stripping value Dose ofantlatripping agent In per cent by weight of bitumen Surface dressing with precoated aggregate 0-25 25-50
50-100 Penetration
Macadam! Built up spray grout 0.6

0.7 1.0
Surface Dressing with

uncoated
Liquid seal
coat
aggregate 0.7
0.8 1.0
0,5
0.6 0.75
08
1.0 1.0
4.2. Mixing Procedure During Construction : The required dose of the anti-stripping agent shall be poured into th~hot bitumen tank and allowed 15 to 30 minutes of circulation or stirred to ensure a homogeneous mix. It is necessary to use a stable antismripping agent or increase the dose according to expected degradation. Alternatively, the correct dose shalibe injected intothe bitumen line by means ofa pump. The agent isfed into the bitumen first before it is sprayed on the aggregate in the mix; thus, no separate mixing time for mixing the agent with bitumen is required. In rolled asphalt and bitumen mastic surfacing works, precoated chippings are pressed intothe hard surfacewhile the mix isstill hot to makethe newly laid surface skid resistant. These chippings shall be precoated with bitumen treated with antistripping compound. TABLE AS-3. TENTATIVE RECOMMENDED MINIMUM DOSE OF ANTISTRIPPING COMPOUND IN BITUMEN PREMIX WORKS
Stripping Dose of antistripping agent in per cent by weight of bitumen
value ol
aggregate
Voids content 3-5 percent 0.3

0.4
VoIds content 5.10 per cent 0.4 0.5 0.8
Voids content 10-15 per cent 0.5 0.6 1.0
0-25 25.50 50-100
0.6
<<
652
Appendices
Annexwe to the Appendix S
TESTING PROCEDURE FOR SOLUBILITY OF ANTISTRIPPING AGENT IN DIESEL OIL

Procedure: 98m1 ofdiesel oil (HDO orLDO) and2m1 ofantistrij~ing agent shall betaken inameasuringcylinderwith stopper. The cylinder along withita contents shall be keptin water bath,maintained as5O+lCforhalfanhour.Issball then betalcenout fromwaterbath and shaken vigorously for 10 minutes, The ssopper shall be removed and the cylinderke* in waterbath for half an hour and examined for separation ur settlemenL Reporting ofresults: An antistripping agent is repoited to be completely soluble in diesel oil ifno separation or settlement is observed for half an hour.
TESTING STRIPPING VALUE OF AGGREGATES USING BITUMEN WITH VARYING PERCENTAGES OF AWIISTRIPPING AGENT. Procedure: Coarse aggregate passing 19mmsieve and retained on 13.2 mm sieve shall be washed and dried in an oven for 24 hours at 110C. Such dried 200 gms ofcoarse aggregates shall be heated at 149Cand then mixed with 801100 penetration gradebitumen5percentby weight of coarse aggregate heated upso 163C. The mixture shall be mixed thoroughly for uniform coating of aggregates by bitumen. The mix shall then be transferred to a 500ml beaker and allowed to cool to room temperature. Distilled water shall be added inthebeaker,which shall be placed in a water bathmaintained at40~ for24 hours. The percentagedegree of stripping 1C shall be assessed visually. The test shall also be conducted with water containing 1 per cent Sodium Chloride, as a precautionary measure to eliminate water contamination. The test is repeated using bitumen containing upto one per cent ofantisiripping agentin stages of0.25 per cent. TESTING EFFICACY OF ANTISTRIPPING AGENT TO COAT AGGREGATES WITH BITUMEN IN PRESENCEOF WATER Procedure: The antistrippingageteshailbe added in percentcontents of 00,0,25,0.50., 035, l.O0and 1.25 to cutbackbitumen MC3(4partsofbiuunen&WlOOand 1 part of kerosene oil). The blends shall be used for testing their abilityto coat the road aggregates under water, (a) 100gm of cleananddry stonedussconforsning to followinggradation shall betaken: Steve Size
236mm
per cent passing

