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'I National Highways Authority of India


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' Consultancy Services for Feasibility study and Detailed Project Report
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for 416 Laning of Karur- Madurai section of NH-7 from Km 30518 to 42616
in the State of Tamil Nadu (Consultancy Package CmllAlll)

CQYKPACT PACKAGE MS R2 [TM)

FINAL DETAILED PROJECT


REPORT

Y VOLUME V :TECHNICAL SPECIFICATIONS

January 2005
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TABLE OF CONTENTS

1 Preamble

2 General Technical Specifications (Specification for Road & Bridge


Works, Fourth Revision, August2001, Reprinted June12003).

Supplementary Technical Specifications


(Amendments/ Modifications/Additionsto existing Clauses of
General Technical Specifications)

4 Additional Technical Specifications

5 Specifications for Building Works

Final Detailed Project Report


-
Contract Package: NS 81 (TN)
Table of Contents i -
,.
Volume V: Technical Specifications
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Volume - V: Technical Specifications


1. PREAMBLE
1.I The Technical Specifications Contained herein shall be read in conjunction with the
specifications for road and Bridge works (Fourth Revision) 2001 including up gradation as
given in Para 2.1
General
The Teohnical Specifications covering the materials and the workmanship aspects as well
as method of measurements and payments are included in this section. These
specifications cover the items of civil and noncivil works coming under scope of this
documeht. All work shall be carried out in conformity with the same. These specifications
are not intended to cover the minute details. The works shall be executed in accordance
with good practices followed for achieving high standards of workmanship, thus ensuring
safety and durability of the construction. All codes and standards referred to in these
specifications shall be the latest thereof, unless otherwise stated.
1.1.2 inclusive Documents
The provisions of special conditions of contract, those specified elsewhere in the tender
documeht, as well as execution drawings and notes, or other specifications issued in writing
by the Engineer shall form part of the technical specifications of this project.
The attention of the contractor is drawn to those clauses of codes, which require supporting
specification either by the Engineer or by 'Mutual agreement between the supplier and
purchaser'. In such cases, it is the responsibility of the tendererlcontractor to seek
clarification on any uncertainty and obtain prior approval of the Engineer before taking up
the supplylconstruction. In absence of such prior clarification, the Engineer's choiceldesign
will be final and binding on the contractor without involving separately any additional
payment.
1.I.4 Measul@mentAnd Payment
h

The methods of measurement and payment shall be as described under various items and
f-. s-
in the Bill of Quantities. Where specific definitions are not given, the methods described in
B.I.S. Code will be followed. Should there be any detail of construction or materials which
m
has not been referred to in the Specification or in the Bill of Quantities and Drawings but the
/-r necessity for which may be implied or inferred there from, or which is usual or essential to
the completion of the work in the trades, the same shall be deemed to be included in the
n rates and prices entered by the contractor in the Bill of Quantities.
h Defective Works

r All defective works are liable to be demolished, rebuilt and defective materials replaced by
the contractor at his own cost and without involving any time extension.
fi

SITE INFORMATION
*
The information given hereunder and provided elsewhere in these documents is given in
& good faith by the Employer but the Contractor shall satisfy himself regarding all aspects of

- site conditions and no claim will be entertained on the plea that @einformation supplied by

- the Employer is erroneous or insufficient.

Final Detailed Project Report. Vol. V : Technical Specifications


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1.2.2 The area in which the works are located is mostly plain to rolling terrain. The longitude and
' '
latitude of the project road lies between 77' 28' E to 78' 30' E and 9' 30' N to 12 00 N
respectively.
1.2.3 General Climatic Conditions
1.2.3.1 The variation in temperature in this region is between 22.6OC and 38.goC.
1.2.3.2 The annual rainfall in the area is in the range of 640 mm to 930 mm, a good portion of which
is concentrated during the months of October to December every year.
1.2.4 Seismic Zone
The works are located in seismic zone IIas defined in IRC-6-19661 IS 1893 -1975

GENERAL REQUIREMENTS
The Technical Specifications in accordance with which the entire work described hereinafter
shall be constructed and completed by the Contractor, comprise of the following:
Part -I General Technical Specifications
The General Technical Specifications shall be the "Specifications For Road And Bridge
Works" (Fourfh Revision - 2001, Reprint July 2003), as corrected in the original issued by
the Ministry of Road Transport & Highways (MORTH), Government of India and published
by the Indian Roads Congress (IRC), with a cross reference to relevant Bureau of Indian
Standards (BIS) for materials or other aspects not covered by the IRC.
Part - II~upplementaryTechnical Specifications
The Supplementary Technical Specifications shall comprise of various
AmendmentslModificationslAdditionsto the "Specifications For Road And Bridge Works"
referred as 'Part-I" above and 'Additional Specifications" for particular items of work not
already covered in Part-I.
A particular Clause or a part thereof in 'Speciflcations For Road And Bridge
WorksV(FourthRevision - 2001, Reprint July 2003) as corrected in the original referred in
-
Part I above, where AmendedlModifiedlAdded upon, and incorporated in Part-ll, referred
to above, such ArnendmentlModificationlAdditionsupersedes the relevant Clause or part of
the Clause.
When an AmendedlModifiedlAdded Clause supersedes a Clause or part thereof in the said
Specifications, then any reference to the superseded Clause shall be deemed to refer to the
AmendedlModifiedlAdded Clause or part thereof.
In so far as AmendedlModifiedlAdded Clause may come in conflict or be inconsistent with
any of the provisions of the said Specifications under reference, the
AmendedlModifiedlAdded Clause shall always prevail.
2.2.4 The Additional Specifications shall comprise of specifications for particular items of work not
-
already covered in Part 1.
2.2.5 The Sub-clauses of the following Sections in the 'Specifications For Road ~ n Bridge
d
Works" (Fourth Revision - 2001) have been amended lmodifiedl added upon:

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
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416 Laning of Karur - Madurai Sections of NH-7

Sections Clauses

2.2.6 Additional Technical Specifications


The following Clauses have been added to the "Specifications For Road And Bridge
Worksn(FourthRevision-2001, Reprint July 2003) '
A-1 Reinforced Earth, Reinforced Soil, Mechanically Stabilised Earth
Structures
A-2 Void Former
A-3 Repair Procedure, Up gradation and Material Specification
A4 Painting on Structures wlth Water Proof Cement Paint for Parapet,
Railing 8 Crash Barrier
A-5 Painting wlth Synthetic Enamel Paint for Kerb,
Structures
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A-6 Solar Powered Road Safety Signals With LED Modules


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Final Detailed Project Report. Vol. V : Technical Specifications Page 3 of 116


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A-7 Solar Street Lights


A-8 Diversion of Existing Water Courses
A-9 Chute Drain For Hlgh Embankment Sectlons
A-10 Utility Ducts and Crossing
2.2.7 In the absence of any definite provisions on any particular issue in the aforesaid
Specifications, reference may be made to the latest codes and specifications of IRC and
BIS in that order. Where even these are silent, the construction and completion of the works
shall conform to sound engineering practice as approved by the Engineer and in case of
any dispute arising out of the interpretation of the above, the decision of the Engineer shall
be final and binding on the Contractor.
2.3 PART-Ill Specifications for Building Works.
Technical Specifications for Building works shall be the latest "Specifications volume I to IV,
1995" as published by the Central Public Works Department, Government of India and
deemed to be bound into this document.

Vol. V :Technical Specifications Page 4 of 116


Final Detailed Project Report.
Contract Package -NS 82 (TN)
General Technical
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PART I -
GENERAL TECHNICAL SPECIFICATIONS
1 This part shall comprise the "Speclflcations For Road And Bridge Works" (Fourth
Revision - 2001, Reprint July 2003), as corrected in the original issued by the Ministry of
Road Transport & Highways (MORTH), Government of India and published by the Indian
*
Roads Congress (IRC), Jamnagar House, Shahjahan Road, New Delhi - 110 011, all as
deemed to be bound into this document.

1.I General conditions regarding use of equipment on works: -


In addition to the general conditions already indicated in Volume-l (of Bidding Documents),
the following requirements regarding the use of equipment in works shall be satisfied.
a The contractor shall be required to give a trial run of the equipment for specification
and tolerance establishing adequacy to meet the requirements of specifications and
completion of work as per programme before commencement of work;
b All equipment provided shall be of proven efficiency and shall be operated and
maintained at all times in a manner as specified by the manufacturers or industry
practice. Regular reports on proper and adequate maintenance shall be submitted to
the Engineer in the format and at intervals as approved by the Engineer.
c No equipment or personnel shall be removed from site without permission of the
Engineer
Where the term crushed stone is referred to in the Specification for Road & Bridge Works of
the MORTH (Clause 1007) for use as aggregate in construction of pavement layers or in
construction of culverts & bridges or in construction of cross drainage works it shall mean
that the aggregates shall be obtained through the use of Cone crusher, Vertical ShaR
Impactor and vibratory screens of suitable capacity.

Quality Control on Works & Materials.


Quality control on materials and execution remains the primary responsibility of the
Contractor
Nevertheless the Engineer will inspect the work from time to time during and after
construction and get the quality of the work tested (by himself, by his Testing & Quality
Control Units andlor by any other agency deemed fit by him) generally as per the
requirements of the Handbook of Quality Control for Construction of Roads & Runways (IRC
Special Publication No. 11 & Section-900 of MORTH Specifications).
& Measuring Equlpments
Su~eylng
The Contractor for his use shall procure equipment for surveying and measurement of the
work. The same shall also be made available to the Engineer at site for any work connected
with the Contract without any charge.

Final Detailed Project Report. Vol. V : Technical Specifications


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-
PART II
SUPPLEMENTARY TECHNICAL SPECIFICATION
(AMENDMENTSIMODIFICATlONSlADDlTlONS TO EXISTING
CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS PART I) - -
SECTION 100 GENERAL
Clause 102 Definitions
The following abbreviations shall be added in this Clause.
'BIS" - Bureau of Indian Standards
'CECRI" - Central Electrochemi&l Research Institute
'CPCB" - Central Pollution Control Board
"CPCC" - Cement Polymer Composite Coating System
'HDPE" - High Density Polyethylene
"MDD" - Maximum Dry Density (as per IS: 2720-Part 8)
'MORTH" - Ministry of Road Transport and Highways
"NHAI" - National Highways Authority of India
'PMC" - Polymer Modified Cement
'BOW - Bill of Quantities
'QA" - Quality Assurance
"WBM" - Water Bound Macadam
WMM" -Wet Mix Macadam
Clause 103 Add at the end of the clause
The latest editions of these standards till 30 (thirty) days before the final date of
submission of the tender shall be adopted.
Clause 105 Scope of Work
Clause 105.3 Add the following below the existing clause:
"The Contractor shall establish, adhere to, monitor and maintain an adequate
quality assurance programme (QA-programme) based on the requirements of
EN IS0 9001.
The QA-programme shall cover the quality assurance aspects of all services
rendered, all items to be supplied and all construction activities to be performed
under the Contract, also including temporary structures and equipment which
will influence the quality of the completed works or the progress of the Contract.
The QA-programme shall as a minimum cover subjects listed below:
G=-;
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Organisation and Management Responsibility


Document and data control
construction programme
Method statements
Process control
Working, inspection, testing and documentation procedures
Safety and emergency procedures
Control and documentation of purchasing and handling of materials
Product realisation
Non-conformity and corrective Ipreventive action
Measurement, analysis and improvement
Internal quality audits
Servicing
Education and training of staff
Site Environmental Plan
Competence Iskill requirement for Human resources
Customer communication
The general procedures of the QA-programme shall be submitted to the
Employer and Engineer for approval not later than twenty-eight days after the
date of receipt of letter of acceptance. The special part of the QA-programme
shall be submitted successively to the effect that it shall have been approved
prior to the commencement of the activities to which the programme shall
apply".
Clause 105.4 Delete the words '......... 15 days in advance..........."in the first line of the
Clause and replace it with "Submission of Contractor's programme of work,
method etc., as covered in this Clause shall be at least one month in advance,
unless the Quality Assurance plan of the project as finalised and approved by
the Engineer demands other time schedule for various submissions and
approvals in which case the QA plan requirements will prevail. In the latter
case, as directed by the Engineer, he shall furnish"
Clause 106 CONSTRUCTION EQUIPMENT
Add the following sub Para (g) and (h) after sub Para (9:

g) Adequate standby equipment including spare parts shall be available.

h) All measuring devices and gauges shall be in good working condition.


Measuring devices that can affect product quality shall be calibrated prior
to use and at prescribed intervals against certified equipment. Calibration
procedures shall be established, maintained and documented and

Final Detailed Project Report. Vol. V : Technical Specifications


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corrective actions taken when results are unsatisfactory. Accuracy and


fitness of measuring devices shall be ensured by proper maintenance".
Clause 107 Contract Drawings
Clause 107.3 Replace the Sub-clause as Follows:
'Two copies of design drawings, on the basis of which actual execution of the
work to be proceed, shall be given to the contractor by the Engineer
progressively according to the work programme submitted by the Contractor
and approved by the Engineer.
After careful study of the drawings issued by the Engineer, The Contractor shall
prepare 3 sets of detailed construction drawings I working drawings with
necessary fieldlconstruction information and shall submit the same to the
Engineer for approval along with a construction methodology at least 28 days in
advance of the scheduled date of the start of the activity
After reviewing the construction drawing, the Engineer shall issue back 1 sets
drawing to the contractor duly stamped "Good for Construction" along with
Drawing Number, Revision Number and date at least 14 days in advance of the
scheduled date of the start of the activity
The contractor will supply four copies of the approved drawings for the
engineers use.
One set of Copy 'Construction drawing" shall be kept at Construction site and
"Original" set shall be Kept at contractors site office under document control
section and should be available for Inspection IVerification at any time. All
Superseded / Obsolete drawing should be clearly marked as 'Superseded" or
'Obsolete
The contractor shall maintain a document control procedure for 'Construction
Drawings" also as per QA - Programme in accordance with provision of Clause
105.3. The contractor shall include all the above activities in their Construction
Programme, which is to be submitted in accordance with the Provision of Sub.
Clause 14.1 of COPA
Clause 108 Site Information
Clause 108.4 This Sub-clause shall read as follows:
The Contractor shall identify quarries; borrow areas and other sources of
materials required for the work. He shall satisfy himself that the required
materials are available in adequate quantities and complying with the
requirements of specifications. No claims shall be enterlained on account of
non-availability of materials, and increase in leads, etc.
As far as possible natural sand shall be used for sandlfine aggregates. If natural
sand is not available with in 50Km or Government has stopped sand mining, the
contractor shall obtain suitable alternative viz. crushed stone, crushed sand,
etc. to substitute the natural sand. All alternative sand shall confirm to 1% 383
and tests for conformity shall be carried out as per IS: 2386 (Parts 1 toylll). No
separate payment will be made on account of non-availability of natural sand,
arranging crusher sand and increase in leads, etc.

Final Detailed Project Report. Vol. V :Technical Specifications page 8 of 116f.


Contract Package -NS 82 (TN)
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It is the sole responsibility of the contractor to arrange the quarries, borrow


areas etc., on license Ilease basis or otherwise, and study in detail before
tendering, the scope of taking the quarry on lease. Advance information must
be collected by the contractor regarding the procedure laid down and the
consequent delay in arranging the quarries on lease and must make alternative
arrangement to procure the quarry products from lease holders. No separate
payment will be made for arranging such quarries, borrow areas, etc."
Clause 109 Setting Out
Clause 109.8 Add the following paragraph in the Sub-clause 109.8
109.8.1 Surveying Equipment and Personnel
The Contractor shall provide the necessary surveying equipment, accessories,
surveyors and labourers required for setting out and related measurements,
including making available these to the Engineer and his representatives at
different stages of the work. The surveying equipment shall be of high standard
of manufacture as approved by the Engineer, in good working condition with
adequate numbers and shall include inter alia the following:

i) Precision automatic level with micrometer attachment with tripod and


levelling staff reading to 5 mm accuracy by direct observation and to 1
mm accuracy by estimation or better.
ii) -
Theodelite with tripod Electronically operated with computerised output
attachment reading to 20 seconds of angle accuracy or better.
iii) Total Station with 2 spare batteries and a charger, three tripods plus
tangents sufficient for a 4 km range, together with an electronic data
reorder. 6 data packs and all necessary software for operation.
iv) Precision staffs
v) 3 metre straight edge and measuring wedge fitted with handles, wedges
100 mm height and 1 mm accuracy.
vi) Field umbrellas
vii) Ranging rods 50 mm diameter 3 m long straight with one end each
metallic, conical and painted alternatively black and white along the
length.
viii) Camber templates 2 lane fitted with handles.

ix) Steel tape graduated in metres, centimetres and millimetres


a) 10 m long
b) 20m long
c) 50m long
d) Reference markers and pegs
The Contractor shall maintain the surveying equipment in good
the full duration of works and replace the ones which get worn
become unworkable.

-. -.'