100
1.18mm 600mic. 300mic.
80 75
45
3~4of its volume with distilled water at 40C. The The bottle shall be Filled to bitumen-antistripping agent blend shall be added in the bottle at the rate of 7.5 per cent by
weight of stone dust. The stopper shall be replaced and the bottle shall be vigorously shaken for two minutes.The water shall be then drained off and the stone dust shall be transferred to a piece of paper and examined visually forsatisfying complete coating. The minimusn per cent content of antistripping agent at which the stone dust sample is thoroughly coated shall be recorded. The test shall be repeated at 60C water as well as 1 per cent solution of Sodium in Chloride in water for both the testing temperatures.
653
<<
Appendices (b) The under water coating test shall further be conducted with coarse aggregate, passing 19 mm sieve and retained on 13.2 mm sieve. In this case the per cent content of she cuthack-antistripping agesn blendshall be kept at 5 per cent by weight of coarse aggregate. In order to take care of contamination in water, the test shall also be carried out in the I per cent Sodium Chloride in water.
~i) shall be taken as the dose of antistripping agent. TESTING FOR THERMAL STABILITY OF ANTISTRIPPING AGENT
The minimum per cent contentof antistripping agent atwhich stone dust/coarse aggregate
is thoroughly coated as per (a) and
Procedure: Blends of antistripping agent and bitumen of 80/100 grade shall be prepared with 0.00,0.25,0.50, 0.75 and 1.00 per cent consents of antistmipping agent and kept in oven at 163C for five hours. After the heat exposure, she blend samples are fluxed with kerosene oil so obtain the consistency of MC 3 and tested for under water coating test
Reporting of test results: An antistripping agent ahall be deemed to be beat resistant if the dose requirement before and after beat exposure remains unchanged.
QUANTITATIVE EVALUATION OF RETAINEDMARSHALL STABILITY VALUES AFTER IMMERSION IN WATER Procedure: For quantitative evaluation, the tests shall be carried out as stipulated in ASTM D1075 (Effect ofWater on Cohesion ofcompactedBisuminous Mixtures). Thegradasion of aggregates shall be such as to give sufficient voids in the compacted bituminous mix to bring out the effects of stripping. The gradation of aggregates shall be as under: Steve Size 19.00mm 13.20 mm 9.50mm 4.75mm 2.36mm 600 mic 300 mic lSOmic 75 mic per cent Passing
.
100
75-100 60-80 35-55 20-35
10-22
6-16 4-12 2-8
The Marshall test specimens shall be prepared using Sper centbitumen of80/100 grade by weight of aggregates blended with varying percentages of anristripping agents from 0 to I per ient in steps of 0.25 per cent The test samples shall give a void content of about 6per cent. At least 8 standard Marshall specimens for each of the varying antistripping agent percentages shall be prepared. Bath set of 8 test specimens shall be sorted out in two groups of4 each so that the average specific gravity of the specimen in group I shall be essentially the same as in group IL Group-I shall be tested for Marshall Stability in the usual procedure ASTM D1559. Group-Il specimens shall be immersed in water for 24 hours at 60C 1C. nd then shall be teased a immediately for Marshall stability as per ASTM D 1559. CalculatIon: The numerical index of resistance of bituminous mixtures to the detrimental effect of water shall be expressed as the index of retained stability: Average Marshall Stability ofGroup-Il Average Marshall Stability of Group-i x 100 per cent
RequIrement for acceptance: A minimum of 75 per cent of resaiised Marshall strength shall be required for acceptance.
654
<<
Appendices
Appendix 1000-1 DRAFT DOCUMENT ON IS : 9077-1979 CODE OF PRACTICE FOR CORROSION PROTECTION OF STEEL REINFORCEMENT IN RB AND RCC CONSTRUCTION (REVISED)
FOREWORD
This Indian Standard has been revised taking into consideration the experience gained over the years, developments thote have taken place subsequently and also considering the need for evolving suitable acceptance tests for quality control. In this regard, the electrochernical tests developed at the Central Electrochemical Research Institute, Karaikudi, and also the tens specified in ASTMA775(A775 M-90 for powder epoxy coating have been considered. This revised standard supersedes earlier standard namely 15:9077-1979. While revising this standard, is was decided so cover the various test procedures required to ensure the quality of individual product as well as the finished products. Is was also decided that this standard should include very stringent test procedures particularly for finished products so that these procedures can be used to evaluate not only the corrosion resistance of a particular finished product covered by this standard but also any other finished product such as galvanising, powder epoxy etc.
1. SCOPE; 1.1. This standard (revised) specifies the recommended practice for surface preparation, surface pretreatment and anti-corrosive treatment based on inhibited and sealed cement slurry as an in-situ process forcorrosion protection ofmild steel reinforcesnent/ IIYSD bars in conventional reinforced concrete structures and conventional reinforced brickwork, constructions This practice is alto applicable for non-prestressing steels (mild steel reinforcement/HYSI) bart) used in prestressedConcrete ssmcture.
1.2. This standard applies only for in-situ corrosion pmtecsicn of rn:ild steel reinforcement) HYSD bars after all bending and shaping operations are completed. However, this does not preclude the possibility of using this practice as a factory process. 2. ANT1CORROSIVE TREATMENT PROCFSS SEQUENCES The anticorrosive treatment should necessarily include the following sequential steps~ (a) Surface preparation (dc-rusting)
Since presence of oil, grease, dirt, heavy scale and rust will adversely affecttheperformance of any anticorrosive treatment, it is essential to adopt suitable surface preparation technique, Surfacepreparation can be either by acid pickling or by sand blasting. (b) Surface pretreatment
Surface preparation should be immediately followed by a surface treatment step to ensure temporary protection during the time lag between the dc-rusting and finish coating. Thispretreatsnent should not adversely affect either tbe adhesion ofthe finish coat or corrosion performance. (c) Inhibited Cement Slurry coating
A minimum of2 coats should be applied to ensurefull coverage. (d) Sealing treatment
Sealing treatment should make the coating harder and less permeable.
<<
655
Appendices A typical flow diagram is shown in Fig. 1000/1. 3. PROCEDURE FOR SURFACE PREPARATION 3.1. Sand Blasting Sand blasting of the steel surface to SAE 2 1/2 standards can be done 3.2. De-rusting by Pickling The pickling weld should be preferably based on hydrochloric acid and should include an efficient inhibitor so prevent base metal attack. A typical dc-mating solution should have the following characteristics: (a) (b) inhibitor efficiency should not be less than 97 per cent. weighs loss of a polished standard mild steel reinforcerrsesst / HYSD bars specimen when dipped in the solution for 10 minutes shouldnot be more than 2 g per sq. metre. Specific gravity when tested using a standard specific gravitybottle should be around 1.12.
(c)
4. PROCEDURE FOR SURFACE PRE-TREATMENT De:in.sted surface should be immediately converted by using phosphating treatment. It should be ensured by a suitable rinsing process that no residual acid is remaissing on the surface atthe time ofpisosphating. A typical phosphating composition ofbnsahable consistency should have the following characteristics: (a) (b) (c) (d) (e) (I) Coating weighs when tested as per test procedure A given hereunder should be around 4.5 gsns./sq.m. Density ofthe product should be in the range of 1.22 to 1.4 kg/litre. Presence of fungicide shall be tested by dissolving the jelly in deionized water, the resulting solution shall be yellow incolour. Presence of phospisasingchesnical in jelly shall be ensured with ammonia molybdate test pH of the composition when tested in a standard specific gravity bottle should be asound 2.5 0.1 Nail scratch test should clearly leave a mark on the specimen. This indicates the existence ofthe coating. 5. PROCEDURE FOR INHIBITED CEMENT SLURRY COATING 5.1. A typical inhibitor admixture used should have the following characteristics:(i) It should in liquid form ready for mixing with the ordinary portland cement
(ii) Specific gravity when tested using a standard specificgravity bottle should be 1.04 +0.02 (iii) pH when tested using a pH meter should be 12.75 ~0.25 (iv) Tolerable limit for chloride in inhibitor - admixture when tested using anodic polarisation technique (as per test procedure H) should be 300 ppm 25 5.2. OrdInary Portland Cement This should conform to lS:269 and should be sieved topaaa through 75 microns IS sievc.
656
<<
STEPS STORAGE YARD

DURATION (For iOns length Rebar)
PICKLING
TANK
15
30 stirs
RINSING
3 4
sin
sin
PHOSPHATING (brushing) REACTION TIME RINSING A SOLUTION (Brushing)
-f
F
40 sin 2
~-Ii~~IiIII]
3
3
main
sin rain
INHIBITED CEMENT SLSJRRY FIRST COAT (Brushing) AIR DRYING B SOLSYTION (Brushing)
~iiiiixiiiii~
2
12 2
24 rain 3 sin
INHIBITED CEMENT SLURRY SECOND COAT (Brushing) AIR DRYING B SOLUTION AIR DRYING B SOLUTION AIR DRYING B SOLUTION (Brushing) (Brushing) (Brushing)
sin
~i~ixiiiiiiiii~
2-4 2
-
~iiiiiiiiii~
12 2
24 h 3
sin h
sin
h
2-4
sin h
AIR DRYING
2-4
STACKING YARD
[I~I~~1
Fig. 10O~W1:Flow Diagram for Anti-Corrosive Treatment of Reinforcement Bars
<<
657
Appendices 5.3. Cement and inhibitor admixture shouldbemixed inspecified proportionso have suitable consissency. Coating should be appliedpreferably by brushing. However, underspecific circurn~ stances spraying or dipping is also allowable. 5.4. Sufficient time lag should be allowed in between successive coatings to ensure final setting of theundercoat. A minimum of6 to 12 hours may be necessary. 5.5 A minimum oftwo coats with sufficient time lag in between should be applied. 6. SEALING TREATMENT The sealing treatment should be performed over the coated surface immediately after final setting of the sop coat. Sealingtreatment can be applied by brushing. spraying or dipping. 6.1. A typical sealing solution should have the following characteristics:(a) (b) (c) Specific gravity when tested using a standard specific gravity bottle should be 1.09 +0.02 pH when measured using a pH meter should be4 2.25 0.25 Tolerable limit for chloride in sealing solution using anodic polarisation technique should be 450 25 ppm (as per test procedure B).
7. SPECIFICATIONS FOR FINISHED END PRODUCT 7.1. Finished coating when visually examined should be fairly uniform in thickness and should be devoid of any defects such as cracks, pinholes, peeling, bulging etc. No surface area shoud be left uncoated. No rust spot should be visible so the naked eye. 7.2. Thickness of theCoating The minimum thickness ofshe coating shall be 200 microns. Preferable range is 200 so 400 microns. 7.3. Bond Strength of the Coated Rebar The bond strength of she coated rebar and concrete shall not be less than that specified in IS:456 at per clause No, 0,2, 5, ii and 44.1.2 and tested as per IS:2770 (Part 1). 7.4. Hardness ofthe coating when measured using a pencil hardness tester shall be around 5 IIto7H. 7.5. Tolerable limit for chloride in 0.04 Normal NaOH medium using anodic polarisasion technique (as per test procedure B) shall be around 4500 to 5000 ppm. 7.6. No film failure as evidenced by evolution of hydrogen gas at the cathode or appearance of corrosion products at the anode shall take place during one hour oftesting (as per test procedure C). 8. GENERAL REMARKS: Is is advisable that severely rusted and heavily pitted reinforcements are not accepted for treatment. TEST PROCEDUREA Determination ofphosphate coating weight
7.5 cm a 2.5 cm or 7.5 cm a 5 cm mild steel polished and degreased specimens are to be used for this test. First the blank loss of unphospbated specimen is to be found out. For this, the initial weighs (W,) is accurately weighed. The specimen is kept immersed in the Clarks solution or patented inhibitedde-russing solution for 1 minute. The specimen is removed, rinsed
658
<<
Appendices in distilled water and dried using hotairblower. The specimen is immediately weighed (W 2) The difference between W1 andW2 is termed as blank loss. Another specimen (polished arid degreased) is brushed with phosphating jelly and kept for 45 minutes. Then the specimen is washed free ofjelly, rinsed in clean water and dried using hot air blower. The phosphated specimen (Vi,) is accurately weighed. After weighing, the specimen is kept immersed in Ouks solution or patented inhibited dc-rusting solution for one minute. Then the specimen is removed, rinsed in distilled water and dried using hot air blower. The specimen is immediately weighed (W4). Coating weight = W3- W4 - blank loss. TEST PROCEDUREB Anodic Polarisasion Technique Mild steel reinforcement / HYSD Bar test specimens of size 10mm in dia and 100 mm in length wish stems of size 5mm india and 50mm in length is polished, degreased and sealed at bottom edge and as the stem with suitable scalers like wax, lacquer. Then test specimen is kept immersed in tess solution and potential is momtored using high impedance mulsimeter against suitable reference electmde such as saturated calomel electrodel copper-copper sulphate elecsrode. After getting stabilised potential using appropriate current regulator (0-100 mA), the test specimen is anodically polarised at a constant current density of 290 ~.tAcm using a platinum/stainless steel/TSIA/polished mild steel reinforcement/HYSD Bar as cathode. Potential with tiref is followed for 5 minuses after current is applied. The maximwn chloride concentration upto which the potential remains constant for 5 minutes is taken as a measure of tolerable limit, TEST PROCEDURE C Resistance to Applied .Vol cage Test Two mild steel reinforcement / HYSD bars of size not less than 10mm india and 800mm in length shall be given anti-corrosive treatment as per specified procedure. The end of the rebars shall be soldered with insulated copper elecsrical connecting wire (14 gauge) to serve as electrical contact poinL Coated rebus at the two ends shall be sealed with an insulating material to a length of 25 mm as each end, Test area shall be the area between the edge of the bottom sealed end and immersion line which shall not be less than 250mm in this case. The coated rebus shall be suspended vertically in a non-conductive plastic container of size not less than 150 mm x 150 mm square and 850 mm high. The rebars shall be so suspended as so have a clearance of25 mm at bottom, 45 mm at the sides and 40mm in between the rods. Thecontainershall thenbe rifled toa heightof800mm with an aqueous solution of7 percent NaCI, A potential of2 Yin between the coated rods shall be impressed for a period of60 minutes using a high resistance volt meter for direct current having an internal resistance ofnot less than 10 mega Ohms and having a range upto S V (minimum). Storage batseries may be used for impressing the voltage. During this 60 minuses oftesting, there shall not be any coating failure as evidenced by evolution of hydrogen gas at the cathode or by appearance of corrosion products of iron at the anode.
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659
H~TORV SINKING OF WELL NO OF LOWEST BED LEVEL L0WESr WATER LEVEL,