Final Detailed Project Report. Vol. V :Technical Specifications


Contract Package -NS 82 (TN)
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The surveying equipment and related resources shall be provided under the
general obligations of the Contractor requiring no separate payment".
Clause 110 Public Utilities
Clause 110.1 This Clause shall be replaced with the following
The information provided in the bid documents about public utilities like
waterloillgas pipelines, sewers, cables etc. may not be exhaustive, and it shall
be the responsibility of the Contractor to ascertain the utilities that are likely to
be affected by the works through site investigations and collection of
information from the concerned utility owners:
Clause 110.3 This Sub-clause shall read as under:
"Any utility likely to be affected by the Contractor's work shall be brought to the
notice of the Engineer1Employer and such work shall be undertaken only after
getting written clearance from the Engineer".
Clause 111 Precautions for Safeguarding the Environment
This whole clause shall be substituted by following:
Clause 111.I General
The Contractor shall take all precautions for safeguarding the environment
during the course of the construction of works. He shall abide by all rules,
regulations and laws in force governing pollution and environmental protection
that are applicable to the area where the works are situated.
NOISE:
The Contractor shall militate against any sustained increase in base line
ambient sound levels at sensitive receptors during construction of work.
All construction operations shall be performed in a manner to minimise noise
and vibration. The parameters for noise are detailed below.
70 dB (A) for day and night;
50 dB (A) for day and 45 dB (A) for night for sensitive receptors
If the noise levels are found to be above these standards and it is determined
by the Engineer that these levels are due to the equipment or plant being
deployed by the Contractor, he shall undertake, at his own cost measures as
approved by the Engineer, to bring these levels down to the specified levels.
Blasting should be done as per Indian Explosive Act. People living near such
blasting sites shall have prior information of operational hazards. Blasting will
not be undertaken at night. Workers at blasting sites will be provided with
earplugs. Material haulage roads will be properly regulated.
Labour shall be warned against the hunting of wild life, if any. No archaeological
site shall be disturbed.
Clause I 11.2 Borrow pits for Embankment Construction
Borrow pits shall not be dug within the Right-of-way of the road. ~ r a ~ e h d s
will not be used for earth borrowing. The Contractor will ensu

p7i
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excavation techniques are used to improve stability and safety of the borrow
area. The excavation shall be carried out in such a way that the area does not
inundate during monsoons or generate cesspools of water to become mosquito
breeding sites. The stipulations in Clause - 305.2.2 shall govern.
Clause 111.3 Quarry Operations
The Contractor shall obtain material from licensed quarries only after the
consent of the forest department or other concerned authorities. The quarry
operation shall be undertaken within the purview of the rules and regulations in
force. The Contractor shall ensure scheduling the movement of transport
carrying material to and from the site during non-peak hours. The trucks
carrying all the dusty material, red earth, moorum and fly ash/ pond ash shall be
covered with a tarpaulin and provided with adequate free board to prevent
spillage. End boards shall be provided in loaders to prevent spillage. Stockpiling
of material shall be properly planned so as to ensure that no traffic jam takes
place on the highway.
Clause I 11.4 Control of Soil Erosion 8 Sedimentation
The Contractor shall carry out the works in such a manner that soil erosion is
-
fully controlled. The stipulations in Clause 306 shall govern.
Clause 111.5 Precautions against Dust
The Contractor shall take all reasonable steps to minimize dust nuisance during
the construction of the works. All existing highways and roads used by vehicles
of the Contractor or any of his sub-contractors or suppliers of materials or plant,
and similariy any new roads which are part of the works and which are being
used by traffic shall be kept clean and clear of all dust I mud or other
extraneous material dropped by the said vehicles or their tyres. Similarly, all
dust or mud or other extraneous material from the works spreading on these
highways shall be immediately cleared by the contractor. Clearance shall be
affected immediately by manual sweeping and removal of debris, or, if so
directed by the Engineer, by mechanical sweeping and clearing equipment, and
all dust, mud and other debris shall be removed entirely from the road surface.
Additionally, the road surface including haul road from Quarries and Plants shall
be hosed or watered using suitable equipment to avoid dust pollution. Special
care shall be taken to combat dust problem originating from use of fly ashlpond
ash.
Clause 111.6 Pollution from Hot MIX Plant, WMM Plant, Batchlng Plant 81Crusher and
Other Construction Machinery
The Contractor shall ensure the use of a relatively new, well maintained hot mix
plant (batch type) so that any emission conforms to the CPCB norms and be
fitted with a dust extraction unit to avoid prolonged engine powered equipment
illness. Hot Mix Plant, WMM plant Batching Plant & Crusher shall be located
more than 500 m from any community or residence. The contractor has to
obtain necessary consentlclearance from State Pollution Control Board to
operate Hot Mix Plant, WMM plant Batching Plant & Crusher before
commencement of works.

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All vehicles, equipments and machinery needed for construction will be


regularly maintained to ensure that pollution emission levels conform to CPCB
norms. All vehicles should be fitted with silencers.
Construction vehicles, machinery & equipment will move or be stationed in
designated areas to avoid compaction of soil to ensure the preservation of the
top soil for agriculture.
Clause 111.7 Road Safety
The Contractor shall provide adequate circuit for traffic flow around construction
areas, control speed of construction vehicles through road safety and training of
drivers, provide adequate signage, barriers and flag persons for traffic control. If
there are traffic jams during construction, measures shall be taken to relieve the
congestion with the assistance of traffic police. Safety of workers undertaking
various operations during construction will be ensured by providing helmets,
masks, safety goggles, etc.
Clause 111.8 Sanitation 8 Waste Disposal in Construction Camp
The Contractor shall ensure that construction camps are located at a distance
of minimum 200m from water sources. Special attention shall be paid to the
sanitary conditions of the camps. The Contractor shall ensure that sufficient
measures are taken i.e. provision of garbage tanks and sanitation facilities.
Waste in septic tanks shall be cleaned periodically. Garbage shall be collected
in four soakage pits at each construction site and disposed of daily. The
Contractor shall provide adequate measures for the health care of workers and
arrange their regular medical check-up to ensure that they do not suffer from
any communicable disease. At every workplace, good & sufficient water supply
will be maintained to avoid waterborne I water related diseases. If any pits are
dug at construction Icamp sites which are not filled and then may turn into
mosquito breeding sites during monsoons, either these shall be filled up
properly so that no water accumulates or sprayed frequently with pesticides to
prevent mosquito breeding.
Clause 111.9 Substance Hazardous t o Health
The Contractor shall not use or generate any material in the works, which is
hazardous to the health of persons, animals or vegetation. Where it is
necessary to use some such substance which can cause injury to the health of
the workers, the Contractor shall provide suitable clothing or appliances to his
workers, vb. earplugs, helmets or dust masks.
Clause 111.I0 Damage to existing Structures
Any structural damage caused to the existing roads/structures by his
construction equipment shall be made good without any extra cost.
Clause 111.I1 Use of Nuclear Gauges
Nuclear gauges shall be used only where permitted by the Engineer. The
Contractor shall provide the Engineer with a copy of the regulatio
the safe use of nuclear gauges he intends to employ and shall
regulations.

Final Detailed Project Report. Vol. V : Technical Specifications Page 120f 116
Contract Package -NS 82 (TN)
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Clause 111.12 Environmental Monitoring


In order to carry out periodic checks, environmental monitoring will be carried
out by the Engineer as per schedule and if any parameter is found above the
acceptable standards, mitigation measures Icontrol measures as decided by
the Engineer shall be complied with by the Contractor.
Clause 111.I3 Protection of Existing Trees
Some of the existing trees within the right of way are likely to be cut down by
the Employer prior to handing over of the site to the contractor.
The Contractor shall take all necessary measures to ensure safety and
protection of the remaining trees from any action whatsoever relating to his
construction operations in the adjoining areas.
Giant neighbourhood trees recognized locally as important shall be preserved
and engineering designs modified to accommodate these wherever possible.
Clause 111.14 Disposal of Materials Outside Work Site
Notwithstanding other relevant provisions in the contract, the excess material
generated by dismantling, excavation, waste material and lubricants, used oil,
gasoline and other such substance etc., shall be removed from site outside the
right of way at regular intervals and site shall kept clean from all such
disposable materials. Grease, cotton and other waste construction materials
shall be disposed off in shallow soakage wells constructed at each construction
site. Such intervals shall not exceed one month under any circumstances. The
selection of the disposal site shall be the responsibility of the Contractor and he
shall ensure that the selected site does not result in any claim for damages to
the Employer or violation of any existing laws.

Clause 111.15 Compliance with the foregoing will not relieve the Contractor of any
responsibility for complying with the requirements of any highway authority in
respect of the roads used by him.
Clause 112 Arrangement for Traffic During Construction
Clause 112.1 General
Delete the last sentence and add the following:
'Two weeks before undertaking work which would involve any obstruction
whatsoever to traffic, the Contractor shall submit, for the Engineer's approval, a
Traffic Control Plan.
The plan shall include:
i) Typical drawings for temporary diversions in accordance with Sub-clause
112.3
ii) Typical details of arrangements for construction under traffic including
details of traffic arrangements proposed to be in place after the cessation of
work each day.

- -

Final Detailed Project Report. Vol. V :Technical Specifications


Contract Package -NS 82 (TN)
Blnl vmve Wlth
BCEOM ,x.Faarve.e assslates 4/6 Laning of Karur - Madurai Sections of NH-7
-F t ,
rn-*h
Consultancy Servicefor Feasibility Study and Preparation ofDPR

Special consideration shall be given in the preparation of the Traffic Control


Plan for the safety of pedestrian and works and delineation of the roadway at
night.
Temporary diversions will be constructed only with the approval of the
Engineer". The Safety barricading shall be provided with Temporary crash
barrier, Cautionary IWarning signs, Cones, Flashing lights and taps as per the
approved drawings and confirming to IRC SP-44 (1994).
The contractor has to Procure and supply the safety wares to his Engineers,
supervisors and workers at site. The personals that are working at site should
ware the safety wares.
Flagman shall be posted at on day and night basis wherever required and as
instructed by the Engineer. The flagman should have all safety wares including
laser torch.
The contractor should appoint a Qualified full time safety officer with required
assistants at site. The person should be graduate IDiploma holder in safety or
fire Engineering with minimum 5 years experience. The contractor shall also
provide a New hard top jeep exclusively to use of Safety officer. The jeep
should have same specification as per clause 124 below.
Clause 112.2 Add at the end of second paragraph as follows:
'Where it is absolutely necessary that the camber of the existing road is to be
corrected before the commencement of the additional carriageway in order to
avoid ponding of rain water, the same uni-directional camber has to be provided
first".
Add at the end of this clause
'The granular base course and bituminous surface dressing will be executed as
per clauses 404 and 508 (Two coat surface dressing with Bitumen). The
Contractor shall not be entitled to any payment for these items of work as per
Clause 112.6 of the Technical Specifications".
Clause 112.3 This Clause shall be read as under.
'In stretches where it is not possible to pass the traffic on part width of the
carriageway, a temporary diversion shall be constructed as described below:

ShouldersWidth
Type of Road pavement Elements (Compacted)
No. way Wld,h each side

I. National 7.0 m 200 mm granular sub-base.


Highways & State 225 mm WMM or WBM base
Highways course.
Surface dressing 2 coats.

2. Major District 5.25 m 1.O 150 mm granular subbase.


Roads and other 150 mm WBM or WBM
rlc

cy ,'I
Final Detailed Project Report. Vol. V :Technical Specifications
-,
Contract Package -NS 82 (TN) ,
klnt Venhre Wlth
BCEOM
RE*OI-ODYIUr*Hns
::;?same associates
. . 4/6 Laning of Karur - Madurai Sections of NH-7
Lnsdmmrm
~p..(br-mw Consultancy Service for Feasibility Study and Preparation of DPR

'I' Carriage- Width


Type of Road Pavement Elements (Compacted)
No. way Width each slde
District Roads
Premix carpet with seal coat/
mix seal surfacing.
3. Village Roads 3.25 m 1.O 150 mm granular sub-base
and Cart Tracks
150 mm W.9.M or WBM

Drainage should be provided as directed by the Engineer.


The alignment and longitudinal section of diversion including junctions and
temporary cross drainage provisions shall be as approved by the Engineer".
Add at the end of this clause:
'The granular sub-baselbase course and premix carpet with seal coat/mix seal
surfacing will be executed as per clause 401 (grading Ill materials as per Table
400-2), 404 and 5091510 respectively. Payment for these works shall be
governed by Clause 112.6 (2"d Paragraph) of the General Technical
Specifications".
Clause I 12.6 Add the following as third paragraph:
The Safety barricading and additional Temporary Crash banier provided shall be
measured in linear metre and monthly rental charges shall be paid as Lm-month
for the full compensation for construction, maintaince and disposal. Similarly
Providing other additional safety boards and apparatus shall be paid as No-
Month for rental charges. Providing red taps shall be measured and paid in linear
metre. Supplying safety wares are measured and paid as 'No" of safety wares
supplied and maintained.
Clause 114 Scope of Rates for Different Items of Work
Clause 114.2 Item (ii) of Clause 114.2 shall read as follows:
"A detailed resources based construction programme (using computerised
critical path network method) in a form which facilitates control of the progress of
the works and consequences of any changes in terms of time. The programme
shall also include detailed network activities for the submission and approval of
materials, procurement of critical materials and equipment, fabrication of special
products1 equipment and their installation and testing and for all activities of the
Contractor that are likely to affect the progress of work, etc. including updating all
such activities on the basis of decisions taken at the periodic site review
meetings or as directed by the Engineer. The Contractor shall submit data via
electronic media to the Engineer in a form readily compatible with the Engineer's
planning system."
Add the following as item (xvii) for sub-clause 114.2:
'Monthly progress report in a format acceptable to the Engineer. The report shall
state the progress which has been achieved compared with the planned
progress, illustrate delays in proportion to the progress planned, analyse the

Final Detailed Project Report. Vol. V : Technical Specifications -,is of 116


Contract Package -NS 82 (TN)
/
BCEOM , , blmventuewlth
aatvee assorbates 4/6 Laning of Karur - Madurai Sections of NH-7
m - '.~ ~
I"Ass%Mlm*rm
~ p rm -
o a p ConsulrancyServicefor Feasibility Study and Preparation of DPR

consequences and state planned corrective measures, Intermediate progress


reports may also be required.
The first issue of the detailed construction programme including the detailed
description of the system and the procedures shall be submitted to the Engineer
for acceptance not later than 28 days after the date of receipt of the letter of
acceptance."
Clause 114.4 Add the following as Clause 114.4:
'If any work executed by the Contractor does not meet the specifications, it shall
be deemed as rejected. The Engineer, in his sole discretion, may consider a
proposal by the Contractor to retain an element or part of such work. The
Contractor's proposal shall be supported by calculations, drawings and other
data to prove the soundness of the proposal and shall clearly describe the
additional measures required to ensure the intended performance of the work.
Ratelprice for the rehabilitation of such work shall be settled mutually between
the Engineer and the Contractor and in case of failure to arrive at an agreed rate,
the Engineer's decision regarding the rate shall be final and binding".
Clause 115 Methodology and Sequence of Work
The Clause shall read as follows:
The Contractor shall submit a method statement. The method statement shall be
submitted in two parts.
The General part of the method statement shall describe the Contractor's
proposals regarding preliminary works, common facilities, and items that require
consideration at the early stage of the contract. The General part shall be issued
along with the first issue of the construction programme (refer clause 114.2) and
shall include information on :

a) Sources of materials like coarse aggregate and fine aggregate, quantity


and quality of materials available in different sources;

b) Sources of manufactured materials like cement, steel, reinforcement,


prestressing strands and bearings. Wherever possible the Contractor shall
identify at least two sources for each of the items; he shall also submit
samplesltest certificates of recently manufactured materials for the
consideration of the Engineer.

c) Location of site facilities like batching plant, hot mix plant, aggregate
processing plant, etc.

d) Details of facilitieslapproaches for transportation of personnel, equipment


and materials like concrete for construction of pavements, foundations and
substructures in river bed.

e) Information on procedures to be adopted by the Contractor for prevention


and mitigation of negative environmental impact due to construction
activities.

f) Any other information required by the Engineer subsequent to the scrutiny


of the method statement submitted along with the Bid.

"
Final Detailed Project Report. Vol. V :Technical Specifications Page 16 of I1
Contract Package -NS 82 (TN)
k!ntVenWre Wllh
n
-
BCEOM "-y;aaw, as,oc,ates
4/6 Laning of Karur - Madurai Sections of NH-7
I t , ~ r m W c h
~prmm~-~oup ConsultancyServicefor Feasibility Study and Preparation of DPR
t

The general part of the Q.A. Programme shall accompany the methods
statement.
The special part of the method statement shall be submitted to the Engineer by
the Contractor for each important item of work like construction of embankments
and subgrade, pavements, pile foundations, concreting, prestressing, repair and
rehabilitation of existing structures, concrete superstructure and for any other
item as directed by the Engineer. These statements shall be submitted at least 4
weeks in advance of the commencement of the activity or item of work, unless
otherwise stipulated in the contract. The statement shall give information on :

i) Details of personnel both for execution and quality controbof the work.

ii) Equipment deployment with details of number of units, capacity, standby


arrangements.
iii) Sequence of construction, details of temporary or enabling works like
diversions, cofferdams, formwork including specialised formwork for
superstructure, details of borrow areas, method of construction of
embankment and subgrade, pavements, piles, concreting procedures,
details of proprietary processes and products (e.g. details of prestressing
systems, proprietary piling systems, bearings, expansion joints etc.) and
details of equipment to be deployed. Wherever necessary, technical
literature, design calculations and drawings shall be included in the method
statement.

iv) Testing and acceptance procedures including documentation.

v) Special part of the Q.A. Programme referred in clause 105.3 for the
particular item of work shall be submitted along with the method statement
for the concerned activity.
vi) The Engineer shall examine and approve the method statement or direct
the Contractor to re-submit the statement with required modifications. The
modified statement shall be submitted within 14 days of receipt of
Engineer's comments.
The sole' responsibility for the safety and adequacy of the methods adopted by
the Contractor shall rest on the Contractor irrespective of any approval given by
the Engineer.
Clause 115.1 Approval of proprietary product/ process1system
Only proprietary products proven by international usage in comparable projects
shall be permitted to be used. Fully authenticated details of licensing and
collaboration arrangement shall be submitted by the manufacturer, where
relevant.
Within 90 days of award of work the Contractor shall submit the following
information for all proprietary products for approval by the Engineer.

i) Name of manufacturer of productl processl system.


Complete details of the manufacturer of the productl processlsystem shall
be furnished. Details of projects where similar producffp

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
F I
BCEOM
F * D Y ~
-~
.%,
Joht Venwe W l h
'.aart,e
T ~
assorlates
I" m t l m "m,
416 Laning of Karur - Madurai Sections of NH-7

have been successfully used shall be furnished. Authenticated copies of


license1collaboration agreement shall be furnished.

ii) General features of the product/product processl system.


Detailed write-up with methods statement shall be furnished for each
product1 processl System. This shall include complete working drawings &
installation drawings, technical specifications covering fabrication,
materials, system of corrosion, protection etc.,
iii) Details of product development and development testing.
iv) Acceptance test and criteria.
Manufacturer shall submit a quality assurance system document. Details of
acceptance test and criteria of acceptance shall be furnished in this
document.
v) Installation procedure.
vi) Maintenance procedure and schedule.
vii) Warranty proposal.
The Engineer may order any additional tests for the purpose of accepting the
product. The manufacturer shall make the facility for such additional tests
available. The charges of these additional tests shall be borne by the Engineer."
Clause 116 Crushed Stone Aggregates
This clause shall read as under:
'Where the terms crushed gravellshingle, crushed stone, broken stone, stone
aggregate or aggregate appear in any part of the Tender document, Drawings
issued for work, they refer to aggregates obtained through the use of Cone
crusher, Vertical Shafi Impactor and vibratory screens of suitable capacity."