HEIGHT OF (~UT~ING EDGE
_______
AIPENJ)JX
120041-I
HIGHEST FLOOD LEVEL
_____________
FOUNDING LEVEL
HEIGHT OF CURB __________
SThINING REDUCED LVI I ~RI ) I3UTIDM t UI UNG EDGE RI. OFTCP OF SlEININU BEIORI CASTING RL. OF. RI. OFTOP HEIGHTOF TOTAL OF STFINING 511 INING HFICH1 UI RI Fl RI N( I Al [I R C \S1 SF1 INING LI VII LASTING (CCII 4 CCII 3) (IN(I I DING) (Al WHICH CUllING CURB ANI) CUFFING EDGE IS EDGEPt ACE1)) (COI~$..C0L3) MEFRE 3 4 METRE
SINKING INITI,\1, GAUGE RI Al )1N FINAL (,AU( I RI ADIM SINKING DL RIM I UI DM ~LUI 9 LU] ~ RI. OF BOFIOM UI C I I I IL.( I IX,1 (COI..7 C )E.K~
.
KENTLEDGE DEPTH OF STJMP Bit OW CLTIING EDGE STRATA MI ~ \\ Ii H wEIGHT ECCENTRICIIY Al UNG X AXIS ECUEN]RI ~ Al ONG Y AXJ~ QUANTITY OF [MU[Xii I) MAIl RIM REPORT RIG \RDINC OBS I I S OR SAJI) I~I ()\V 1 DURING SINKING REPORT ANY SPU( tAt MI tHUD 01 SINKING EMPLOYED REMARKS SIGNATURE 01 SUPFR\~ISING Oil ICLR
MUIRI-.
MEIRE
MITRE 10
METRE II
METRE 12 Ii
TONNF 14
METRE I~
MEfl~E
METRE
17
IS
E)
20
21
~____-_
660
<<
APPENDIX 1200/1-2
(PLACE)
(PLACE)
WELL ELO -
PLAN SHOWING WELL NOS.

0% 0-~
Us
- TftAHC DW5~
PLAN OF WELL NO
C) CD
<<
APP ENLEX 1200/Il

TILT ANt) SHIFT IN WELL NO~REDUCED LEVELS (RL~ OFGAUGF MAt KS S) ALONGX~AXlS DATE TOTAL SmINING MFFRF
ALON(JY-AXIS DIFFERFNCE (COL.5 ~ (U!S) (1)15> DIFFERENCE
TOTAL SINKING Mfl1~I 3
(PLACE) ENI)
(PLACE) ENI)
TILT ALONG X~AXIS COLUMN 6
TILT ALONG
RESULTANT
YAXIS
COLUMN 9
.H~
AJONG X-AXIS WITH DIRECTh)N \U RI 13 ALONG Y-AXIS WITH DIRECTION MFIRJ II 1.~ThNT ACTION ~S (COL. I3)~ * TAKEN FOR RCOL, 1~jV~ REC11FICAT1ON MI FRF 15 REMARKS SIGNATURE OF SUPERVISING OFFICER
TiLT
J(COL, l0+ COL,
(COL.8
7 8 9
DIVIDED BY
WLLLDIA II)
DIVIDEF) 1W
WI] I )I~ Ii 12
COL;) 6
-_________.~_________
652
<<
Appendices
Appea4fr
15%/f
INFORMATION TO BE SUPPLIED BY THE MANUFACTURERS OF PROPRIETARY SYSTEMS

L GENERAL
LI. The ifonnation atidi the manufacturer is required so supply shall be in such desail as to obviate 1515515 use of the equipnens due to Ut intention of the manufacturer not hawing been snide clear or disc to wn~gassumptions on Ut past of the user. Li. The user shall refer unusual problem or aoblesns of erection/assembly not in keqir!g with the Seeded use of Ut equipom too she manufacturer of the equipment. 2. INFORMAl ION REQUIRED ii, The masssiifaetusen of Ivopsiesary syssons shall sqiy the following information: a) b) c) d) E)eacripaion of basic fsascsiests of equ.ipmera List of kans of equ~pmu* svailable, giving singe of sizes, spans and such like, with the snassufacussers idasti1~casionnusnbers or other references. The basis on whkls Ut safe wosking loads have beets determined and whether the factor of safety given ~pp4ies so collapse or yield. Whether Ut ss!c&rs data ia based on calcnlEions or teats, ml shall be dearly ssased as there may be wide variasieass between results o&ained by either method. [nstnscaions for use and maintenance, including any points whAck require special attention during eressioss, especsally where safety is concerned. l~aik4Idisnensional information, as follows: (i) Overall dimensions and depth and wifls of members (ii) Line drawing, including perspectives and photographa showing normal uses. (iii) Self ntight~ (iv) Full dimensions of connecsiass and any special positioning arrangements. (v) Sizes of mats, including tube diamesers and thicknesses of materials,
e) I)
(vi) Any pennanera camber buils into Ut ecpsipnens (vii) Sizes of holes and dimensions giving their positions. g) Data relating to strength of equipnens as foLlows
0)
(ii)
Avenge faibre loads as detennined by tests Recorntnasded snasinsumn working loads for various conditions of usc,
(iii) Working resistance moments derived from rests, (iv) Working tar capacities derived from reset
fr)
Recosnmendcsl facross of safety used in assessing recommended loads and dellecsions based cm teas results,.
<<
663
Appendices
(vi)
Deflections under load together with recommended pm-camber and limiting dellectiona,
(xii) If working loads depend on calculations,, working stresses should be stared, U deflections depend on theoretical moments ofio,rtia or equivalent moments of inertia rather than tests, this should S noted, (viii) information on the design of sway bracing against wind and other horizontal loadings. (ix) Ailowahlc loading relating to maximum ntension of bases and/or heads.
<<
664
Appendices
Appendix SPECIFICATION FOR CONSTRUCTION JOINTS
1700/i
Location The location of consftuction joints shall be as shown on the drawing or as approved by the Engineer. If addilionalfnew joints are approved by the Engineer, the following considerations for their location shall he taken into account
(i) (ii) Joints shall he provided in non-aggressive zones or in noo-splash zones, If not feasible., the joints shall he sealed. Joints should be positioned where they are readily accessible for preparation and concreting, such as location where the cross section is relatively small, and where reinforcement is not congested.
(iii) In beams and slabs, joints should not be near the supports. Construction joints between slabs and ribs in composite beams should be avoided, (iv) For box girders, it ia preferable so cast the sofia sod the webs without any joint. (v) location of joints shall minimise the effects of the discontinuity on the dunsbility, structural integrity and the ar.. arsnce of the stnicture.
Preparation of Surface of the Joint I...,aitance shall be removed be,fore. fresh concrete is cast. The surface shall he roughened.~Care shall be taken that they should not dislodge ihe coarse aggregates, Concrete may he brushed with a stiff brush soon after casting while the concrete is still fresh, if the concrete has partially hardened, it shall he treated by wire brushing or with a stiff water jet followed by drying with air jet i rnmediateiy. Fully hardened concrete shafi be treated with mechanical hand tools or grit blasting, hIking care not to split or crack aggregate particles. Before further concrete is cast, the surface should be thorot~ghly cleaned to remove debris and accumulated ntbbish, one effective method being by air jet. Where there is likely to he a delay before placing the next concrete litl, protruding reinforcement shall be protected. Before the next lift is placed, rust, lose mortar or other contamination shall he removed from the reinforcements, In aggressive environment, the conctele shall he cut back to expose the reinforcements for a length of about 50 mm to ensure that contaminated concrete is removed,
<<
665
Appendices
The joint surface shall not be contaminated with release agents, dust or curing membrane., Concreting of Joints The old surface shall be thoroughly cleaned and soaked with water, Standing water shall he removed shortly before the new concrete is placed .iui.d the new concrete shall be thoroughly compacted. Concreting shall be carried out continuously upto the construction joints. Surface retarders may be used to improve the quality of construction
joints.
For a vertical construction joint, a stopping board shall be fixed previously at the predetermined position and shall be properly stayed to prevent its displacement or bulging when concrete is compacted against it, Concreting shall be continued right upto the board,
<<
666
<<
rn
Appendices
I
rn
z
-~
w
n rn
(it ii
,r) 0
at 0 0
x z
rn
667
Appendices
Appendix TESTS ON SHEATHING DUCTS
1800/I
All tests specified below shall be carried out on the same sample in the order given below. At least 3 samples for one lot of supply (not be tested.
exceeding
7000 metre length) shall
The tests are applicable for sheathing transported to site in straight lengths where the pressressing cable is threaded inside the sheathing prior to concreting. These tests are not applicable for sheathing tsar for coiled cable and transported to site as an assembled unit, nor for sheathing ducts placed in position without threading of prestressing cable prior to concreting. (A) WORKABILITY TEST A tett sample 1100 mm long is soldered to a fixed base plate with a soft solder (Fig. 1800(1-I). The sample is then bent so a radius of 1800 mm alternately on either tide to complete 3 cycles. Thereafter, the sealing joints will be visually inspected to verify that no failurel opening has taken place. (B) TRANSVERSE LOAD RATING TEST The lest ensures that stiffness of the sheathing is sufficient to prevent permanent distortion during site handling. The sample i~ placed on a horizontal support 500 mm long so that the sample is supported at all points of outward comagations. A load as specified in Table I is applied gradually at the centre of the supported through a contact surface 12 mm long. It shall be ensured that the load is applied approximately at the centre of two corrugations, Fig. 1800/1-2. The load as specified is applied in increments.
portion
TABLE 1 dia (mm) load (N) 25.35 250
35-45
400
45-55 500
55-65
600
65-75 700
75-85
800
85-90 1000
The sample is considered acceptable if the permanent defonnation is less than cent of the diameter of the sheathing. (C) TENSION LOAD TEST
per
A test specimen is subjected to a tensile loact The hollow core is filled with a wooden circular piece having a diasfleter of 95 per cent of the inner dia of the sample to ensure circular profile during test loading, Fig. 180(W[-3. A coupler is screwed on and the sample loaded in increments, till reaching the load specified in Table 2. If no deformation of the joints nor slippage of couplers is noticed, the rest shall be considered satisfactory. TABLE 2 dia (mm) load (N)
25-35
300
35-45
500
45-55
800
55-65
1100
65-75
1400
75-85
1600
85-90 1800
<<
668
Appendices
(D) WATER LOSS TEST The sample is sealed at one end. The sample is filled with waler and after sealing, the end is connected to a system capable of applying a pressure of 0.05 MPa, Fig. 180W 1-4, and kept constant for 5 minutes using a hand pump with pressure gauge or stand pipe system can be used. The sample is acceptable if the water loss does not exceed 1.5% of the volume.
<<
669
Appendices
<<
0 C) as
1
~ ~
-o
e
I
z
0
t
n 670
I~S PLATE l5O~15C)a()tr.m

-... --.~
153
~53
Appendices
L25s25a4
Cd~L~.)
ELEVATION
I.
PAC KING
TIMB ER
--
...
500
A PLAN
LFRAME 25 x 25 x 4
VIEW
A-A
PIg. llIOWL-2 : Dimensions are in nun,
<<
671
Appendices
SPLATE ISO x!50x~0mm SOFT SOLDERED JOINT
-SHEATHING
PIPE
1100mm LONG
WOODEN CYLINDRICAL MEMBER OF 95% INNER DiAMETER OF
SHEATHING
SOLDERED
1W
JOINT
I 0~ M.SPLATE 100*100*10mm
49
PAN
fig. 1890/13
flin1cn~ions in mm. are
<<
672
Appendices
H S FL. ATE
PVC TUBE ~0rn.m~ SUBJECTED TO A PRE5SURE OFO.O5 MPa Bt PUMP/ WATER HE. AD FOR S MONUTES
so oso~ 0mm
~OL.DERNO
NI 5 pEAT L lOOxlOOx 3 mm~
--100 I SHEATHING SAMPLE LENGTH I
Fig 1800/1 4
F)imcnsions are in mm.
<<
673
PJ.~STRESSINGREPORT: NUMIIER OR NAME OF THE BRIDGE: Ave. Cube Strength at the time of stressing High Tensile Steel (UTS)~ Cube Strength :
at
APPEN[)JX I 800/U Stressing Sequence Drg. No. Marks ofPlant Used Jacks Pumps: Gauges Left end of Cable = A Right end of C~bk.= UI Specified (Jau~e Pressure during Jacking
SPAN No. ___________________________ kglcni 2 ELEMENT/GIRDER No. __________________ LAST DAlE OF CONCRETING____________ DATh OF PRESTRESSING______________ Max-Jack Pressure not to exceed under any circumstances kg/cm2 15 16 17 18
kg/cm2 kg/cm
28 days
COLUMNSI Cable Stressing Secjuence
2 Calculated Elongation mm
11
12
.
13
14
19
~20~211
22
23
24
25
26
Gauge Mark Readings of extension in mm at the pressure of 100 kg/ cm
Gauge Mark Readings cii extens~on in mm it the pressure of200k~/cm ~
SLIP (Draw~in>mm
Reading at ~nstanm ot
I.x,ckiog
~
~e
~
c ~E <r >
~
Inisnediately after locking
kiter Total 24Ht~ Drawmn <