Clause 121 Field Laboratory


Clause 121.1 Add the following at the end of the clause
'This facility will be provided and maintained by the Contractor, as incidental to
work and no separate p,ayment shall be made for this item."

Clause 121.3 Laboratory Equipment


This Clause shall read as under :
'The following items of laboratory equipment procured from reputed
manufacturers duly approved by the Engineer shall be provided in the field
laboratory.
Laboratory equipment shall be provided by the Contractor for the laboratory sufficient to carry out the
entire field and site quality acceptance testing required in the Specifications. List of Laboratory
equipment to be provided and maintained by the Contractor for the Field laboratory shall be as in
Table 100 3. -

Final Detailed Project Report. Vol. V :Technical Specifications


Contract Package -NS 82 (TN)
h i n t V m t v e Wlth
BCEOM
ra~aa*.lfan;m~u:~
,.-aawee asoaates
$ ' ,r ~ . . 416 Laning of Karur - Madurai Sections of NH-7
In lurmlbmwRh
(~.r.mn-oao Consultancy Service for Feasibility Study and Preparation of DPR

Table 100-3 List of Laboratory Equipment to be provided and Maintained for Field Laboratory
A General
i) Balance
a) 10 kg capacity semi-self indicating type -Accuracy 1 gm
Electronic 1 No.
Mechanical 1 No.

b) 500 gm capacity - Accuracy 0.01 gm


Electronic 1 No.
Mechanical (semi-self indicating) 1 No.

c) Chemical balance (electronic) 100 gm capacity


Accuracy 0.001 gm INo.

d) Pan balance 5 kg capacity


Accuracy 0.5 gm. 3 Nos.
e) Platform scale - 300 kg capacity 1 No.
f) Triple beam balance 25 kg capacity -
Accuracy 1 gm 2 Nos.
ii) Ovens electrically operated, thermostatically controlled (including
thermometer), stainless steel interior

a) Temperature range ambient to 300' C, sensitivity lo


C, capacity 120 litre. INo.

b) Temperature range ambient to 150" C, sensitivity I"


C, capacity 250 litre. 1 No.
iii) Sieves :as per

a) Test sieve set 450 mm internal diameter. as per IS complete with lid and ISet
pan of hole sizes 75 mm, 63 mm, 53 mm, 37.5 mm, 26.5 mm, 13.2 mm,
9.5 mm, 6.7 mm, and 4.75 mm.

b) Test sieve set 200 mm internal diameter (brass frame and steellor brass 2 Set
wire cloth mesh) as per IS complete with lid and pan of aperture sizes
2.36 mm, 2 mm, 1.18 mm, 600micron,425micron, 300micron. 150micron
and 75micron.

iv) Sieve shaker capable of taking 200 mm and 450 mm diameter sieves 1 No.
electrically operated with time switch assembly

v) 200 tonnes compression testing machine electric cum manually operated 2 Nos.
fitted with three gauges 0-2000 KN x 10 KN, 0-1000 KN x 5 KN and 0-500 KN
x2KN
vi) Stop watches 115 second accuracy 2 Nos.
vii) Glassware comprising beakers, pipettes, dishes, measuring cylinders (100 to 1 Doz. Each
1000 cc capacity) glass rods and funnels, glass thermometers range 0" C to -
,
'
100" C and metallic thermometers range up to 300" C. n

Final Detailed Project Report. Vol. V : Technical Specifications ''. &e


.2
. 19 of 116
Contract Package -NS 82 (TN)
hint Vamre Wlth
BCEOM
W~UR-CWSUUN~I
?,paawqe ass?cl::es
, In AsmClamnwLh 4/6 Laning of Karur - Madurai Sections of NH-7
~am-mam ConsulfancyServicefor Feasibility Study and Preparation of DPR

viii) Hot plates 200 mm diameter (1500 Watt) 6 Nos.


ix) Enamel trays

a) 600 mm x 450 mm x 50 mm 6 Nos.

b) 450 mm x 300 mm x 40 mm 6 Nos.


c) 300 mm x 250 mm x 40 mm 6 Nos.

d) Circular plates of 250 mm diameter 6 Nos.

x) Water still, 3 litrelhour. with fittings and accessories ISet


xi) Aluminium Tins
a) 50 mm x30 mm 36 Nos.
b) 55 mm x35 mm 36 Nos.
c) 70 mm x45 mm 36 Nos.
d) 70 mm x 5 0 mm 36 Nos.
e) 80 mmx50mm 36 Nos.
xii) Riffle box of slot size 50 mm as per ASTM C-136 1 No.
xiii) Spatula set of 100 mm and 200 mm long 3 Sets
xiv) Water testing kit 1 Set

xv) First aid box 1 Set


B For Soils and Aggregates

i) Liquid limit and plastic limit

a) Liquid limit device with Casagrande and grooving tools and as per IS : 2 Nos.
2720
b) Single point LL device 1 No.
c) Moisture content cans 50 Nos.

d) Ground glass plate with rounded edges 600 mm x 600 mm x 10 mm 2 Nos.


ii) Hydrometer analysis
a) High speed stirrer with stainless steel beaker 1 No.

b) Soil hydrometer set including jar to ASTM : E-100 and C-422 1 Set

iii) Sampling pipettes fitted with pressure and suction inlets, 10ml. Capacity ISet

iv) Laboratory compaction

a) Compaction apparatus (Proctor) to the requirements of IST99 complete 1 No.


with collar, base plate and 2.5 kg rammer (automatic with counter).

b) Compaction apparatus (heavy) to the requirements of I S T I 8 0 complete 3 Nos.


with collar, base plate and 4.5kg rammer (automatic with counter).

c) Vibratory hammer to the requirements of Test BS : 14

Contract Package -
h l n t Vmnre With
BCEOM 1:;1>aawee assmate,
z',I"-llfl .
- R ~ ~ E B ~ Y O ~ W V ~ ~ . 416 Laning of Karur - Madurai Sections of NH-7
m ~Umn-Dolp R

v) Sand pouring cylinder (150 mm) with conical funnel and top and base plate 4 Sets
(with 152 mm diameter of sand cone) to the requirements of ASTM : D 1556

vi) Sampling tins with lids 100 mm diameter x 75 mm height. 112 kg capacity 30 Nos.
vii) Laboratory C.B.R. testing equipment to the requirements of IS and consisting 1 Set
of following:

a) Floor mounted electremechanical load frame 5 tonne capacity with 1 No.


automatic strain control

b) CBR moulds complete with collar, base plate, etc. 18 Nos.

c) Swell stands for holding dial gauge 9 Nos.


d) CBR plunger with penetration dial gauge holder 1 No.

e) Surcharge weight with central hole of 2 kg weight 40 Nos.


f) Spacer disc with handle 2 Nos.

g) Perforated brass swell plate with adjustable cap on handle 18 Nos.


h) Soaking tank for accommodating 9 CBR moulds 1 No.

i) High tensile steel calibrated proving rings of 1000 kg, 2500 kg and 5000 1 Set
kg capacity
j) Dial gauge, 25 mm travel-0.01 mmldivision 12 Nos.
viii) Standard Penetration Test equipment (AASHTO : T-206) including solid cone 1 No.
attachment to fit drive and
ix) Dynamic Cone Penetrometerequipment 2 Nos.
x) Nuclear gauge for density and moisture content determination to the 1 Set
requirements of AASHTO :238 and 239
xi) Baloon Testing apparatus for moisture testing 1 Set
xii) Speedy moisture tester complete with carrying case and supply of reagent 2 Nos.
xiii) Sand equivalent apparatus complete along with chemicals to the requirements 1 Set
of IS :2720-1966 (Part XXIX)
xiv) Reagent grade Sodium Sulphate for soundness test of aggregate chemical 30 kgs.
Sodium Sulphate to the requirements of AASHTO : T - 104
xv) Flakiness test gauge to BS :812 1 No.
xvi) Post-hole auger with extension 1 Set
xvii) Core cutter apparatus lOcm diameter, 10115cm length height complete with 1 Set
20kg hammer
xviii) Flakiness and elongation test gauge 1 Set
xix) Standard measures of 30, 15, 3 litre capacity along with tamping rod 1 Set

xx) Unconfined compression test apparatus .- 1 Set


A

Final Detailed Project Report. Vol. V :Technical Specifications


i
\A - p a g e 21 of 116
Contract Package -NS 82 (TN)
Joint V B h l r e With
BCEOM
nr*anwanmmaur*Hrr : ,
);paawee assocfates
. . 4/6 Laning of Karur - Madurai Sections of NH-7
InassWRlmM1
0p.mn-~.ap Consultancy Service for Feasibility Study and Preparation of DPR

C. For Bitumen and Bituminous Mixes


Constant temperature bath for accommodating bitumen test specimen, 1 No.
i) electrically operated, and thermostatically controlled, stainless steel interior, 50
litre capacity, temperature range ambient to 80" C
ii) Bitumen penetrometer automatic type including adjustable weight 1 Set
arrangement, and needles to the requirements of AASHTO : T - 49
iii) Centrifuge type motorized bitumen extraction apparatus to the requirements of 1 Set
-
AASHTO : T 164 with stock of solvent & filter paper

iv) Bitumen laboratory mixer planetary action, 2 litre capacity, including required 1 No.
accessories electrically operated and fitted with heating jacket
v) Marshall compaction apparatus to the requirements of AASHTO : 245 as per 1 Set
ASTM T 1559-62 and complete with electrically operated automatic loading
unit, compaction pedestal, heating unit, head breaking assembly, flow meter,
load transfer bar, specimen moulds 100 mm diameter with base plate, collars,
specimen extractor, compaction hammer 4.53kg x 457 mm fall (excluding
constant temperature bath)
vi) Dial type thermometer reading 0-200" C range, accuracy 2" C 2 Nos.
vii) Thin Film Oven Test apparatus to the requirements of AASHTO : T- 179, 1 No.
including accessories
viii) Ring and Ball Apparatus as per IS : 1205 1978 - 1 Set
ix) Asphalt Institute Vacuum Viscometer as per IS : 1206 (Part ll) - 1978 1 Set
x) BS U-Tube Modified Reverse Flow Viscometer IS : 1206 (Part 111) - 1978 ISet
xi) Apparatus for Determination of Ductility Test as per IS 1208 - 1978 1 Set
xii) Pensky - Martens closed Tester for testing flash and fire point as per IS : 1 Set
1209- 1978 .
xiii) Apparatus for Float Test IS : 1210-1978 1 Set
xiv) Apparatus for Determination of water content (Dean and Shark Method) IS : 1 Set
1211-1978

xv) Apparatus for Determination of Loss on Heating IS : 1212-1978 1 Set


xvi) Apparatus of Determination of Specific Gravity IS : 1202-1978 ISet
D For control of profile and surface evenness
i) String line arrangement with .paving with sensor powers 4 Sets
ii) ROMDAS-Longitudinal profile calibration device 1 No.
iii) Towed Fifth Wheel Bump Integrator INo.
iv) Camber templates 2-lanelblane straight run cross-section as approved by the 4 Sets.
Engineer
E For Cement, Cement Concrete and Materials

i) Vicat needle apparatus for setting time with plungers, as per 1S-269-J1968 1 Set

.
Final Detailed Project Report. Vol. V : Technical Specifications
-___.'/
v
Pag322 of 116
Contract Package -NS 82 (TN)
Joint Venttre Wlch
BCEOM
-aarpanscero~r~r~
::jaarvee
I
,' . assmates
. 416 Laning of Karur - Madurai Sections of NH-7
I"-tlm*

ii) Moulds

a) 150 mm x 300 mm high cylinder with capping component along with the 48 Nos.
capping set and compound as per IS specification

b) Cube 150 mm moulds and 100 mm (each size) as per IS specification 36 Nos.
c) Beams 750 mm x 150 rnm x 150 mm moulds 18 Nos.
iii) High frequency mortar cube vibrator for cement testing INo.
iv) Concrete mixer power driven, 1 cu. ft. capacity INo.
v) Variable frequency and amplitude vibrating table size l m as per the relevant INo.
British Standard

vi) Flakiness index test apparatus as per B.S. 812 1 No.


vii) Elongation index test apparatus as per B.S. 812 1 No.
viii) Aggregate crushing value impact test apparatus as per B.S. 812 1 No.

ix) Los-Angeles Abrasion apparatus as per IS 2386 (Part 4) 1963 1 No.

X) Flow table as per IS 712- 1973 4 Nos.

xi) Equipment for slump test (C-143)/compacting factor Apparatus complete 4 Nos.
xii) Equipment for determination of specific gravity for fine and coarse aggregate 4 Nos.
-
as per IS :2386 1963 (Part 3)
xiii) Flexural attachment to compression testing machine 2 Nos.
xiv) Core cutting machine with 10cm diameter diamond cutting 1 No.
xv) Needle vibrator 1 No.
xvi) Air entrainment meter as per ASTM : C 231 - 1 No.
xvii) 0.5 cft, Idt cylinder for checking bulk density of aggregate with tamping rod As reqd.

xviii) Soundness testing appziratus for cement ISet


xix) Chemicals solutions and consumables As reqd.

xx) Chloride testing kit for chemical analysis of chloride content 1 No.

xxi) ION exchange kit for rapid determination of sulphate content 1 No.

xxii) Water still 1 No.

xxiii) Concrete permeability apparatus 1 Set


All equipment shall confirm to accepted international standards and shall be subject to the approval
of the Engineer.
The Contractor shall be responsible for the provision of adequately experienced and qualified
laboratory staff in sufficientnumber to be able to meet all testing requirements to the approval of the
Engineer, and for all transportation of staff, testing equipment and samples necessary to allow the
testing to be performed in a time scale compatible with the needs of the Site.
The Contractor shall arrange to maintain the laboratory in satisfactory manner and will carry stocks of
spare equipment and laboratory consumables until the issue of Taking o

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
k l n t V m t v e Wltb
BCEOM
SX~BW~~T*M~~OUW
;;;aawy ayc,ate,
i , 416 Laning of Karur - Madurai Sections of NH-7
I " ~ w m l
opr.mn-m=m Consultancy Servicefor Feasibility Study and Preparation of DPR
i

Full complement of listed equipment procured from an internationally reputed manufacturer after
procurement and approval of Engineer shall be incidental to the work and no payment shall be made
to the Contractor.
The contractor shall arrange any equipment missed out of above table 100-3 which is necessary to
perform the required tests.
Clause 121.4 This clause stands deleted.
Clause 121.5 This clause stands deleted.
Clause 121.6 This clause stands deleted.
Clause 121.7 This clause stands deleted.
Clause 123 PROVIDING AND MAINTAINING WIRELESS COMMUNICATION SYSTEM
Clause 123.2 supply
Add the following after the words '10 sets' in paragraph (a):
'(3 for Employer and 7 for Engineer)"
Add the following after the words '3 sets' in Paragraph (b):
'(1 for Employer and 2 for Engineer)"
Add the following after the words 10 Nos. in paragraph (c):
'(3 for Employer and 7 for Engineer)"
Clause 123A PROVIDING AND MAINTAINING MOBILE PHONE SERVICE
Clause 123A.1 Scope
The work covers the provision and maintenance of Mobile phone communication
service to the Engineer Ithe Employer as described under Bill of Quantities
Clause 123A.2 Description
The Mobile phones shall GSM type and may be Nokia, Samsung or Equivalent
and model as decided by the Engineer. The number of mobile phones to be
provided by the contractor shall be decided by the Engineer, out of the total
provision in the Bill of Quantities and indicated in writing. The cost of each Mobile
phone is limited to Rs. 10,0001- including taxes.
The contractor shall arrange to supply, within 15 days from the date of order by
the Engineer, mobile phones with SIM cards as indicated above. The SIM card
shall be Post Paid type and having National Roaming, CLIP, SMS, etc. and from
an approved service provider like Cell One, Airtel, BPL, etc... The usage charge
of each mobile is limited Rs. 3,0001- per month including cost towards rent,
roaming charges, etc... But excluding the cost of Mobile phone, repair,
replacement (if any) and maintenance.
The Mobile phones shall be maintained in smooth working condition. All expenses
towards the owning, operating and maintenance cost shall be born by the
contractor. In the event of any software, hardware or SIM card problems, the
Contractor shall provide substitute Mobile phone(s) immediately.

Final Detailed Project Report.