>~
~
~
=
~
-~~J
~
~.,
~2
~
..
~ <~
~ ~
~
~
~
. ~
~ ~3
.~
~E
z~
2 <~
~<
~e
<
-.~
~
~
, , .,
i1~~
~ ~<
~,
~1
~3
aiC flaw IC ~ ~i i leers pIVSCflI Ounhig plrst res sIng :
Contrntor
System supolier
Client
<<
674
Appendices
Appendix
1800/Ill
SPECIFICATIONS FOR GROUTING OF POST-TENSiONED CABLES IN PRESTRESSED CONCRETE 1. GENERAL 1,1, The recommendations cover the cement grouting of posttensioned tendons of prestressed concrete members of bridges. This also covers some of the essential protective measures to be adopted for minimising corrosion in PSC bridges. 1.2. The purpose of grouting is to provide permanent protection to the post-tensioned steel against corrosion and to develop bond between the prestressing steel and the surrounding structural concrete. The grout ensures encasement of steel in an alkaline environment for corrosion protection and by filling the duct space, it prevents water collection and freezing.. 2. MATERIALS 2.1. Water Only cle.an potable water free from impurities conforming to section 10(X) shall be permitted. No sea or creek water is to he. used at all. 2.2. Cement Ordinary Portland cement should he used for preparation of the grout. it should he as fresh as possible and free of any lumps. Pozzolana cement shall not be used. 23. Sand it is not recommended to use sand for growing of prestresslug, tendons. in case the internal diameter of the ducts exceeds: 150 mm,, use of sand may be considered. Sand, used, shall conform to 15:383 and shall pass through !S Sieve. No. 156. The weight of sand in the grout shall not he. more than 10 per cent of the weight of cement, unless prope.r workability can be ensure.d by addition of suitable plasticizers. 2,4. Admixtures Acceptable admixtures conforming to 15:9102 may be used if tests have shown that their use improves the properties of grout, i.e. increasing fluidity, reducing bleeding, entraining air or expanding the grout. Admixtures must not contain chlorides, nitrates, sulphides, sulphites or any olhe.r products which are likely to damage the steel or grout. When an expanding agent is used, the total unrestrained expansion should
<<
675
Appendices
not exceed lO per cent. Aluminum powder as an expanding agent is not recommended for grouting be..cause its long term effects are not free from doubt. 2.5. Sheathing 2,5,1. For specifications of sheathing, section 1800 may be referred 2.5.2. Grout openings or vents
a) All ducts should have grout openings at bnt.h ends. For this porpose special openings should be provided where such openings are not available at end anchorages. For draped (curved) cables vents shall be provided at all crown and valley points. 0 is a good practice so provide additions] air vents at suitable intervals not exceeding 20 m. All grout openings or vents should include provisions for preventing grout leakage. Standard details of fixing couplers, inlets, outlets and air vents to the duct! anchorage shall be followed as recommended by the supplier of the prestressing systetn.
h)
23,3. Ducts should be securely fastened at close intervals. All unintended holes or openings in the duct must he repaired prior to concrete placing. The joints of the couplers and the. .sheathing should be made water proof by use of adhesive tape or similar suitable sy~itemcapable of giving leak proof joints. Groin openings and vents must be securely anchored to the duct and to either the forms or to reinforchig steel to prevent displacement during concreting operations due to weight, buoyancy and vibrations. 2.5.4. Ducts require very careful handling as, being of thin metal, they are susceptible to leakage due to corrosion in transit or storage, by It lnng/nppLno in handl ng parttc til irl) ~su_n p1 KL d adjotn tng to l reinforcing steel, by pulling apart at j.oints while insertin,g tendons prior to concreting, or by accidental punctur~ng while drilling for form ties/inserts. Duels are also liable to damage by rough use of internal vibrator and sparks from welding being done. close by. 3. EQuIPMENT 3.1, Grout Mixer and Agitator It is ~ssentialthat the. grout is maintained in a homogeneous state and of uniform consistency so that there is no separation of cement. Use of grout niixers to obtain a colloidal grout is essential. The mixer should ha.ve an additional storage device, with an agitator to keep the groifi moving continuously before it is pumped in the duct. Positive reciprocating type grout pumps should be used.
<<
676
Appendices
3.2. Grout Pump The pump should he a positive displacement type. and should be capable of ejecting the grout in a continuous operation and not. by way of pulses. The grout pump iii ust he fitted with a pressure gauge. to enable pressure of injection to be controlled. The minimum pressure. at which grout should be pumped shall he 0.3 MPa and the grout pump must have a relie.f arrangement. for bypass of the grout. in case of build up ctt pressure beyond 1 MPa, The capacity of the grout pump should he such as to achieve forward speed of grout of around 5 to 10 metres per minute.. The slower rates are referable as they reduce the possibility of occurrence of voids. If th.e capacity of the pump is large, it is usual to grout two or more cables simultaneously through a comtnon manifold. Use of hand pumps for ,grouting, is not recommended. Use of comrresse.d air operated equipment for injection is prohibited, as it is likely that there. will he some air trapped itt grout. 3.3. Water Pump Before comrnentenient of grouting, a stand by direct feed high pressure water pump should he available at site for an emergency. In case of any problem in growing the. ducts, such pump shall immediately be connected to the duct and all grout flushed by use .of high pressure. water flushing. it is, therefore, necessary to have adequate storage~of clean potable water for operation of the water pump for such eaergencies. 3.4. Grout Screen The grouting equipment should contain a screen having a mesh size of 106 micron size of 150 microns if sand is used.). Prior to introduction into the grout pump, the grout should he passed through such screen. This screen should he easily accessible for inspection and cleaning. 3,5. Connections and Air Venls Standard details of fixing inlets, outlets and air vents to the sheathing and! or anchorage should he followed as recommended by specialist supplier of the system of prestressing. In general, all connections. are to he of the Quick couple type and at change of diameters suitable reducers are to be provided. 4. PROPERTIES OF THE GROUT 4.1. Water/cement ratio should be as low as possible, consistent with workability. This ral.io should not normally exceed 0.45.
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677
44.nendice.s
4.2. Before grouting, the properties of the grout mix should he tested in a laboratory depending on the facilities available. Tests should be. conducted for each job periodically. The recommended test is. described beLow. 4.3. Compressive Strength: The. compressive strength of 100 mm cubes of the grout shall not be les.s than 17 MPa at 7 days. Cube.s.shall be cured in a moist atmosphere for the first 24 hottrs and subsequently in water, These tests shall be conducted in advance to ascertain the suitability of the grout mix. 5. MIXING OF GROUT 5.l. Proportions of materials should be based on field trials made on the grout belore commencement of grouting, but subject to the limits specified above. The materials should be measured by weight. 5.2. Water should h, added lo the mixer, first, followed by Portland ccitt ent and s~mnd, if used. Admixture if any, may be addt,.d as recommended by the manufacturer. 5.3. Mixing time depends upon the type of the tnixer, but will normally be betwee.n 2. and 3 niinutes. However, mixing should he for such a duration as to obtain uniform and thoroughly blended grout, without excessive tempe.rature. increase or loss of expansive properties of the. admixuires. The grout should he continuously agitated until it is injected. 5.4. Once mixed, no water shall he added to the grout to increase us fluidity. 5.5. Hand mixing is not permitted. 6. 6 ROUTING OPERATIONS 6.1. General
a) Grouting shall be carried out as early as possible hut not later than 2 weeks of stressing a tendon. Whenever this stipulation cannot be complied with for unavoidable reasons, adequate temporary protect~on the steel against corrosion of by methods or products which will not impair the tsltintate adherence of the iejected grout should he ensured till grooting. The sealing of the anchorage ends after concreting is considered to he a good practice to prevent ingress of water. For structores in aggressivc environment, sealing of the anchorage ends is mandatory.
Notes i) Application of some patented water soluble oils for coating of sieel/VPI powder injection! sending in of hot, dry, oilfree compressed air through the vents at frequent intervals have shown some good results.
<<
67:.
Appendices
ii) Some of the method.t recommended for sealing of anchorages are to seal the openings with h:itstmen impregnated gunny bag or water proof pape:r or by building a brick l:)edestal plastered on all faces enclosing the exposed wirea outside the anchorages. Aey traces of oil if applied to steel for presenting corrosion should he removed before grouting operation.. Ducts shall be flushed with water for cleaning as well as for wtttiog the surfaces of the duct walls. Water used for flushing should be of same citsslity as used for grousing. Is may, however, contain about I per cent of staked lime or quick lime. All water should he drained thorough the lowest vent pipe or by blowing compressed air through the duet The water in the duct shoukl he blown out with oil free compressed air.
iii) iv)
v)
Blowing out water from duct for cables longer than 50 m draped up at both ends by compressed air is not effective, outlet! vent provided at or near the lowest point shall be used to drain out water from duct vi) lhe connection between the noxate of the injection pipe and duct should be such that air cannot he ssteked in.
vii) All outlet points including vent openings should be kept open prior so commencement of injection grout viii) Before grousing, all air in the pump and hose tlsould be expelled.. circuit of the pump should be air-tight ihe suction
6.2. Injection of Grout