Contract Package -NS 82 (TN)
Vol. V : Technical Specifications ,-- :'$
\ '

Page24of 116
Nlnt Venture Wlth
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Clause 123A.4 Ownership


The mobile phone shall be the property of the contractor. The mobile phone and
the SIM card shall be returned to contractor as and where condition after
completion of the project.
Clause 123A.5 Measurement for Payment
The Measurement for provision of Mobile phone service to the Engineer Ithe
Employer and maintaining the same shall be on monthly basis and payment shall
be made every month after providing the Mobile phones
Clause 123A.6 Rates
The Contract Unit rates for supply and maintain Mobile phone service shall cover
all the expenses towards the cost of GSM mobile phones of approved make and
model with all standard accessories like cell charger, cover, etc.. and cost for
arranging post paid SIM card of approved service provider, monthly usage
charges, repair and maintenance including replacement cost, if any.
Clause 124 PROVIDING AND MAINTAINING VEHICLES FOR THE ENGINEER
The heading of this clause shall read as undek
"PROVIDING AND MAINTAINING VEHICLES FOR THE EMPLOYER AND
ENGINEER"
Clause 124.1 Scope
This Clause shall be read as under:
'The work covers providing and maintaining Multi Utility Vehicle (MUV) andlor
hard top jeeps for use by the Engineer and the Employer as described under the
Bill of Quantities."
Clause 124.2 Description

Paragraph 1 of this Clause shall be read as under:


"The Multipurpose Utility Vehicle (MUV) shall be petrol or diesel driven, Air
Conditioned and having cylinder capacity of minimum 2100 cc for Team Leader I
Resident Engineer of the Engineer and Project Director of the Employer. The
MUV shall be fitted with Power steering and a minimum seating capacity of 5+1.
The hard top jeeps shall be petrol or diesel driven and having cylinder capacity of
minimum1700 cc, Non N C for other personnel of the Engineer and other staff of
the Employer. The hard top jeeps shall be 4-wheel drive and a minimum seating
capacity of 5+1. The number of vehicles to be provided by the contractor shall be
decided by Employer for himself and Engineer in consultation with the Employer
in case of use by the Engineer at various times out of the total provision in the Bill
of Quantities and indicated in writing."
Add the following sentence after Paragraph 3 "The total usage per vehicle is
limited to 4000 Km per month".
Clause 124.4 Withdrawal of Vehicles
The first sentence for this Clause shall be read as und/ers
- " 3' ,

Final Detailed Project Report. Vol. V : Technical Specifications -Page25of 116


Contract Package -NS 82 (TN)
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The contractor shall withdraw particular vehiclelvehicles for the non-use by the
Engineer/Employer if so directed by the EngineerJEmployer
Clause 124.5 Measurement of Payments
The Payment for providing and maintaining vehicle shall be on vehicle month
basis calculated on pro-rata basis for actual number of days the vehicle provided
in satisfactory working order in that particular month. If the total usage per vehicle
exceeds 4000 Km per month, an amount of Rs.4 per Km. shall be paid to the
contractor for the extra Km used over and above the initial 4000 Km per month. A
log book shall be maintained in each vehicle by the Contractor in the form
acceptable to the Engineer. No Payment shall be made for the period of
withdrawal as per Clause 124.4 irrespective of the fact whether vehicle war
available or not.
Clause 124.6 Rate
Add the words 'and Employer" after the word "Engineer" in second line.
Clause 126 Supply of Video Cassettes
Clause 126.1 Add at the end of this clause:
"One of the video films should cover the entire contract stretch before start of
actual execution of work highlighting the different tasks contemplated to be
executed in the contract. Similarly one of the video films should cover the entire
contract stretch after completion of all the works, highlighting the tasks scheduled
to have been done as per contract, the details of tasks executed as per orders of
the Engineer and the deviation, if any."

Clause 127 Supply of As Built Drawlng


Clause 127.1 Scope
On the completion of works, the Contractor shall arrange to furnish to the
Employer two (2) bound sets of all -As Built" drawings for every component of the
Works at his own cost, all such copies being on Polyester film of quality to be
approved by the Engineer or his Representative. The Contractor also supplies four
sets of Soft copies in CD ROMs.
All the Construction drawing including Plan & profile drawing shall be updated and
incorporated as built conditions and to be plotted on A-2 size Polyester film.
Clause 127.2 Measurement of Payments
The payment for supplying As-built drawing shall be on lump sum per set. One
set includes two hard copies and four soft copies of drawings.
Clause 127.3 Rates
The contract rate for supplying 'As-built" drawing shall include all drafiing
expenses like Computer, software & hardware, all stationary and all expenses
towards CAD operator, Engineer, etc.

Final Detailed Project Report.


Contract Package -NS 82 (TN)
BCEOM ;
, ~~~rnvemwew~tt~
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r Madurai Sections of NH-7
' In-mnm

Clause 128 Providing Passenger Shelter.


Clause 128.1 Scope
Passenger shelter shall be constructed as per the approved drawing and
confirming to Part-Ill Specifications for Building works.
Clause 128.2 Measurement of Payments
The payment for Passenger shelter shall be measured in numbers.
Clause 128.3 Rates
The contract rate for Providing passenger shelter shall include all expenses like
labour, material, machinery, tools & Tackles etc.
SECTION 200 SITE CLEARANCE
Clause 201 Clearing and Grubbing
Clause 201.I Scope
Replace with following paragraph:
"This work shall consist of cutting, removing and disposing of all materials such
as trees of girth up to 300 mm., bushes, shrubs, stumps, roots, grass, weeds etc.
and top soil minimum 100 mm but not exceeding 150mm in thickness, rubbish,
etc., which in the opinion of Engineer is unsuitable for incorporation in the work
including draining out stagnant water, if any, from the area of road land, drains,
cross drainage structures and other area as specified in the drawings or as
directed by the Engineer. It shall include necessary excavation by harrow discs or
any other suitable equipment, back filling of the pits resulting from uprooting of
trees & stumps by suitable soil and making the surface in proper grade by
suitable equipment and compacted by power roller to required compaction as per
Clause 300. The work also includes keeping the cleared material in stock pile with
in the ROWnot less than 5001-11 in distance, measuring and recording the volume,
keeping the stock pile till completion of bituminous work, re-using the top soil in
turfinglseeding and disposal of unsuitable material. The quantity of stock pile
should have a minimum volume equivalent to the area of Clearing and grubbing
carried out with 100mm thickness and the same shall be deducted from volume of
excavation or added to the volume of filling in the respective area.
Clause 201.5 Measurements for Payment
Replace the last sentence of the first paragraph and add the following
"Cutting including removal of foundations of sign boards, hoarding boards,
concrete posts, kilometre stones, boundary stones etc., and back filling of pits
shall be considered incidental to the clearing and grubbing operations. Removal
of stumps above 300mm girth left over after trees have been cut by any other
agency and backtilling to required compaction shall be measured in terms of
number according to the sizes given below:
Above 300mm to 600mm

'q ,;
Final Detailed Project Report. Vol. V : Technical Specifications ---P+;! 27 of 116
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Above 900mm to 1800mm


Above 1800mm

Clause 201.6 Rates


Clause 201.6.1 Replace the second sentence as follows:
'These will also include removal of sign boards, hoarding boards, concrete posts,
km stones including their foundations, excavation and back filling to required
density, where necessary, and handling, salvaging and stock piling and disposing
of the stocked materials with all lifts and up to a lead of 5000 m."
The Contract unit rate for remove of stumps above 300mm girth left over after
trees have been cut by any other agency and shall include excavation and
backfilling to required compaction, handling, salvaging and stack piling and
disposing of the stocked materials with all lifts and up to a lead of 5000 m."
Clause 201.6.2 The Contract unit rate for cutting (including removal of stumps and roots) of trees
of girth above 300mm shall include excavation and backfilling to required
compaction, handling, salvaging and stack piling and disposing of the stocked
materials with all lifts and up to a lead of 5000 m."
Clause 202 Dismantling Culverts, Bridges and Other Structures IPavements.
Clause 202.4 Back-filling
After noperations"add 'and wells encountered in the alignment". Add after last
sentence T h e wells may be capped thereafter if directed by the Engineer".
Clause 202.5 Disposal of Materlals
Delete this Sub-clause and replace with :
'Materials determined by the Engineer as having salvage value shall be placed in
neat stacks of like materials within the Right of Way as directed by the Engineer
with all lifts and leads up to 5 km.
All materials obtained from dismantling operations, which, in the opinion of the
Engineer cannot be used or auctioned, shall be removed from the site by the
Contractor and disposed off at the nearest dip or other approved location in
accordance with all statutory requirements. The Engineer may permit the disposal
of boulders, concrete fragments and other incombustible materials by burial within
the road reserve, outside paved areas. When buried, the tops of these materials
shall not be less than 300mm below the existing ground level."
Clause 202.7 Rates
Delete the last sentence of the first paragraph and replace with
'These will also include excavation and backtilling where necessary to the
required compaction and for handling, piling and disposal of the dismantled
materials with all lifts and leads as specified in Sub-clause 202.5. The cost of
cartage of materials with no salvage value to disposal sites with all leads is
deemed to be included in the rates for dismantling,"

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
Jolllt -v Wlul
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r - ~ m M U m m
-'
\
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. . 4/6 Laning of Karur - Madurai Sections of NH-7
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Section 300 EARTHWORK, EROSION CONTROL AND DRAINAGE


Clause 301 Excavation for Roadway and Drains

Clause 301.I Scope


Insert the following between the words 'roadway" and "side drains" in the second
line :
"road shoulders, verge, medians,"
Clause 301.3.7 This Clause shall be read as under :
"In works involving widening of existing pavements or providing paved shoulders,
the existing shoulders/verge/median shall be removed to its full width. The
subgrade material within 0.2m from the lowest part of the pavement for widened
portion or paved shoulders shall be loosened and recompacted as per Clause
305 to a density not less than 97% of maximum dry density determined according
to 1832720 (Part 8). Any unsuitable material encountered in this portion of
subgrade shall be removed and replaced with suitable material and compacted in
accordance with Clause 305."
Clause 301.3.11 Disposal of excavated materials
Delete this Sub-clause and replace with:
"All the excavated materials shall be the property of the Employer. Suitable
material obtained from the excavation of the roadway, shoulders, verges, drains,
cross drainage works, etc. shall be used for:
i) Filling roadway embankment.

ii) Filling existing pits/ ponds in the right of way as directed by the Engineer,
including levelling and spreading, with all lifts and leads.
iii) For landscaping of the road as directed by the Engineer, including levelling
and spreading, with all lifts and leads.
Unsuitable and surplus material, which, in the opinion of the Engineer cannot be
used in the works, shall be removed from site by the Contractor and disposed of
at the nearest dip or other approved location in accordance with all statutory
requirements."
Clause 301.6 Preparation of Cut Formation
Delete the first sentence of the second paragraph and replace with:

'Where the material in the subgrade (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
be loosened and removed to a depth of 500mm, replaced and recompacted in
layers in accordance with the requirement of Clause 305."
Clause 301.8 Measurement for Payment
Delete the first sentence of the first paragraph and replace with:

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
hint V m t r r e With
BCEOM
F I W ( ~ O ( Y I U ~
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,, .. . 4/6 Laning of Karur - Madurai Sections of NH-7
*-"I
ConsuItancy Servicefor FeasibiIity Study and Preparation of DPR

'Excavation for roadway shall be measured by taking cross-section volume


calculated in accordance with Clause109 and deducting clearing and grubbing
volume in accordance with Clause 201 and other excavation volume which are
measured and paid separately in the respective area."
Delete item (v) of last paragraph and replace with:
'(v) Disposal of surplus material up to 5000m lead"
Clause 301.9 Rates
Clause 301.9.1 In item (ii) replace '1000m" with 'all leads"
Add new item after item (vi) :
(vii) The removal from site and disposal within a lead of 5000 m of all surplus or
unsuitable materials obtained from excavation operations, which, in the opinion of
the Engineer cannot be used in the Works, shall be included in the Contract rate.
Clause 301.9.2 This Clause shall be read as under :
The Contract unit rate for loosening and recompacting the loosened materials at
subgrade level shall include full compensation for loosening to the specified
depth, removing the loosened soil outside the roadway excavation, rolling the
surface below, breaking the clods, spreading the excavated soil in layers,
watering where necessary and compacting to the requirements.
Clause 301.9.5 Replace '1000m" with '5000m" in the sentence
Clause 301.9.6 Replace 'lOOOma with '5000m" in the sentence
Clause 304 Excavation for Structures
Clause 304.3.4 Preparation of Foundation
In Paragraphs 2 and 3 of Clause 304.3.4, substitute 'concrete M10' in place of
'1:3:6 nominal mix'.
Backfilling
Clause 304.3.7
Delete the word 'Mechanical tamper' in line 7 and substitute it with "Roller"
Clause 304.5.1 Replace lOOOm with 'all leads" in item (v)
Clause 304.5.3 Delete 'beyond the initial lead of 1000 m" and replace with "for all leads."
Clause 305 Embankment Construction
Clause 305.2 Materials and General Requirements
Clause 305.2.1 Physical requirements
Clause 305.2.1.1 Insert the following between the words "moorum" and 'gravel" in the second line:
"Sand, Crusher run, Crusher dusr
Clause 305.2.1.2 This Clause shall be read as under:
'Highly expansive soils such as CH, MH or OH 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 in construction of any subgrade or
embankment."

L /

Final Detailed Proiect Report. Vol. V : Technical Specifications Page 30 of 116


Contract ~ a c k a ~ 82 e -(TN)
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Clause 305.2.1.4 Delete second sentence of clause 305.2.1.4.


Clause 305.2.1.5 Add the following at the end of first sentence:
'The material to be used in subgrade should satisfy the requirement of the 4 day
soaked design CBR of 10% when tested as per IS: 2720 (Part 16) at 97%
maximum dry density (IS: 2720-Part 8)."
Clause 305.2.2.2 Borrow materials
Paragraph 1 of this Clause shall be read as under :
"No borrow area shall be made available by the Employer for this work. The
arrangement for the source of supply of the material for embankment meeting the
prescribed specifications as well as compliance to the different environmental
requirements in respect of excavation and borrow areas as stipulated, from time
to time, by the Ministry of Environment and Forest, Government of India and the
local bodies, as applicable shall be the sole responsibility of the Contractor."

The Table 300-2 shall be read as under:


Compaction requirement for embankment and subgrade

Relative compaction as percentage of


SI. No. Type of WorWMaterial maximum laboratory dry density as per
IS:272O (Part 8)

1. Subgrade and earthen shoulders Not less than 97


2. Embankment
a) Up to 6m height Not less than 95
b) High embankment (exceeding 6m Not less than 97
height)
3. Expansive clays Such material is not allowed

Paragraph 8 of this Clause given below Table 300-2 shall read as under:
'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 dry density and optimum moisture content obtained
in accordance with IS: 2720 (Part 8) for each of the fill materials he intends to
use. o

ii) The graphs showing values of density against moisture content from which
each of the values in (i) above of the maximum dry density and optimum
moisture content were determined.
iii) The Dry density-moisture content -CBR relationships for each of the .fill,
@
,'
materials he intends to use in the subgrade."
- - 3
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----, 1

Clause 305.3 Construction Operations


Clause 305.3.4 Compacting ground supporting embankment1subgrade
Add the following sentence at the end of paragraph 2.
"Where necessary to facilitate compaction of the groundlsubgrade to 97% relative
compaction as stated above, a further depth of maximum of 0.25 meter thickness
shall be loosened, watered and compacted in accordance with Clauses 305.3.5
and 305.3.6 to not less than 95% of maximum dry density, determined in
accordance with IS: 2720 (Part 8)"
Clause 305.3.5.1 Replace the first sentence of the paragraph as follows:
"The embankment and subgrade material shall be spread in layers of uniform
thickness, provided demonstrated successfully and approved by Engineer, not
exceeding 250 mm compacted thickness over the entire width of embankment by
mechanical means, finished by a motor grader and compacted as per clause
305.3.6."
Clause 305.3.5.2 Spreading materials in layers and bringing to appropriate
moisture content.
The first sentence of paragraph (3) of this clause shall read as follows.
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 percent above or 2 percent below the optimum moisture content determined
in accordance with IS : 2720 (Part 8): Determination of moisture content dry
density relation using heavy compaction.
In paragraph 3 substitute 'IS : 2720 (Part 8)" for 'IS 2720 (Part 7) or IS : 2720
(Part 8)as the case may be".

Clause 305.3.6 Compaction


Substitute in 3d line of second paragraph of this clause:
'15-30 tonne weight having tyre pressure of at least 7 kg/sq.cm." in place of
'adequate capacity capable of achieving required compaction."
Clause 305.4.3 Earth work over existing road surface (Dismantling of Existing Road
Surface and use of materials recovered)
Add second paragraph as follows:
'Where the existing bituminous layer be scarified as per drawing or as directed by
the Engineers, the dismantled materials may be reused as indicated below:

1) The existing bituminous surface shall be scarified by using suitable


equipment as per direction of engineer.

2) Dismantled materials shall be used as cost effectively as possible in the


new pavements if it conforms to the specifications requirements and as
approved by the Engineer. The following uses of di
suggested.

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hint Venare wim
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i) The surplus materials, reclaimed from the existing bituminous layer may
be used in the subgrade of service roads, intersection and junctions and
as directed by the Engineer. If directed by the Engineer, the material
shall be mixed with materials brought from borrow areas. Compaction
shall be carried out to the requirements of clause 305.3.6.
ii) The dismantled bituminous material may be used as (1) fill in the
median; (2) in earthen shoulder; (3) in base of service roads and (4) in
intersections/junction of feeder roads provided all the relevant clauses
of earthwork with regard to specification are satisfied."
Clause 305.4.4 Embankment and Subgrade around structures
In the last line of paragrapha, substitute 'compacted thoroughly to the
requirements of Table 300-2" by 'compacted thoroughly to not less than 97%
MDD"
Clause 305.4.8 For stage construction of high embankments, controlled rate of filling shall be
carried out as indicated below.
The embankment shall be constructed over a drainage layer and in the first month
the total height should be limited to maximum 6.0 (six) metre only. The balance
embankment construction should be done after a rest period of 2 (Two) months
for strength gain and consolidation. The rest period need not be given in case
where the construction of the initial 6 metre height of embankment takes more
than 4 months.
However, based on the available subsoil data the contractor may suggest his
loading schedule or any other method to take care of the excessive settlement
problem for approval of the Engineer.
Clause 305.8 Measurement for Payment
Paragraph 1 of this Clause shall read as under
"Earth EmbankmentlSub-grade construction shall be measured by taking cross-
section volume calculated in accordance with Clause109 and adding clearing and
grubbing volume in accordance with Clause 201 in the respective area."
Clause 305.9.1 a) After "subgrade", in the second line of paragraph 1, add the following words :
"and all granular surface'
b) Add 'including removal of top soil" after word 'material" appearing in first line
of item (v)
Clause 305.9.6 Read "2000mnin place of 'lOOOmn in the last sentence.
Clause 306 Soil Erosion and Sedimentation Control
Clause 306.4 Measurement for payment
Substitute Clause 306.4 as follows:
'All temporary sedimentation and pollution control works shalt-be deemed as
incidental to the earthwork and other items of work and,
payment shall be made for the same."