a) h) c) d) After mixing the grout ~shouldbe ke 1* in continuous movement. Injection of grout must be continuous and should not be interrupted. For vertical cable or cables inclined more than 60 degrees to the hori~.,.ontal, injection should be effected from the lowest anchorage or vent of she duct The method of injection should ensure complete filling of the ducu, To verify this, it is advisable to compare the volume of the space to be fitted by the injected grout with the quantity of grout actually injected. Grout.ing should be commenced initially w~tha low pressure of injection of upto 0.3 .M,Pa increasing it until the grout comes out at the other end. Th.e grout should be. allowed to flow freely from thd other end until the consistency of the grotit at this end it the same that of the grout at the iniecrion end. When the grout (Iowa at the otlter end, it should be closed off and building up of pressure comntenced, Full injection pressure at about 0.5 MPa shall be maintained for at least one minute before closing the injection pipe. It is recommended practice to provide a stand pipe at the highest point of the tendon profile to hold all water displaced by sedimentation or bleeding. If there is a Stilt up of pressure much in excess of I MPa without flow of grout coming at the other end, the grouting operation shuuld be discontintted and the entire duct flushed with ltigh pressure water, Also, the bypass system indicated in para 3.2 above is essential for further safety. In the case of cablea draped downwards e.g. in cantilever constnsction simultaneous injection from both ends may be adopted Fig. lSOO!lII- 1. Grout not used within 30 minutes of miaing should he rejected.
e)
I) g)
<<
679
Appendices
~Eit11 PSPE ~
LWL
THPDLSOH tUTH CO:MSSsE.S.SED A~t
c~ivtLt
s~c:~ PLUG ~
5T55
~ ~
CROUT
10~SINT
a rwt.
OUCT ~IT.H
SSAT.tFS
:
~AT[ S
cR5.5
SLOW
RAT IFS SN DUCT
~ 5,
CossutNCe
OFSOUTLNG 5SMULT,ANEOUSLV FROM 60TH ENDS SE.MOVE tNTLFSMt,DLATE PLODS AT SNTESFVALS TO CHICK FLOW WATER OLIN FLOW NAT sv s~ DucT
~
4. FLUD INTISMEDIATE VENTS A~rER GFSOUT FLOWS
r
050551
COLOURED W.ATL~
osoijr
5. WHCN WATCR FLOW OUT Of TOP LTNT ThKIS ON COLOU~OF CsstNT STeW PUw.SIaO eWOUT 555GM ONE END CONTLNU5.
(~5~T U 6. tF GROUT 6E5~NSTO FLOW FROM 105 VEPeT,STOS PuNFPSNG AND PESTAST rFsoM OTpStFS END SF C LEAFS WATER FLOWS FROM TOP VrF~r ~ r~r,I ~i,Jn.
-.~.,,_
WHEN PUMSSNO FROM BOTH CNDS tN TURN ,CAUSES GROUT TO FLOW FROP~4TOP VENT PLUG
.
PLUG
PLUG
GROUT
.5.. PLUG ALt.. VENTS AND tNCREASI FUASF PRESSURE AT 6~DTHENDS TO o.~MP~HOLD TH~SPRESSURE 5055 AT LEAST ONE MSNUTI
Fig. 111051/1 ft.! Procedure
for (houtin,f
of Cables Draped Downwards
<<
680
Appendices Appendix 1800/IV
C ROUTING
,loh Naistc: Span No.
.__._.__
RECORD
~_.._.
__~_
Cable No:
Datc of Cable lrss:allation:
_____.
Date of Grouting:..
11501k.
type of Ccrsicnt: CPC/I 150FF \Vcckotd 5 cur of Manufacture ot OP
W!C
Ratio:
.........
Name and amotirst of admixture used, il any
________________
...__._.~. ._ . ___________.~. __________
lcmpcrature: Mixing waler jisrte: tLC~SJip.rtteStt Cable dues:

Grouting pressure Start,.
_.
...,~
Grout Finish
1_englls
(;rout mixer
Grout ptsmp
..._..____.
Diarrteter
._......
_._....
Voltime of grout .n litres
Regrouting ___________________.______________
(~crnentconsu sp~iort: 1)seoresseal l 5re~gtoutitigebeUks: of
._........_..
: :
Aetu:sl
________________________________
Free
blockaee
Inlet:
Vents:
Yes/No Yes/No
outlet Cable duct
: : :
Yes/No Yes/No
f..eak age obserscd :
Yes/No
Sealed
Yes/No
11 cable duct blocked: Remedial Measures Grotjtirs~observ:is ions: Passane of ,grous i.:rougls vents i~sss~: of grout througlt i:sutlet ge i\ny equijarnent Solute Post eroutine ebeLks Prohbirtg by still ~ii.e kern arks
_______________ _____________ ________
Yes/No Yes/No
______________ .____________
.Si,ers:stijres ssf cslt. :ers IreseItt sluitng gtcsuting:

tliL:rst
(Tontractor 681
Systerts Supplier
<<
1:spendiees
Li)
Disconnec Lion is facitiutted if a short length of tles.thie tube connects the duct and injection pipe. This can be squeezed and cut off after she grout has hardened
7. PRECAUTIONS AND RECOMMENDATIONS FOR EFFECTIVE GROUTING

si ln cold and frosty weather, injection should be postponed, unless speciat pnTcsutions are taken. If frost is likely so occur a ithin 48 hours after injection, heat must he applied to the member astd maintained for at least 48 hestirs after inject ion so that the temperature of the grout does not fall below 5 dc. grees Ccl stu.s, Prior to cottunencemens of grouting, care must be taken to ensure that the duct is completely free of frost/ice by flushing with warn water, but not with steam. lbe temperature of the grout shall not exceed 25 degrees Celsius. For increasing the workability of grout, tts temperature may be lowered by use of chilled water or by putting ice outside she grout storage container. When the cahlcs are threaded after concreting, the duct must be tetnporaril~ stiffened during cond.sct ing by insertmg bunch of strandt, wires or reinforcemen or a rigid PVC pipe or any other suitable method. Duruig concreting, case shall be taken to ensure that the sheathing is not damaged. Needle vibrators shall be used with extreme care by well experienced staff only, to ensure against such damage. It is A gsrod prsctic:e to sstose she cables in h:rsh iti rections dursng the c:oncreting opemations. This can easily he done by light hammering she ends of the wtresf stndnds during concreting It ts also advisable that 3 to 4 hours after cdncreung the cable should be moved bosh ways through a distance of about 20 ems. With such movement, any leakage of tnorumr svhich has taken place in spite of all precautions, loses bond with the cables, thus reducing the chance of blockages This operation can also be clone by fit irig prestresssng jacks, at one end pulling the entire cable and then repeating she ot.Teration by fixing the jack at the other esid. The cables to he gmouted should be separated h1 as much distance as possible In ease. sif stage pmest nr ssing, cables tsTnsioncd in tbe. first stage should not rr.mnain usigrosite.d till all cables are stressed Is is good pmacttce, while grouting any duct in stage prestressing, to keep all the remaining duets filled up with watem containing I per cent time or by running water through such dtsete till the gn:tut has set. After grouting the particular cable, the water in the other cables should be draineit and removed wish compressed air so prevent corrosion Care should he t:tkemt so avoist leaks frnm one duct to atsother at joints of precast metnbers in pamntettlar End faces whese anchorages are located are vulnerable points of entry of water. thisy hase io he necessarily protected with an effective harrier. Recesses shosild be packed with mortar concrete and should preferably be painted with water proof paint. After grouting is completed, the projecting portion of the vents cut off and the face protected to prevent corrosion. should he
h)
c)
d)
e)
5) g)
hi
i)
.ti
<<
682

MOST Specifications For Road & Bridges

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Ministry of Surface Transport (Roads Wing)

SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

Published by Indian Roads Congress New Delhi 1997

Ministry of Surface Transport (Roads Wing)

SPEd FICATIONS FOR ROAD AND BRIDGE WORKS

LIBRARY & DOCUMENTATION CENTRE

NEW DELHI-lgg7 Prk~e 400/Rs. Plus packing & postage charges

Reprinted First Revision Reprinted Reprinted Reprinted Second Revision Reprinted

Reprinted Reprinted Reprinted

April, 1990 June, 1992 February, 1993

(The Rights of Publication and Translation are rese,ved)

PREFACETO THE THIRD REVISION

New Delhi November, 1994.

M. V. SASTRY Director General ( Road Development)

123 124 125 126

SECTION NO. 200

SECTION TITLE SITE CLEARANCE

CLAUSE NO. 201 202

EARTHWORK~ EROSION CONTROL AND DRAINAGE

SUB-BASES, BASES (NONBITUMINOUS) AND SHOULDERS

SURFACE COURSES (BITUMINOUS)

501 502 503 504 505 506

220 247 255 257 259 263 266 273 278

QUALITY CONTROL FOR ROAD WORKS

1002. 1003. 1004. 1005. 1006. 1007. 1008. 1009.

GENERAL SOURCES OF MATERiAL

1101. 1102. 1103. 1104. 1105.

STEEL PILES TIMBERPILES

RAKER (INCLINED) PILES

Contents SECTION NO. SECTION TITLE CLAUSE NO.

CLAUSE TITLE BO11OM PLUG

1301. 1302. 1303. 1304.

WING/RETURNiPARAPET WALL ACCEPTANCE OF WORK MEASUREMENTS FOR PAYMENT

1402. 1403. 1404, 1405. 1406. 1407,

1503. 1504. 1505. 1506. 1507.

406 406 407 407 407

STEEL REINFORCEMENT (UNTENSIONED)

1601. 1602. 1603. l6O~ 1605.

GROUTING OF PRESTRESSEI) TENDONS PRE-TENSIONING SAFETY PRECAUTIONS

447 447 450 451

1903. 1904. 1905. 1906.

2001. 2002. 2003. 2004. 2005. 2006. 2007. 2008. 2009.

POT BEARINGS INSPECTION AND TESTING TESTS AND STANDARDS OF ACCEPTANCE

2101. 2102. 2103. 2104. 2105.

ACCEPTANCE TOLERANCES MEASUREMENTS FOR PAYMENT

536 538 538 539 539 543

2405. 2406. 2407. 2408. 2409. 2410.

ix PACE NO. 556

TESTING OF MATERIAL FOR GUIDE BIJND AND HIGH

MEASUREMENTS FOR PAYMENT

CONCRETE BLOCK FLOORING OVER CEMENT 2506.

ACCEPTANCE MEASUREMENTS FOR PAYMENT

REQUIREMENTS STEEL PLATE SLIDING

MEASUREMENTS FOR PAYMENT

CEontents PAGE NO.

621 622 622 623

624 624 624

LIST OF I.R,C, PUBI.ICATIONS

ANTI STRIPPING AGENTS USFEI) FOR BITUMINOUS MATFERIALS AND MiXES

1 2oO/I~ P00/I 2 200/LI 500/I

666 661 662 663

I 700/I 1700/TI 1800/I 18(X)/tI 1800/Ill I 8(X)/IT