Final Detailed Project Report. Vol. V :Technical Specifications


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Clause 306.5 Rates


This Clause shall be deleted.
Clause 309.3.2 Grading requirements for filter material shall conform to class I of Table 300-3.
SECTION 400 SUBBASES, BASES (NON-BITUMINOUS) AND SHOULDERS
Clause 401 Granular sub-base
Clause 401.I Scope
The second sentence of this clause shall read as follows.
The Granular Sub-base shall be provided by using close graded material, mixing
in a Mechanical mix plant, carriage of mixed materials to work site, laying in two
.
uniform layers as lower sub-base (drainage) layer and upper sub-base layer with
Motor Grader and compacting with vibratory power roller to achieve desired
density as necessary according to lines, grades and cross-section shown on the
drawings or as directed by the Engineer.
Clause 401.2 Materials
Clause 401.2.1 Paragraph Iof this Clause shall read as under:
'The material to be used for the work shall be crushed stone, aggregate, crusher
run, crusher dust, natural sand or combination thereof, depending upon the
grading required: Use of moorum, gravel & laterites for GSB either alone or in
combination shall NOT be allowed. The material shall be free from organic or
other deleterious constituents and conform to the Grading 1 given in Table 400-
1."
Add the following as the third paragraph of clause 401.2.1.
"Where the layer is intended to serve as a drainage layer in addition to being a
part of the structural pavement, the material must satisfy drainage criteria. For
such requirement, material passing sieve 2.36 mm and down should be as per
Table 400.1 .A"
TABLE 400.1 .A. 1
I.S. Sieve Designation Grading
2.36 mm 10-15
850 micron
425 micron Less then 3

Clause 401.2.2 Physical Requirements


This clause shall read as under :
"The materials shall have a 10 percent fines value of 50 kN or more (for sample
in soaked condition) when tested in compliance with BS:812 (Part 3):

Final Detailed Project Report. Vol. V : Technical Specifications -- --'pagH4 of 116


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Clause 401.3 Strength of sub-base


When directed by the Engineer, this shall be verified by performing CBR tests in
the laboratory. The CBR tests shall be conducted on specimens soaked for 4
days as per IS: 2720 (Part 8). The required CBR value must be shown to be
achieved at the percentage compaction specified for the layer.

Clause 401.4.1 Preparation of subgrade


Add afler the first paragraph :
'The existing pavement, where it is to be overlaid by a granular base and
embankment of less than 500mm total thickness shall be scarified in
accordance with Sub-clause 501.3.2. Where the existing pavement contains
multiple bituminous layers, the scarification shall be to the underside of the
lowest bituminous layer. General areas within the Works where multiple
bituminous layers exist will be advised by the Engineer. The Contractor will
verify that all bituminous layers have been removed using appropriate methods
approved by the Engineer. The bituminous surfacing material removed from the
existing pavement may be used in other parts of the works provided it complies
with the relevant specification clauses.
After scarification and removal to the satisfaction of the Engineer of the bitumen
surface from the existing pavement to be overlaid, the existing pavement shall
be lightly sprinkled with water if necessary and rolled with three passes of an
80-100kN smooth wheeled roller. The existing pavement shall then be proof
rolled with and an 8-tonne single drum vibrating roller in the presence of the
Engineer who shall determine the suitability of the existing pavement for
overlay.
Afler proof rolling, the surface of the existing pavement shall be lightly tyned as
directed by the Engineer where the overlay includes a sub-base layer but the
compacted depth of the sub-base layer is less than 75mm. In other cases,
tyning is not necessary."
Clause 401.4.2 Spreading and compacting
The second paragraph of this clause shall read as follows:
'Granular Sub-base shall be prepared in an approved mixing plant like pug mill,
concrete batching plant or concrete mixer located at Plant ILaboratory area.
The mixed materials shall be carried to work site by Tipper Idumper. If so
desired by the Engineer, trial runs with the equipment shall be carried out to
establish its suitability for the work."
The third paragraph of this Clause shall be deleted
The fifth paragraph of this Clause shall read as under:
"The Granular sub-base material shall be spread in layers of uniform thickness
not exceeding 175 mm compacted thickness over the entire width of sub-base.
Immediately thereafter, rolling shall start with the helpof a vibratory roller of 100
kN static weights with plain drum or heavy pneumatic tyrd roller of 300 kN

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weight. Rolling shall commence at the lower edge and proceed towards the
upper edge longitudinally for portions having unidirectional cross fall and super
elevation and shall commence at the edges and proceed towards the centre of
portions having cross fall on both sides."
Clause 406 Wet Mix Macadam Sub-BaselBase Course
Clause 406.1 Scope
Delete "in one or more layers" and replace with 'in two uniform layers" in the
last sentence of first paragraph.
Read "150mm" in place of "200mm" in the last sentence of second paragraph.
Clause 406.2 Materials
Clause 406.2.1.I Physical Requirements:
Add at the end of first paragraph:
"The fraction of materials passing through 4.75 mm sieve shall be crusher run
screening only. The river sand or quarry sand shall not be permitted either as
such or mixed with crusher-run-screening in the Wet Mix Macadam." .
Add the following at the end of the last paragraph:
"Soundness test shall be carried out in accordance with IS: 2386 (Part- 5),
1963. The average loss of weight of coarse aggregate afler 5 cycles shall not
exceed 12% when tested with sodium sulphate and 18% when tested with
magnesium sulphate as specified in IS: 383-1970"
Clause 406.3.3 Preparatlon of Mix
Delete last sentence of paragraph 1 of Clause 406.3.3.
Clause 406.3.4 Spreading of Mix
Replace the first and second sentence of second paragraph as follows:
'The first layer of mix shall be either spread by paver finisher or motor grader.
The second or final layer of mix shall be spread by paver finisher preferably in
full width of the pavement including hard shoulder."
Clause 406.3.5 Compaction
Delete second sentence of first paragraph.
Read "150mm" in place of '200mmn in the third sentence of first paragraph
Clause 407 Shoulders, Islands and Median
Clause 407.1 Scope
Replace the Sub-clause with the following:
'The work shall consist of constructing shoulder (hardlpavedlearthen) on
eitherlone side of the pavement, median in the road dividing the carriageway
into separate lanes and islands for channelising the traffic at junctims in
accordance with the requirements of these specifications and in odnformlt-y with
the lines, grades and cross sections shown on the drawings or as Ire
the Engineer". $"by,
, b -. \

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Clause 407.2 Materials


Replace the first paragraph by the following paragraph:
"Hard shoulder on either1 one side of the road shall be of Granular sub-base
conforming to the requirements of Clause 401. Earthen shoulder on either1one
side of the road shall be of selected earth conforming to requirements of Clause
305. The median IIslands shall be of selected earth conforming to requirements
of Clause 305"
Clause 407.6 Measurements for Payment
This Clause shall read as under :
Construction shall be measured as finished work in position as below :

a) Shoulders ( Hard IPaved Iearthen )


i. For Excavation in cu. m.
ii. For Earthwork in cu. m.
iii. For Granular sub-base in cu. m.
iv. For sub-base, base, surfacing courses in units of respective items.
v. For kerb in running meters
b) Island and Medians
i. For earthwork in cu. m.
ii. For kerb in running meters
iii. Kerb foundation in cu. m
iv. For sub base, base and tile finish in square metres complete as per
Clause 409."
Clause 408 Cement Concrete Kerb and Kerb With Channel
Clause 408.5 Construction Operations
Clause 408.5.1 Substitute first sentence of Clause 408.5.1 as under:
'Kerb shall be laid on firm foundation of 150 mm thick grade M-15 cast-in-situ
concrete and extending 50 mm as shown in drawings."
Clause 408.5.2 Add the words 'or to accommodate drainage pipes" at the end of the paragraph
after the words 'drainage openings".
Clause 408.5.3 This Clause shall read as under:
"After laying the kerbs and just prior to hardening of the concrete, saw cut
grooves shall be provided at 5 m intervals as specified by Engineer."
Clause 408.6 Measurement for Payment
Delete 'in linear metre" and replace with 'in cubic metre" in the second
paragraph.
-a,

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SECTION 500 BASE AND SURFACE COURSES (BITUMINOUS)


Clause 501 General Requirements for Bituminous Pavement Layers
Clause 501.2.2 Coarse Aggregates
The first sentence of paragraph 1 shall read as:
'The course aggregates shall consist of crushed rock and shall be obtained
through the use of Cone crusher, Vertical Shaft Impactor and vibratory screens
of suitable capacity."
The third paragraph of this Clause shall be deleted
Clause 501.3 Mixing
Replace the first sentence of paragraph 1 as follows:
'Pre-mixed bituminous materials, including bituminous macadam, dense
bituminous macadam, semidense bituminous concrete and bituminous
concrete, shall be prepared in hot mix plant of batch mix type of minimum
capacity of 150 tonnes per hour with bag filter and capable of yielding a mix of
proper and uniform quality with thoroughly coated aggregates. The Hot mix
plant shall be attached with an electronically controlled Pyrometer and have a
system to take print out of quantity and temperature of Bitumen, Aggregate and
Mixed material."
Clause 501.5.3 Spreading
Replace the first sentence of paragraph I as follows:
"Except in areas where a mechanical paver cannot access, bituminous
materials shall be spread, levelled and tampered by electronic sensor paver
having a paving width of carriage way and paved shoulder (Max. 9.0m) together
and with a guide wire (or guide wires) fixed at points not exceeding every 5.0
meters. At the discretion of the Engineer the Contractor may be required to lay
all EM layers, Profile Corrective Course and first layer of DBM with longitudinal
joints but second or final layer of DBM and BC layer shall be laid in full paving
width without any longitudinaljoints."
Add at the beginning of the 4'" paragraph:
'The temperature of mix at the time of laying shall be in the range of 120 - 140
degree Celsius."
Clause 501.6 Compaction
Replace the last two sentence of paragraph 2 as follows:
'The intermediate rolling shall be done with a smooth wheeled tandem vibratory
roller of 8-10 tonne weight followed by a pneumatic tyred roller of 12-15 tonnes
weight having nine wheels, with a tyre pressure of at least 5.6 kg Isq.cm. The
finish rolling shall be done with 8 -10 tonnes smooth wheeled tandem rollers."
Add at the end of 6'" paragraph :
"Rolling shall continued till the density achieved satisfies the requirements of
Clause 903.4.2 and all roller marks are eliminated."

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Clause 501.8 Preparation of Surface


Clause 501.8.3.2 In the last sentence replace "lOOOmnwith "all leads".
Clause 501.8.3.4 Laying the profile corrective course
Clause This Clause shall be read as under:
501.8.3.4.1
"The surface on which profile corrective course is to be laid shall be thoroughly
swept clean of dust and any other extraneous material using mechanical broom
and dust collected, removed or blown off using compressed air except in places
where mechanical means cannot reach.
After preparing the granular surface as in Clauses 501.3.1., 501.3.2 and
501.3.3, the profile corrective course with materials as per Clause
501.2.31501.2.4 shall be laid and compacted to the requirement of particular
specification clause. Where a bituminous profile corrective course is to be laid
over primed granular surface, a tack coat conforming to Clause 503 shall be
applied prior to laying the profile corrective course."
Clause This new Clause shall be added as under :
501B.3.4.2
'An existing bituminous surface shall be prepared as per Clauses 501.3.3 and
501.3.4.1. The bituminous profile corrective course shall be laid after applying
tack coat conforming to Clause 503, and compacted to the requirement of
specification Clause."
Clause 501.8.8.1 In the last sentence replace "1000m" with "5000m".
Clause 502 Prime Coat Over Granular Base
Clause 502.1 Scope
This Clause shall be read as under:
"This work shall consist of the application of a single coat of low viscosity
Bitumen Emulsion @ 0.6Kg to 0.9Kg per square metre to a porous granular
surface preparatory to the superimposition of bituminous treatment or mix."
Clause 502.8 Delete the second sentence from the paragraph as under:
'Payment shall be.............................. in Clause 502.4.3."
Clause 503 Tack Coat
Clause 503.1 Scope
This Clause shall be read as under:

''This work shall consist of the application of a single coat of low viscosity
Bitumen Emulsion @ 0.20Kg to 0.25Kg per square metre to an existing
bituminous road surface and @ 0.25Kg to 0.30Kg per square metre to a primed
granular surface preparatory to the superimposition of bituminous treatment or
mix."
Clause 503.8 Delete the second sentence from the paragraph as under:

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"The rate shall cover..............................accordingly."


Clause 504 BITUMINOUS MACADAM
Clause 504.2 Materials
Clause 504.2.1 Bitumen
This Clause shall be read as under:
"The Bitumen shall be paving bitumen of penetration grade 60170 as per lndian
Standard Specification for Paving Bitumen -IS: 73."
Clause 504.2.2 Coarse Aggregates
The first sentence of paragraph 1 shall read as:
'The course aggregates shall consist of crushed rock and shall be obtained
through the use of Cone crusher, Vertical Shaft lmpactor and vibratory screens
of suitable capacity."
The third paragraph of this Clause shall be deleted
Clause 504.2.5 Proportioning of materials
Add following between first and second sentence:
"Grading-l shall be used for compacted thickness of a layer of 75 mm and
above while Grading-2 shall be used for compacted thickness of a layer of less
than 75 mm thickness. The Contractor shall give job mix formula for the mix
design indicating mix properties. The laying of mix shall be done after approval
of the Engineer."
Clause 504.8 Rate
Add the words 'except for the item of tack coat" after the words 'required
operations' in second line.
The item (vii) of Clause 501.8.8.2 shall be substituted as under :
'The rate shall include any variation in the bitumen content in excess of
percentage by weight of bituminous mix given in Table 500-4 and no
adjustment on this account shall be admissible."
Clause 507 Dense Bituminous Macadam
Clause 507.2 Materials
Clause 507.2.1 Bitumen
This Clause shall be read as under:
T h e Bitumen shall be paving bitumen of penetration grade 60R0 as per Indian
Standard Specification for Paving Bitumen -IS: 73."
Clause 507.2.2 Coarse Aggregates
The first sentence of paragraph 1 shall read as:
'The course aggregates shall consist of crushed rock and shall be obtained
through the use of Cone crusher, Vertical Shaft lmpactor and vibratory screens
of suitable capacity."

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The second paragraph of this Clause shall be deleted


Clause 507.2.5 Aggregates grading and binder content
Add following between first and second sentence:
'Grading-l shall be used for compacted thickness of a layer of 75 mm and
above while Grading-2 shall be used for compacted thickness of a layer of less
than 75 mm thickness. The Contractor shall give job mix formula for the mix
design indicating mix properties. The laying of mix shall be done after approval
of the Engineer."
Read "Modified Marshall method" in place of "Marshall method" in the Note: 2.
of Table 500-10.
Clause 507.3.2 Binder content
Delete 'Marshall method" and replace with 'Modified Marshall method" in the 3d
lane of first paragraph.
Replace the second paragraph by the following paragraph:
The modified Marshall method described in MS-2 requires modified equipment
and procedures; particularly the minimum stability value in Table 500-11 shall
be multiplied by 2.25, and the minimum flow shall be 3mm.
Clause 507.3.3 Job mix formula
Insert the following paragraph between existing paragraph 3 & 4:
'Mix design shall be carried out in accordance with the modified Marshall
method described in Asphalt Institute Manual MS-2."
Clause 507.9 Rate
This Sub-clause shall be substituted as under:
'The Contract unit rate for Dense Bituminous Macadam shall be payment in full
for carrying out the required operations except for the item of tack coat including
full compensation for all components listed in Clause 501.8.8.2 (i) to (xi).
The rate shall include any variation in the bitumen content in excess of 4.5
percent by weight of bituminous mix and no adjustment on this account shall be
admissible."
Clause 508 Semi-Dense Bituminous Concrete
Clause 508.1 Scope
The last sentence of this Clause shall read as:
"A single layer shall be 25mm to 40mm in thickness."
Clause 508.2.1 Bitumen
This Clause shall be read as under:
"The Bitumen shall be paving bitumen of penetration grade 60/70 as per Indian
Standard Specification for Paving Bitumen -IS: 73."

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Clause 508.9 Rate


This Sub-clause shall be substituted as under:
"The Contract unit rate for Semi-Dense Bituminous Macadam shall be payment
in full for carrying out the required operations except for the item of tack coat
including full compensation for all components listed in Clause 501.8.8.2 (i) to
(xi).
The rate shall include any variation in the bitumen content in excess of 4.75
percent by weight of bituminous mix and no adjustment on this account shall be
admissible."
Clause 509 Bituminous Concrete
Clause 509.1 Scope
The last sentence of this Clause shall read as:
"A single layer shall be 25mm to 65mm in thickness."
Clause 509.2.1 Bitumen
This Clause shall be read as under:
'The Base binder shall be paving bitumen of penetration grade 60170 as per
Indian Standard Specification for Paving Bitumen -IS: 73. Modified Bitumen
confirming to IRC -SP-53-1999 shall be used which is compatible with the base
binder and which allows the properties given in Clause 521.3 to be achieved.
The modifier, in the required quantity shall be blended at the refinery or at the
factory plant capable of producing modified binder. Technical specification
clause 521 for modified binder and IRC:SP-53-1999 shall be referred to"
Clause 509.2.4 Filler
This Clause shall be read as under:
"Filler shall consist of finely divided hydrated lime or cement as approved by the
Engineer."
Clause 509.2.5 Aggregate Gradation
Add the note below Table 50&18:
'The grading of the aggregate mix as used in the work shall be a smooth curve
within the approximate parallel of the envelip in Table 500-18".
Clause 509.9 Rate
This Sub-clause shall be substituted as under:
T h e Contract unit rate for bituminous concrete shall be payment in full for
carrying out the required operations except for the item of tack coat including
full compensation for all components listed in Clause 504.8 (i) to (vi)."
"The rate shall include any variation in the bitumen content in excess of 5.0
percent by weight of bituminous mix and no adjustment on this account shall be
admissible."

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Contract Package -NS 82 (TN)
Clause 521 MODIFIED BINDER
Clause 521.2.2 Modifier
The last sentence of this Clause shall read as:
"The modifier, in the required quantity shall be blended at the refinery or mixed
in the approved factory capable of producing modified binder."
Clause 521.6 Measurement for Payment
Replace the Sub-Clause with the following:
'Modified binder supplied in the contract shall not be measured separately.
Bitumen layer using modified bitumen shall be included in the particular item of
the works."
SECTION 800 TRAFFIC SIGNS, MARKINGS & OTHER ROAD APPURTENANCES
Clause 801 Traffic Signs
Clause 801.1.2 This Clause shall be read as under:
'All road signs shall be of retro-reflectorised type and made of micro prismatic
sheeting conforming to ASTM D4956, Type VIII or Type IX, fixed over
aluminium sheeting as per these specifications."
Clause 801.I.2 In this clause, the 5m sentence shall be read as:
' The retro-reflective sheeting shall be super high-intensity retro-reflective,
having highest retro-reflective characteristics at long and medium road
distances as determined by RAvalues of Table -2 of ASTM D 4956, at 0.I0and
0.2' observation angle. This sheeting is typically an un-metallized micro-
prismatic retro-reflective element material."
-
Table 2 of ASTM D 4956

Clause 801.3.7 Colour


Add the following in the clause
All the facility information and place identification signs shall have colours
specified in IRC 67-2001.

v? ,I c .

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Clause 801.3.11 Warranty and durability


The Clause shall read as:
"The Contractor shall obtain from the manufacturer a Seven Year Warranty for
satisfactory field performance including stipulated retro-reflectance of the super
high-intensity retro-reflective micro-prismatic sheeting and submit the same to
the Engineer. In addition, a Seven Year Warranty for satisfactory in-field
performance of the finished sign with super high-intensity micro-prismatic
sheeting, inclusive of the screen printed or cut out letters/legends and their
bonding to the super high intensity retro-reflective sheeting shall be obtained
from the ContractorlSupplier and passed on to the Engineer. The
Contractorlsupplier 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 dimensional change and
shall not have less than the percentages prescribed in Table 14 of ASTM
D4956 for Type Vlll or Type IX."
Clause 801.4.1 Last sentence of the sub-clause shall read as follows:
All signposts shall be embedded in concrete (M-15) for stability and safeguard
against theft. The cost of concrete shall be deemed to be included in the rate of
signboard.
Clause 801.4.2 Add the following Sentence to the clause
"Alternate band of Black and white Painting for the posts to be done and the
cost thereof is included in the Sign boards Installation items."
Clause 801.5 Measurement for Payment
Add, 'as well as other informatory Iand any other types of sign" after the word
"identificationsigns" in the 3d line.
Clause 801.6 Rate
Add, 'including cost of concrete" after the word 'at the site" in the 2"dline.
Clause 802 Overhead Signs
Clause 802.5 Materials
Clause 802.5.3 Replace "1.5mmBwith '2.0mmn in the last sentence
Clause 802.5.6 This Clause shall be read as under:
"All Overhead signs shall be of retro-reffectorised type and made of micro
prismatic sheeting confirming to ASTM 04956, Type Vlll or Type IX, fixed over
aluminium sheeting as per these specifications."
Clause 802.9 Rates
Clause 802.9.1 The second sentence of this clause shall read as:

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"All other works like excavation concrete, reinforcement, formwork and


backfilling for foundation are incidental to structural steel works and no separate
payment shall be maid."
Clause 803 Road Markings
Clause 803.2 Materials
Delete 'of ordinary road marking paint," from the is'
line of this clause.
Clause 803.2 Ordinary Road Marking Paint
This Clause shall be -deleted".
Clause 803.6 Application
Clause 803.6.1 The first sentence of this clause shall read as:
'The road marking shall be made with the appropriate road marking machinery
as approved by the Engineer."
Clause 804 Hectometre IKllometre Stones
Clause 804.3 The first sentence of this clause shall read as:
'The hectometre Ikilometre stones shall be made of concrete of grade as
shown in the drawings"
Clause 804.5 Rates
Add, 'including cost of excavation, foundation, reinforcement, formwork,
backfilling, etc..."after the word "equipment" in the 3d line.
Clause 810 Metal Beam Crash Banier
Clause 810.2 Materials
Clause 810.2.1 This Clause shall be read as under:
"Metal beam is a "W profiled corrugated beam as specified in drawings made
from cold rolled steel strip of 3.0mm thick using high strength steel of IS : 5986
Fe 510 grade and have properties as under:
a) Ultimate Tensile Strength (Min.) 483 Mpa.
b) Yield stress (Min.) 345 Mpa.
C) Elongation (Min.) in 50mm 12%
The beam after forming shall have formed width of 311 mm and depth of 83 mm
and shall have punched holes for fixing as specified in drawings.
The metal crash barrier post is made from cold rolled steel strip of 5 mm
thickness and of steel conforming to IS: 5986 grade Fe. 360 as specified in
drawings.
The spacer is made of cold rolled steel channel with cross section and material
same as that of post.
All bolt nuts and washers as specified in drawings shall
IS: 1364 unless otherwise specifled and are hot dip gal

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Clause 810.2.3 Add at the end of this Clause:


I
'The size of the concrete foundation block for embedding the posts and grade
of concrete shall be as shown on the drawing."
I
Clause 810.4 Installation of Posts
This Clause shall be substituted as under:
"The posts shall be embedded in the concrete foundation block of size and
i
grade of concrete along with the depth of embedment of post as shown in the
drawing.
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."
Clause 810.7 Measurement for Payment
Clause 810.7.1 The 2* sentence 'Terminals ...........for by numbers" shall be deleted.
Clause 810.7.2 The first sentence of this clause shall substituted as:
'No separate measurement for payment shall be maid for Terminals IAnchors
of various types required for the work. The cost of these elements shall be
deemed to be included in the rate quoted by the contractor."
Clause 810.8 Rates
Add at the end of last sentence of Clause 'and drawings."
SECTION 900 QUALITY CONTROL FOR ROAD WORKS
Clause 901 General
Clause 901.1 This Clause shall read as under:
'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 approved by the Engineer
and the same with adequate equipment and personnel in order to carry out all
required tests and Quality Control work as per Specifications andlor as per
Clause 121 andlor as directed by the Engineer. The list of laboratory equipment
and the facilities to be provided shall be as per Clause 121 and shall be
approved by the Engineer in advance."
Clause 901.5 This Clause shall be read as under:
'The Contractor shall provide necessary cooperation and assistance in
obtaining the samples for tests and carrying out the field tests as required by
the Engineer from time to time. This may include provision of laboratory,
equipment, transport, consumables, personnel, including labour, attendants,
assistance in packing and despatching and any other assistance considered
necessary in connection with the tests."

Y- ,
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Clause 902 Control of Alignment, Level and Surface Regularity


Clause 902.3 Surface Levels
Add "and or thickness" after the word "levels" in the is'
line of the first
paragraph.
Add at the end of first sentence "or as desired by the Engineer" in the last
paragraph.
Add the following sentence at the last: Towed fiflh wheel Bump Integrator Test
is to be conducted on the Bituminous surfaces to evaluate the surface
regularity. Results are to be taken on Electronic Graph. In Each lane, at four
locations longitudinally, in Uni.-direction, this bump integrator test is to be done.
Clause: 902.4 Surface Regularity of Pavement Courses
Add afler the last paragraph:
"In addition to the above requirements, the surfaces of both the base course
(DBM) and wearing course (BC) shall have smooth longitudinal profiles which
provide a high standard of riding quality. Roughness testing with towed fifth
wheel Bump lntegrator shall be carried out up on completion of the DBM top
layer and again up on completion of the BC to evaluate the surface regularity.
The riding quality of the base course surface and the wearing course surface
shall have Unevenness lndex (UI) values of not greater than 2000 and 1800
respectively. Results are to be taken on Electronic Graph.
Pavement Unevenness Index:
Roughness testing shall be carried out for each lane length constructed, at four
locations longitudinally, in uni-direction. The equipment has to be run on the
road stretch under study once for each wheel path in each direction. For the
purpose of determining rideability:
t Each lane shall be divided into sections of 500m long
t Any remaining length less than 500m shall be included with the section
immediately preceding it and an average value of Unevenness lndex (UI)
determined for the total section.
Average value of Unevenness lndex (UI) is expressed in terms of mrntkm. If 'W'
indicates Distance counter Reading in test length and '8'the bumps counter
reading in 'cm' then,
UI Value = B IW x R x 10 mmlkm
Where R is the Distance counter Reading per Km = 1000
Roughness testing shall be canied out using a calibrated Bump lntegrator trailer
in accordance with IRC and CRRl guidelines.
A lower riding quality than that specified above may be accepted at the
discretion of the Engineer subject to deductions to the schedule rate applied to
the quantity of base course and lor wearing course represented by the test
section.

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a) For DBM base course

Roughness (UI, mmlkm) Deduction (%) for the value of the


section
Less than 2000 No deduction

-
2000 2200 2

-
2200 2400 4

-
2400 2600 8

2600 - 2800 16

Greater than 2800 Material to be removed

b) For BC wearing course

Roughness (UI, mmlkm) Deduction (%) for the value of the


section
Less than 1800 No deduction
1800 - 2000 2

-
2000 2200 4
2200 - 2400 8
2400 - 2600 16

Greater than 2600 Material to be removed

Deductions may be applied to both the DBM and BC courses on a given test
sections in accordance with the above tables."
Clause 903 Quality Control Tests Durlng Construction
Clause 903.4 Tests on Bituminous Const~ctions
In Table 900-4, serial No.6 for Dense Bituminous MacadamlSemi Dense
Bituminous Concrete and for Bituminous Concrete, add the following at the end
in the frequency (Minimum) column:
"10% of the density tests shall be done within 300mm width from edges."
SECTION 1000 MATERIALS FOR STRUCTURES
S",
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Clause 1002 SOURCES OF MATERIAL


This Clause shall be substituted as under:
'The Contractor shall identify the sources of materials like coarse aggregate
and sand and notify the Engineer regarding the proposed sources prior to
delivery.
Samples of material from the source shall be tested, in the presence of
Engineer's representative, for conformity to specifications. It shall also be
ensured that the variation in test results of different samples is within
acceptable limits. If the product from the approved source proves unacceptable
at any time, the Contractor shall provide new sources of acceptable material
from other sources at his own expense conforming to specifications.
For manufactured items like cement, steel reinforcement, prestressing strands,
the Contractor shall intimate the Engineer details of the source (plant where the
material is manufactured), testing facilities available with the manufacturer and
arrangements for transport and storage of material at site. If directed by the
Engineer, the Contractor shall furnish samples and test results of recently
manufactured material. The Engineer, at his discretion, may require the
Contractor to test the materials in an independent laboratory approved by the
Engineer, and furnish test certificates. The cost of these tests shall be borne by
the Contractor. The sampling and test procedures shall be as laid down in
Indian Standards or where these are not available as per the directions of the
Engineer. Only material from the sources approved by the Engineer shall be
brought to the site. If the material from the approved sources proves
unacceptable at any time, the Contractor shall provide new sources of
acceptable material conforming to specifications from other sources at his own
expense
For proprietary items like bearings, expansion joints refer clause 115.1.
Clause 1006 Cement
Add the following as f), g) & h) after e) of lst
paragraph.
f) Portland Poaolana Cement IS: 1489 Part-1
g) Portland Blast Furnace Slag Cement IS: 455
h) Low heat Portland Cement IS: 12600
Use of Portland pouolana cement may be permited only in plain cement
concrete.
Add the following at the end of this clause.
Each delivery of cement to Site shall be accompanied by a certificate confirming
that the cement complies with the requirements of the relevant standards and
the Contractor shall forward a copy of this certificate to the Engineer within 24
hours of the delivery to Site
Clause 1007 Coarse Aggregates
The first sentence paragraph -1 shall read as:

Final Detailed Project Report. Vol. V :Technical Specifications


Contract Package -NS 82 (TN)
plain and reinforced Cement concrete (PCC and RCC) or pre-stressed
(PSC) works, Coarse aggregate shall consist of clean, hard, strong,
dense, non-porous and durable pieces of crushed stone obtained through the
use of Cone crusher, Vertical Shatt Impactor and vibratory screens of suitable
capacity.'
~ d the
d fdlowing at the end of 2* paragraph:
*costof all tests shall be born by the Contractor."
~h~ first sentence of paragraph -4 shall substituted as:

Clause 1008 SandlFine Aggregates


Add the following at the end of 2"' paragraph:
"The alkali aggregate reactivity should be measured and reported for obtaining
approval for the source."
Add the following paragraph at the end of the Clause:
"As far as possible natural sand shall be used for sandlfine aggregates. If
natural sand is not available with in 50Km or Government has stopped sand
mining, the contractor shall obtain suitable alternative viz. crushed stone,
crushed sand, etc. to substitute the natural sand. All alternative sand shall
confirm to IS: 383 and tests for conformity shall be carried out as per IS: 2386
(Parts I to VIII). No separate payment will be made on account of non-
availability of natural sand, arranging crusher sand and increase in leads, etc"
Clause 1009 STEEL
Clause 1009.2 Steel For Prestressing
Add (e) to the list of prestressing steel:
'e) Uncoated Stress relieved low relaxation steel confirming to IS: 14268."
Clause 1009.3 Reinforcement IUntensioned Steel
Add the following at the beginning of this clause:
Table 1000-3 shall be modified as:
Grade Bar Type confirming to Characteristic Elastlc
Designation. governing IS Strength fy Modulus
specification. Mpa. GPa.
Fe 240 IS: 432 Part 1 Mild Steel 240 200

Fe 415 IS: 1786 Deformed Bars 415 200

Fe 500

Fe 415
I
IS: 1786 Deformed Bars

IS: 1566 TMT Bars


1
I 500
415
17
a '/

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Clause 1010 Water


Delete the clause and substitute as given below.
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.
In case of doubt regarding development of strength, the suitability of water for
making concrete shall be ascertained by the compressive strength and initial
setting time tests
The sample of water taken for testing shall represent the water proposed to be
used for concreting, due account being paid to seasonal variation. The sample
shall not receive any treatment before testing other than that envisaged in the
regular supply of water proposed for use in concrete. The sample shall be
stored in a clean container previously rinsed out with similar water.
Average 28 days compressive strength of at lease three 150 mm concrete
cubes prepared with water proposed to be used shall not be less than 90 per
cent of the average of strength of three similar concrete cubes prepared with
distilled water. The cubes shall be prepared, cured and tested in accordance
with the requirements of IS:516
The initial setting time of test block made with the appropriate cement and the
water proposed to be used shall not be less than 30 minutes and shall not be
more than + 30 minutes from the initial setting time of control test block
prepared with the same cement and distilled water. The test blocks shall be
prepared and tested in accordance with the requirements of IS:4031 (part 5).
The pH value of water shall be not less than 6. Potable water is generally
considered satisfactory for mixing concrete. As a guide the following
concentrations represent the maximum permissible values:
a) To neutralize 100 ml sample of water, using phenolphthalein as an
indicator, it should not require more than 5 ml of 0.02 normal NaOH. The
details of test are given in 8.1 of IS : 3025 (Part 22).
b) To neutralize 100 ml sample of water, using mixed indicator, it should not
require more than 25 ml of 0.02 normal H2SO4 The details of test shall be
given in Clause 8 of 1833025 (Part 23).
c) Permissible limits for solids shall be as given in following table.

I Permissible Limits for Solids I


I Permissible Limit mg
- -

I -
I Tested as per I
1 Omanic I IS 3025 (Pt. 18) 1 200 mgllit 1
Inorganic IS 3025 (Pt. 18) 3000 mgllit
Sulphates (as SOS) IS 3025 (Pt. 28) 400 mgllit
Cholorides (as CI) IS 3025 (Pt. 32) 2000 mgllit
for concrete work not containing
embedded steel and 500 mgilit for
prestressed1 reinforced concrete
I work.
Suspended matter IS 3025 (Pt. 17) 2000 mgllit A

f/-

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Contract Package -NS 82 (TN)
-
BCEOM
+
.

-
Mixing or curing of concrete with seawater is not permitted because of
presence of harmful salts in seawater.
Water found satisfactory for mixing is also suitable for curing concrete.
However, water used for curing should not produce any objectionable stain or
A
unsightly deposit on the concrete surface. The presence of tannic acid or iron
A compounds is objectionable
Clause 1012 Concrete Admixtures
Add the following at the end of paragraph 2 of Clause 1012.1:
"Admixtures shall not impair the durability of concrete; they shall not combine
with the ingredients to form harmful compounds or endanger the protection of
reinforcement against corrosion. Only chloride free admixtures shall be used."
Paragraph 3 of 1012.1 shall read as follows :
"For all admixtures being used the packing shall be marked with the name of
the supplier/manufacturer, brand name (name of product) and main effect. A
certificate for the admixture in question shall be submitted. The certificate shall
include the following information:
n A) General

h a) Chemical name of the active component in the admixture.

h
b) Values of dry material content, ash content and relative density of
admixture, which can be used for uniformity tests.
A
c) Chloride ion content expressed as a percentage of weight of cement.
h d) pH value and colour.

e) Normal side effects e.g. whether the admixture leads to air entrapment
at recommended dosage and if so to what extent.
h
9 Side effects when overdosed.
g) Compatibility of admixture with the cement should be tested.
h) Increase in risk of corrosion to reinforcements and embodiments due
to the use of admixture.

i) Latest date of test and name of test laboratory.


B) Storing
a) Shelf life.
h
b) Max. & min. allowable temperature.
c) Other instructions (e.g. requirements of stirring).
C) Dosage
a) Maximum and minimum to be specified as a percentage of weight of
cement.

-
A

h
S-

Add the following at the end of the clause:

- . _I

Final Detailed Project Report. Vol. V : Technical Specifications Page 52 of 1


L4
Contract Package -NS 82 (TN)
-
* 4/6 Laning of Karur - Madurai Sections of NH-7

"After selecting a few acceptable brands & types of admixture based on the
manufacturer's data/technical literature, independent acceptance tests should
be camed out for the same using the approved combinations of cement
/sand/aggregates intended for use in the Project. After establishing the basic
acceptability using strength criteria (compression & tensile strengths) a
number of trial mixes be designed using different proportions of
admixtureslcernentlwater etc. to establish the data bank on the behaviour of
the admixture for the project site conditions. A spectroscopic signature of
accepted product should be obtained and preserved for comparison for
acceptance of the production lots."
h
Retrials should be conducted with change in sourcehype of cement
fi Workmanship

The dosage should be tinalised on the basis of field trial and special
mechanical devices should be used for dispensing the admixture in the
batchinglmixing plant. No addition of admixture after dosage is permitted
(including addition in transit mixers).
Manufacturer's experts should be available for consultation/trouble-shootingof
problems associated with their product. The conditions of storage, shelf life
etc., as specified by the manufacturer should be strictly observed. The
manufacturer's Quality Assurance Plan during process of production should be
obtained and filed for referencelrecord."

P Clause 1013 Reinforced Concrete Pipes

n
Delete the Clause and add the following:
"Reinforced concrete pipes for highway structures shall be of the class
specified by the designer for the particular application. In absence of such
specification, the class shall be NP-4 type conforming to requirements of IS:
458."
h
Clause 1014 Storage o f Materials
T? Clause 1014.3 Aggregates
h The following shall be added to this Clause:
"Aggregates shall be stored or stockpiled in their respective size in such a
manner that the various sizes will not become intermixed before proportioning.
They shall be stored, stockpiled and handled in such a manner that will
prevent contamination by foreign materials."
Clause 1015 Test and Standards of Acceptance
Add following after paragraph 2:
'Independent testing of prestressing steel shall be carried out by the contractor
for each consignment from each source at site in the laboratory approved by
the Engineer before use. These tests are in addition to the tests canied out by

- Y
the manufacturer."
..<
. ... .
..
. . .

.-

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&
Contract Package -NS 82 (TN)
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SECTION 1500 FORMWORK


Clause 1501 Description
This Clause shall be substituted as under:
"The Contractor shall prepare a formwork mobilisation and utilisation plan and
submit the plan for Engineer's approval at least 28 days before the
commencement of construction of structures. The requirement of formwork
shall be worked out considering the overall construction programme of all the
structures in the contract. Sufficient formwork shall be mobilised, to enable the
structure to be cast in one or more stages, as specified in the drawings. The
plan shall take into account the time required for erection of formwork,
retention in position, stripping, and removal and subsequent use in the next
and subsequent structures.
Notwithstanding Engineer's approval of mobilization plan, if due to any reason,
Contractor has to arrange additional formwork, to meet the requirements of the
construction program, it shall be done by the Contractor without any extra cost
to the Employer."
Clause 1502 Materials
This Clause shall read as under:
'All materials shall comply with the requirements of IRC-87.
'Materials and components used for formwork shall be examined for damage
or excessive deterioration before use I reuse and shall be used if found
suitable after necessary repair.
Only steel formwork shall be used. The steel 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 plastic spacers shall be permitted.
Structural steel tubes used as support for forms shall have a minimum wall
thickness of 4 mm."
Clause 1503 Design of Formwork
Clause 1503.2 The following shall be added to this Clause:
'For distribution of load and load transfer to the ground through staging, an
appropriately designed base plate must be provided which shall rest on fih
sub-stratum. The loading from the form work shall be distributed to the soil or
the penanent works below (e.g. pile cap) in such a manner that any total or
differential settlement is within acceptable limits."
Clause 1504 Workmanship
Clause 1504.1 The following shall be added to the end of this sub-clause :
"The loading from the formwork shall be distributed to the soil or the
permanent works below (e.g. pile cap) in such a manner that any total or
differential settlements are within acceptable limits."

- ,
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Clause 1505 Formed 8 Unformed Surface Finishes


Substitute the following Clause in place of the existing clause:
The surface finishes for formed and unformed surfaces are classified and
defined as below. Surface irregularities permitted for the various classes of
finishes are termed either 'abrupt' or 'gradual'. Fins or offsets caused by
displaced or misplaced form sheeting, lining or form sections, by loose knots in
form lumber or by otherwise defective form lumber are considered abrupt
irregularities. All other cases are described as gradual irregularities. Gradual
irregularities will be measured with a template consisting of a straight edge for
plain surfaces or its equivalent for curved surfaces. The length of template for
testing gradual irregularities on formed surfaces shall be 1.5 m in length, the
permissible gradual irregularities being measured over this length of the
template.
Finish F1, F2 and F3 shall describe formed surfaces.
Finish U l , U2 and U3 shall describe unformed surfaces.
Class F1 Finish
The class F i finish shall apply to all formed surfaces for which class F2 or F3
is not specified. It shall generally be formed by steel frame mounted with steel
sheet. It shall be so constructed that there shall be no loss of material from the
concrete during placement and compaction. After hardening, the concrete shall
be in the required positions and shall have the shape and dimensions called
for in the drawings. Any abrupt irregularities shall not exceed 10mm. All fins
and drifts in excess of the above limits shall be made good by chipping and
grinding if required by the Engineer. Small blemishes caused by entrapped air
or water may be expected but the surface shall be free from voids,
honeycombing or other large blemishes. Class F1 finish shall be generally
specified for all surfaces buried in ground or not visible during service or for
surfaces that are to receive further rendering treatment such as plastering etc.
Class F2 Finish
Class F2 finish shall be obtained by use of properly designed forms with steel
sheet lining. The abrupt irregularities shall not exceed 5mm and gradual
irregularities shall be less than 8mm. Small blemishes caused by entrapped air
or water may be permitted but the surface shall be free from honeycombing,
voids and large blemishes. Surface irregularities in excess of those stipulated
shall be removed by chipping or rubbing with abrasive stone. Class 2 finish
shall apply to exposed surface of pier and abutments, pier cap and abutment
caps.
Class F3 Flnish
Class F3 finish shall be formed by specially designed close jointed rigid forms
having lining or high quality form plywood. The surface irregularities shall be
limited to nil for abrupt irregularities and 3 mm for gradual irregularities. Class
F3 finish may be obtained from class F2 finish by carefully removing ail abrupt -
irregularities including fins and projections by rubbinglgrinding. If steel forms
are used they shall have steel sheet backing faced with plywood.
cdt!
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In addition, finish F3 shall include filling air holes with mortar and treatment of
the entire surface with sack rubbed finish. It shall also include clean up of
loose and adhering debris. For a sack rubbed finish, the surface shall be
prepared within two days after removal of the forms. The surface shall be
wetted and allowed to dry slightly before mortar is applied by sack rubbing.
The mortar used shall consist of one part cement to one and one half parts by
volume of fine (I.S.No. 16 mesh) sand. Only sufficient mixing water to give the
mortar a workable consistency shall be used. The mortar shall then be rubbed
over the surface with a fine burlap or linen cloth so as to fill all the surface
voids. The mortar in the voids shall be allowed to stiffen and solidify after
which the whole surface shall be wiped clean with clean burlap such that all air
holes etc., are filled and the entire surface presents a uniform appearance
without air boles, irregularities etc. Class F3 finish shall apply to all exposed
surfaces of superstructure.
Class U1 finish
This is the screeded finish used on surfaces over which other finishes such as
wearing coats etc., are to be placed. It is also the first step in the formation of
U2 and U3 finishes. The finishing operation consists of levelling and screeding
the concrete to produce an even and uniform surface so that the gradual
irregularities are not greater than 5 mm. Surplus concrete should be removed
immediately after consolidation by striking it off with a sawing motion of a
straight edge or template across a wooden or metal strip that has been set as
guide. Unless the drawings specify a horizontal surface or show the slope
required, the tops of narrow surfaces, such as stair treads, walls, curbs and
parapets shall be sloped approximately 10 mm per 300 mm width. Surfaces to
be covered with concrete topping, terrazzo, and similar surfaces shall be
smooth screeded and levelled to produce even surfaces, irregularities not
exceeding Smm.
Class U2 Finish
This is a floated finish used on all outdoor unformed surfaces not prominently
exposed to view such as tops of piers etc. The floating may be done by hand
or power driven equipment. It should not however be started until some
stiffening has taken place in the surface concrete and the moisture film or
'shine' has disappeared. The floating should work the concrete no more than is
necessary to produce a surface that is free from screed marks. All joints and
edges should be finished with edging tools. It shall include the repair of gradual
irregularities exceeding 5 mm. All abrupt irregularities shall also be repaired
unless a roughened texture is specified
Class U3 Finish
This is a trovelied finish used on all surfaces exposed to view at close quarters
such as tops of parapets and kerbs etc. Steel trovelling should not be started
until after the moisture film and 'shine' have completely disappeared from the
floated surface and the concrete has hardened enough to prevent an excess of
fine material and water from being worked to the surface. Excessive trovelling,
especially if started too soon, tends to produce crazing and lack of dwability.

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Too long a delay will result in a surface too hard for proper finishing. Steel
trovelling should be performed with a firm pressure that will flatten and smooth
the sandy surface free of blemishes, ripples and trove1 marks. It shall include
the repair of all abrupt irregularities and the repair of gradual irregularities
exceeding 5 mm. It shall also include finishing the joints and the edges of
concrete with edging tools.
Clause 1506 Precautlons
Add the following as items (vii) and (viii) to the end of this clause:
vii. Adequate support against sideway and lateral loads due to
construction operations and wind shall be provided.
viii. Forms shall be rigid and of adequate section to reduce deflections.
Forms shall have sufficient rigidity to resist horizontal pressures
caused by flowing concrete resulting from use of superplasticisers.
The formwork shall resist the lateral pressure caused due to fast rate
of placement by concrete pumps.

Clause 1508 Removal of Formwork


Add the following as paragraph 5 to Clause 1508.
"For prestressed units, the side forms shall be released, as early as possible
and the soffit forms shall permit, without restraint, deformation of the member,
when prestressing is applied. Form supports and forms for cast-in-situ
members shall not be removed until sufficient prestressing has been applied to
carry the dead load and any formwork supported by the member and
anticipated construction loads".

Clause 1509 Reuse of Forrnwork


This Sub-clause shall be substituted as under:
"After forms are stripped, all materials to be reused shall be thoroughly
cleaned. Holes bored through sheathing for form ties shall be plugged by
driving in common corks or foamed plastics. Patching plaster may also be
used to fill small holes. After cleaning and before re-fixing, each formwork shall
be got approved by the Engineer."
Formwork and staging shall be so used as to maintain quality of the exposed
surface. However, if in the opinion of the Engineer, any particular
panellmember has become unsatisfactory for use at any stage, the same shall
be rejected.
All bent steel props shall be straightened before reuse. The maximum
deviation from straightness shall not exceed 11600 of length. However the
maximum number of users shall be limited to 20 times since only steel form
work is to be used. The maximum permissible axial loads in used props
. . shall
be suitably reduced depending upon their condition."

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Clause 1510 Speciallsed Formwork


Replace the words 'slipfm work" by 'dimbing fomnnrorlC in the first sentence of this
dause.
Second paragraph of this Clause shall be deleted.
Replacethe word 'plywood" by "marine pipood" in the fourth paragraph of this dause
Clause 1513 Rate
Add the following at the end of the first paragraph:
T h e unit rate shall also include all costs for preparation of erection scheme,
designs of false work and forrnwork and their approval."
SECTION 1600 STEEL REINFORCEMENT (UNTENSIONED)
Clause 1602 General
Substitute in I* line of second paragraph of this clause as:
'Reinforcements shall be Thermo Mechanically Treated (TMT) bars
conforming to IS: 1566 or HYSD bars conforming to IS: 1786"
Clause 1604 Bending of Reinforcement
The first paragraph of this Clause shall read as under:
'The reinforcement shown on the drawings shall be considered merely
symbolic representations of the shape and position and shall not be used by
the Contractor to justify any deviation from the stipulated requirements. Bar
bending schedules and any supplementary drawings as may be required shall
be furnished by the Contractor and got approved by the Engineer before start
of work. The bending schedules shall state the number, shape and length of
bar and weight in respect of each type. System of bar referencing should be
coherent and systematic. A separate bar bending schedule shall be prepared
for auxiliary bars like spacers chairs etcm
Clause 1605 Placing of Reinforcement
Paragraph (c) (i) of clause 1605 shall read as follows:
'Cover blocks shall be made of concrete or cement mortar with the same
durability properties as the surrounding concrete and with the same type of
constituents. In visible surfaces, the cover blocks shall be of the same colour
and texture as the surrounding concrete. The Contractor's proposal for cover
blocks shall be submitted to the Engineer for acceptance."
Clause 1605(f) Add the following as Clause 1605(f):
"Tolerances:
1. Tolerance of cover: Deviation shall not exceed + I 0 rnm. No negative
tolerance is allowed.
2. Tolerance in position: Tolerance for deviation from the positions shown in
the drawings shall not exceed the following:

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Structural depth d (mm) Tolerance(mm)

Clause 1606 Bar Splices


Clause 1606.1 Lapping
First sentence of Clause 1606.1 shall read as follows:
"To the extent possible, all reinforcement shall be provided in full lengths as
indicated in drawings."
Add the following as paragraph 2 of Clause 1606.1:
"The location of joints in continuous reinforcing bars, not shown in drawings,
shall be submitted to the Engineer for acceptance. If nothing contrary has been
specified, the number of bars to be joined in any cross-section shall not
exceed one-third of the total."
Clause 1607 Testing and Acceptance
Add the following as the last paragraph of Clause 1607:
Manufacturer's test certificate regarding compliance with Indian Standards for
each lot of steel shall be obtained and submitted to the Engineer. If required by
the Engineer, the Contractor shall cany out confirmatory tests in the presence
of a person approved by the Engineer. Cost of these tests shall be borne by
the Contractor. The sampling and testing procedure shall be as laid down in
I.S.1786-1985. However if any test piece selected from a lot fails, no re-testing
shall be done and the lot rejected

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SECTION 1700 STRUCTURAL CONCRETE


Clause 1703 Grades of Concrete
Clause 1703.2 Delete Table 1700.2 and 1700.3 and substitute as below:
a) For bridges In prestressed concrete or those with total length more than 60 m or
those that are built with Innovative deslgnlconstruction.

Structural Member Minimum grade of Minimum grade of Maximum water cement


concrete Conditions of concrete Conditions of ratio conditions of exposure
Exposure Exposure

Moderate Severe Moderate Severe


a) PCC members M25 M30 360 0.45 0.45
b) RCC members M30 M35 380 0.45 0.40
c) PSC members M35 M40 400 0.40 0.40

b) For bridges other than those mentioned in Table A for culvers and other incidental
construction.

Structural Member Minimum grade of Minimum grade of Maximum water cement


concrete Conditions of concrete Conditions of ratio conditions of exposure
Exposure Exposure

Moderate Severe Moderate Severe Moderate Severe


a) PCC members MI5 M20 250 310 0.50 0.45
b) RCC members M20 M25 310 360 0.45 0.40

I) Conditions of exposure
-
Severe Marine environment: alternate wetting and drying to sea spray; alternate wetting
and drying combined with freezing, buried in soil (having corrosive effect); members in
contact with water where the velocity of flow and the bed material are likely to cause erosion
of concrete.

2) Moderate - conditions other than 'severe'

3) The minimum cement content is based on 20mm size aggregates. For larger size
aggregates it may be reduced suitably by not nore than 10 percent Similarly for smaller size
aggregates, it may be suitably increased, but not more than 10 percent.

4) For under water concreting the cement shall be increased by 10% more than that required to
develop the strength for the same mix placed in dry. However it shall not fall below the
minimum cement content specified in above table.
Add the following at the end of this Clause.
Nominal mlx concrete is that concrete for which concrete is n o wj
:g
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designed by tests and in which the proportions of materials are in accordance


with the drawings and the specification Clause mentioned below:
i) All the materials for this concrete shall conform to section 1000 of MORTH.
ii) Minimum cement content and maximum water cement ratio for above said
nominal mix concrete shall conform IRC 21-2000 Table -7:- Proportions
for Nominal Mix Concrete.
iii) Mixing of above-said nominal mix concrete shall conform to Clause 1708
of MORTH.
iv) Transporting, Placing and Compaction of above said nominal mix concrete
shall conform to Clause 1709 of MORTH."
Clause 1704 Proportioning of Concrete
Last sentence of paragraph 1 shall be as follows :
'Other type of admixtures shall be used with the approval of the Engineer."
Clause 1704.6 Add the following as clause 1704.6
'Materials for pumped concrete:
Materials for pumped concrete shall be batched consistently and uniformly.
Maximum size of aggregate shall not exceed one-third of the internal diameter
of the pipe.
Grading of aggregate shall be continuous and shall have sufficient ultra fine
materials (materials finer than 0.25 mm). Proportion of fine aggregates passing
through a 0.25 mm sieve shall be between 15% and 30% and that passing
through 0.125 mm sieve shall not be less than 5% of the total volume of
aggregate. Admixtures to increase workability can be added. When pumping
long distances and in hot weather, set retarding admixtures can be used. Fluid
mixes can be pumped satisfactorily after adding plasticisers and super
plasticisers. Suitability of concrete shall be verified by trial mixes and by
performing pumping tests."
Clause 1705 Admixtures
This Clause shall be read as under:
"Duly tested admixturesladditives conforming to 1816925 and IS:9103 (without
replacement of cement) may be used subject to satisfactory proven use, with
the approval of the Engineer. Admixtures generating hydrogen or nitrogen and
containing chlorides, nitrates, sulphides, sulphates and any other material
liable to adversely affect the steel or concrete, shall not be permitted.
The admixture shall be compactable with cement.
The general requirements, physical and chemical requirements shall be as per
Clause 1012."
Clause 1707 Equipment
Paragraph 1 of this Clause shall read as under:

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"Unless specified otherwise, equipment for production, transportation and


compaction of concrete shall be as under"
a) For Production of Concrete:

i) Batching and mixing of the concrete shall be done in a concrete


batching and mixing plant fully automatic of a suitable capacity. The
plant shall be approved by the Engineer
ii) In special case, for culverts, the Engineer may allow mixing of
concrete by a diesel or electrically operated mechanical mixer with
integrated weigh batching facility having a capacity of 0.5 cum. And
automatic water measuring system.

Clause 1709 Transporting, Placing And Compactlon Of Concrete


Add the following paragraph at the end of the clause :
"For Placing Concmte with Pumps: Pipe lines from the pump to the placing
area should be laid out with a minimum of bends. For large concrete
placements, standby pumps shall be available. Suitable valves (air release
valves, shutoff valves, etc.) shall be provided as per the site needs. The
pumping of concrete shall be preceded by a priming mix to lubricate the pump
and pipeline. A rich mix of creamy consistency shall be required for lubricating
the pipelines. Continuous pumping shall be done to the extent possible. After
concrete has been placed the lines and all related equipment shall be cleaned
immediately. A plug sponge ball shall be inserted in the end near the pump
and shall be forced through the line by either water or air pressure. Pipes for
pumping should not be made from materials which can harm concrete.
Aluminium alloy pipelines shall not be used".
Clause 1710 Construction Joints
"In the first paragraph add after the words "the surface shall be roughened" the
words 'the coarse aggregate shall be made visible to a depth of 5mm to
1Omm"
In the third paragraph under the heading "Preparation of the Surface of the
Joint" add the following at the end of paragraph:
"Bush hammering is not permitted since it loosens the coarse aggregate and
results in extensive microcracks."
Concreting of Joints:
Under the heading 'Concreting of Joints", add the following at the end of sub-
para 3:
"At vertical construction joints, a fine mesh on the inner surface of the stopping
board shall be placed, if directed by the Engineer, to facilitate removal of
laitance"

i
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Clause 1712 Adverse Weather Condition


Clause 1712.2 Hot weather Conditions
Add the following at the end of paragraph 1 of the above clause:
"Where the Contractor proposes to use ice to cool the concrete or mixing water
or any of the ingredients, the Contractor shall provide a refrigeration plant to
avoid use of contaminated ice."
Clause 1713 Protection and Curing
Clause 1713.1 Water Curing
Add the following at the end of paragraph 1.
"Wherever possible, use of water sprinklers or perforated pipes should be
encouraged for curing of concrete. Such arrangement must be maintained for
a minimum period of 14 days after concreting.
Approved concrete curing compounds should be preferred where water curing
cannot be done reliably".
Clause 1715 Tolerances
Clause 1715.1 Sectional Dimensions
Add the following as the second sentence of the Clause:
In the absence of any information in drawings or specifications, for particular
cases, the following limitations shall apply:

r
Dimension (mm) 'a' Tolerances (mm)
'6. = (anornln.l- aactua)l
a 5 200 I6.I <5
200<as2000 16,1 ~ 3 . +5 0.0075a
2000 < a 16.1 4 6 . 5 + 0.001a

~ i n aDetailed
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Clause 1715.2 Deviations from Position etc.


Deviation from specified position in plan
a) Variation in levels at top + 10mm
b) Variation of reduced levels of bearing areas +5mm
c) Variation in plumb over full height of piers + 10mm
d) Surface irregularities measured with 3 m straight edge
i) all surfaces except bearing areas +5mm
ii) bearing areas + 3 mm

e) Variation in length of superstructure - overall and


length between bearings + 10mm
or +0.1% of the
span length, whichever is lesser
Clause 1716 Tests and Standards of acceptance
Clause 1716.2.5 Add "by 3mpamafter the comprehensive strength in sub para (a).
Clause 1716.6 Add at the end of the clause.
Any concrete which gives results below the specified limits in relevant codes
or becomes severely damaged due to cracking or shows excessive honey-
combing and exposure of reinforcement or exhibits any fault which, in the
opinion of the Engineer, so seriously impairs its function that it cannot be
accepted as sub-standard work, shall be declared defective concrete. Such
concrete shall be cut out, removed and replaced by fresh concrete of the
specified quality at the Contractor's cost to the satisfaction of the Engineer.
In case of doubt regarding grade of concrete used, either due to poor
workmanship or based on results of cube crushing strength, tests of concrete
on the basis of any or all of the following shall be carried out. The Engineer
shall be the final authority for interpreting the results of all these tests and the
Contractor shall carry out these tests at his own cost if the tests reveal that
the concrete fails to meet the requirements of the Contract.
a) Core Tests
The points from which cores are to be taken and the number and size of
cores required shall be instructed by the Engineer and shall be
representative of the whole of the concrete being investigated. In no
case, however, shall fewer than three cores be tested. Cores shall be
prepared and tested as described in IS : 516. Concrete in the member
represented by the core tests shall be considered acceptable if the
average equivalent strength of 85% of the corresponding specified grade
of concrete is achieved. The Contractor shall make good the areas from
which the cores were taken to the satisfaction of the Engineer.

Final Detailed Project Report. Vol. V : ~ e c h n i kSpecifications


l
Contract Package -NS 82 (TN)
~4 b) Other nondestructive tests
The Engineer may instruct nondestructive tests such as rebound
hammer tests or ultrasonic tests.
L4
SECTION 1800 PRESTRESSING
rq
Clause 1801 General
h Add the following as the last paragraph of this clause:

n Prestressing system shall conform to FIP Recommendation-


"Recommendations of acceptance of post-tensioningsystems" June 1993."
h
Clause 1802 Materials
h
Clause 1802.2 Sheathing
A I* para is modified as follows:
h The sheathing ducts shall be corrugated type.
High density polyetheline pipe conforming to IRC21-2000 shall only be
provided.
h
Clause 1802.2.2 Replace existing Clause with the following:
The internal area of the sheathing d u d shall be in accordance with the
recommendations of the system manufacturer. In case of 7T13, 12T13, and
19T13 sizes of tendons comprising of 12.7 mm dia strands, the inner
diameter of the sheathing shall not be less than 55 mm, 75 mm and 85 mm

-- Clause 1802.2.3
respectively or those shown in the drawing, whichever is greater. These
dimensions are for post threaded cables.
Add at the end of the clause 'As the project area is under severe environment

-
condition the cables shall be post threaded only.
Clause 1803 ~ e s t iofi Cable1
~ Anchorage Assembly
Add following Paragraphs to the section.
All samples shall be representative of the lot and in the case of wire or strand
shall be taken from the same master roll. At least 5.0m length shall be
selected from each lot for testing. Also two anchorage assemblies, complete
with distribution plates of each size or types to be used, shall be tested
-
Testing of anchorage cable assemblies shall be carried out in accordance
with procedures in FIP document "Recommendations for the acceptance of
Post Tensioning systems" - June 1993.

A
Test Certificate of not more than 2 years from any recognised Institution can
be accepted.
h Clause 1804.5 Insert following para after 1st Para

A
-
Mixture of water-soluble oil such as Drornas B and Water is to be flushed
through empty metallic ducts if used before threading of cables, and after
h
threading of cable at frequency of at least once in a month.
formed on sheathing1 prestressing steel shall be fully flushe

-
A
fi clean water before final grouting by cement grout.

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Clause 2005 Elastomeric Bearings


-- Clause 2005.3 Acceptance Specifications
In para 5, substitute the words "Engineer or his authorized representative" for
the word "Inspector".
Clause 2005.3.5 Inspection Certificate
In para 4, substitute the words "Engineer or his authorized representative" for
the word "Inspector."
Clause 2006 Pot Bearings
This Clause shall read as
"Pot bearing shall confirm to IRC 83 (Part -111) -2002."
Clause 2011 Paper bearing
Add clause 2011af&erthe clause 2010 as under:
Paper bearing shall be reinforced bitumen laminated Krafi paper conforming
to the requirements of IS- 1398.
SECTION 2200 SUB- STRUCTURE
Clause 2204 Piers and Abutments
Para 2 is replaced as follows:
Add the following paragraph at the end of clause:
"Where necessary suitable cofferdams or other means shall be provided to
exclude water from the construction area the Contractor shall provide
necessary pumping equipment for dewatering in working areas".
Clause 2204 Rate
This Clause shall read as follows
"The contract rate for masonry, concrete and reinforcement in substructure
shall include all works as given in respective sections and cover the cost of
incidental items like providing cofferdams, dewatering, providing special
formwork, where necessary, and all other items for furnishing and providing
substructure as mentioned in this section."
Section 2300 Concrete Superstructure
Clause 2304.2 RCC T-beams and slab
Pracast RCC T beam construction only will be permitted
Clause 2305.1 PSC Girder and Composite RCC slab
The first line of the 1" para is modified as follows
'PSC girder shall be precast only as mentioned on the drawing or as directed
by the Engineer."
SECTION 2500 River Training Works and Protection Works
m
I

1 2
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Clause 2504 PitchlnglRevetment on Slopes


The heading of this Clause shall be read as under:
"PitchinglRevetment on slopes and filter media"
Clause 2504.2.2 Filter Media
Para 1 of this Clause shall be read as under:
The material for the filter media shall consist of sand, gravel, stone or coarse
sand to prevent escape of the embankment material through the voids of
stone pitchinglweep holes in abutments as well as to allow free movement of
water without creating any uplift head on pitching, One or more layers of
graded materials, commonly known as filter medium, shall be provided
underneath the pitching. The material for filter media behind abutment shall
conform to general guidelines give in Appendix 6 of IRC-78.

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oprabn-oag

SECTION 2600 EXPANSION JOINTS


Clause 2602 General
Add the following at the end of the clause.
The Ministry of Surface Transport had issued modified interim specifications
for expansion joints vide letter No. RWINH -3405911196-S&R dated
31/11/2000. These specifications are also included vide following
modifications.
TABLE R-I
SUITABILITY CRITERIA FOR ADOPTION OF DIFFERENT TYPES OF EXPANSION JOINTS
SI. Type of Suitability for Expected Special Consideration
No. Expansion adoption Joint Service Life

Buried Joint Simply supported 10 Years Only for deck with bituminous1
spans upto 10 metres asphaltic wearing coat. Steel
plate may need replacement,
if found corroded or distorted
at the time of relaying1
renewal of wearing coat.
Filler Joint Fixed end of simply 10 Years The sealant and joint filler
supported spans with would need replacement if
insignificant movement found damaged.
or simply supported
spans not exceeding 10
metres.
3. Single strip Moderate to large 25 Years Elastomeric seal may need
seal joint' simply supported, replacement during service.
cantilever1 continuous
construction having
right, skew or curved
deck with maximum
horizontal movement
upto 50 mm
* These are proprietary items for which 10 years warranty
suppliers.
L
shall be insisted upon from the

J
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Contract Package -NS 82 (TN)
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Clause 2607 IV. STRIP SEAL EXPANSION JOINT


This Clause shall be read as under:
Clause 2607.1 Components
Strip seal expansion joint shall comprise the following items:
a) Edge Beam
This shall be either extruded or hot rolled steel section or cold rolled cellular
steel section with suitable profile to mechanically lock and seal element in
place throughout the normal movement cycle. Further the configuration
shall be such that the section has a minimum thickness of 6 mm all along
the cross section. The minimum height of the edge beam section shall be
75 mm.
b) Anchorage
Edge beam shall be anchored to the deck by reinforcing bars, headed studs
or bolts or anchor plates cast in concrete or a combination of anchor plate
and reinforcing bars, headed studs or bolts. Anchor bars, studs or bolts .
shall engage the main structural reinforcement of the deck and in case of
anchor plates or loops, this shall be achieved by passing transverse bars
through the loops or plates.
The minimum thickness of anchor plate shall be 12 mm. Total cross
sectional area of bar studs or bolts on each side of the joint shall not be
less than 1600 mm Sq. per metre length of the joint and the center to center
spacing shall not exceed 250 mm. The ultimate resistance of anchorages
shall not be less than 500 KNlm in any direction.
Clause 2607.2 Material
a) The steel for edge beams shall conform to any of the steel grade
corresponding to RST 37-2 or 37-3 (DIN), ASTM A36 or A588, CANlCSA
Standard G 40.21 Grade 300 W or equivalent.
b) Anchorage steel shall conform to IS : 2062 or equivalent.
c) All steel sections shall be protected against corrosion by hot dip galvanizing
or any other approved anticorrosive coating with a minimum thickness of
100 micron.
d) Chloroprene of strip seal element shall conform to Clause 915.1 or IRC : 83
(Part-11). The properties of chloroprene shall be as specified in Table-I.
Clause 2607.3 Fabrication (Pre-Installation)
The strip seal joint system and all its component parts including anchorages
shall be supplied by the manufacturer1system supplier.
The width of the gap to cater for movement due to thermal effect preskess,
shrinkage and creep, superstructure deformations (if any) and sub-structure
deformation (if any) shall be determined and intimated to the rna-urer.

~-

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Contract ~ a c k a ~ 82 e -(TN)
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Depending upon the temperature at which the joint is to be installed, the gap
dimension shall be preset.
- -
TABLE R 2 STRIP SEAL ELEMENT SPECIFICATION
Sealing element is made of chloroprene and must be extruded section. The
working movement range of the sealing element shall be at 70 mm.

PROPERTY SPECIFIED VALUE


Hardness
DIN 53505 63 f 5 Shore A
ASTM D 2240 (Modified) 55 * 5 Shore A
Tensile Strength '
DIN 53504 Min I 1 MP
ASTM D 412 Min 13.8 MPa
Elongation at fracture '
DIN 53504 Min 350 per cent
ASTM D 412 Min 250 per cent
Tear Propagation Strength
Longitudinal Min 10 Nlmm
Transverse Min 10 Nlmm
Shock Elasticity Min 25 per cent
Abrasion Min 220 Cu.mm
Residual Compressive Strain
(22 h17O deg Cl30 per cent Max 28 per cent
strain)
Ageing in hot air
(14 days170 deg. C)
Change in hardness Max +7 Shore A
Change in tensile strength -
Max 20 per cent
Change in elongation at fracture Max - 20 per cent
Ageing in ozone
(24 hl50 pphm125 deg Cl20 per No cracks
cent elongation)
Swelling behaviour in Oil
(168h125 deg. C)

.- ASTM Oil No. I


A

A
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i
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PROPERTY SPECIFIED VALUE


Volume Change Max + 5 per cent
Change in Hardness -
Max 10 Shore A
ASTM Oil No. 3
Volume Change Max + 25 per cent
Change in Hardness Max + 20 Shore A
Cold Hardening Point -
Max 35 deg. C
"Only one set of specifications viz. ASTM or DIN shall be followed depending
on the source of supply"
c) Each strip seal expansion joint system shall be fabricated as a single stage
construction as excessive length prohibits monolithic fabrication. It shall fit
the full width of the structure as indicated on the approved drawing. The
system shall be pre-set by the manufacturer prior to transportation.
Prestressing shall be done in accordance with the joint opening indicated
on the drawing.
d) The finally assembled joint shall then be clamped and transported to the
work site.
Clause 2607.4 Handling and Storage
a) For transportation and storage, auxiliary brackets shall be provided to hold
the joint assembly together.
b) The manufacturerlsupplier shall supply either directly to the Engineer or to
the Bridge Contractor all the materials of strip seal joints including sealants
and 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.
Clause 2607.5 Installation
a) The joint shall be installed by the manufacturerlsupplier or their authorized
representative who will ensure compliance to the manufacturer's
instructions for installation
b) 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 be 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
c) The recess shall be shuttered in such a way that dimensions in the joint
drawingare maintained. The formwork shall be rigid and firm.
.. \
,' . ..
d) Immediately prior to placing the joint, the presetting
Should the actual temperature of the structure be

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temperature provided for presetting, correction of the presetting shall be


done. After adjustment, the brackets shall be tightened again
e) 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 anchorage steel on the 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
f) High quality concrete shall then be filled in to the recess. The packing
concrete must feature low shrinkage and have the same strength as that of
the superstructure, but in any case not less than M-35 grade. Good
compaction and careful curing of concrete is particularly important. After
the concrete has cured, the movable installation brackets and shuttering
still in place shall be removed
g) The neoprene seal shall be field installed in continuous length spanning the
entire roadway width. To ensure proper fit of the seal and enhance the
ease of installation, dirt, spatter or standing water shall be removed from
the steel cavity using a brush, scrapper or compressed air. The seal shall
be installed without any damage to the seal by suitable hand method or
machine tools
h) As soon as the concrete in the recess has become initially set, a sturdy
ramp shall be placed over the joint to protect the exposed steel beams and
neoprene seals from the site traffic. Expansion joint shall not be exposed to
traffic loading before the carriageway surfacing is placed
i) The camageway surfacing shall be finished flush with the top of the steel
sections. The actual junction of the surfacing Iwearing 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 be cleaned
beforehand. It is particularly important to ensure thorough and careful
compaction of the surfacing in order to prevent any premature depression
forming in it.
Clause 2607.6 Acceptance Criteria
a) All steel elements shall be finished with corrosion protection system.
b) For neoprene seal, the acceptance test shall conform to the requirements
-
stipulated in Table I. The manufacturerlsupplier shall produce a test
certificate accordingly, conducted in a recognised laboratory, in India or
abroad.
c) The manufacturer shall produce test certificates indicating that anchorage
system had been tested in a recognized laboratory to determine optimum
configuration of anchorage assembly under dynamic loading.
d) Prior to acceptance 25 percent of the completed and installed joints, subject
to a minimum of one joint, shall be subjected to water tightness test. Water
shall be continuously ponded along the entire length for a m i q l m u m o d

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of 4 hours for a depth of 25mm above the highest point of deck. The width
of ponding shall be at least 50mm beyond the anchorage block of the joint
on either side. The depth of water shall not fall below 25mm anytime during
the test. A close inspection of the underside of the joint shall not reveal any
leakage.
e) As strip seal type of joint is specialized in nature, generally of the
proprietary type, the manufacturer shall be required to produce evidence of
satisfactory performance of this type of joint.
Clause 2607.7 Tests and Standards of Acceptance
The materials shall be tested in accordance with these specifications and shall
meet the prescribed criteria. The manufacturerlsupplier shall furnish the
requisite certificates from the recognized testing laboratory of India or abroad.
Clause 2609 Measurement for Payment.
Insert the following as the second sentence of the paragraph.
The expansion joint shall be measured along the width of the deck slab from
one end to the other including length through footpaths and parapets.
SECTION 2700 WEARING COAT AND APPURTENANCES
Clause 2702 Wearing Coat
Clause 2702.1.1 This Clause shall read as under:
Bituminous wearing coat shall comprise the following:
i. A coat of mastic asphalt, 12 mm thick, with a prime coat over the top of
the deck before the wearing coat is laid. The prime coat of mastic asphalt
shall be 30% straight run 30140 penetration grade bitumen and 50% light
solvent (Benzol) to be laid over the deck slab. The insulation layer of 12
mm thick mastic asphalt with 75% limestone dust filler and 25% of 30140
penetration grade bitumen shall be laid at 375F with broom over the
prime coat.
ii. 50 mm thick asphaltic concrete wearing coat in a single layer as per
Clause 512 of MORTH specification for Road and Bridge works (3rd
Revision).
Clause 2703.5 RailinglCrash Barrier
Cast-in-situ railingslcrash barrier shall be constructed in accordance with the
requirements of structural concrete Section 1700. The reinforcement shall
conform to Section 1600. The formwork shall conform to Section 1500. The
material for railinglcrash barrier and the work shall conform to relevant clauses
of General Technical Specification. The work in general shall conform to MOST
Specification Section 2700 Clause 2703.
The reinforcement of the crash barrier shall be weldednapped with the existing
reinforcement of the deck slab in the case of existing bridge as shown in the
drawing and work will be executed as per special Specification No. 9.2.pWd

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Clause 2706 Weep Holes
This Clause shall be read as under:
"Weep holes shall be provided in solid plain concretelreinforced concrete, brick
or stone masonry abutments, wing walls, return walls as shown on the drawings
or as directed by the Engineer to drive moisture from the back tilling. Weep
holes shall be provided with 100 mm diameter A.C. pipe and shall extend
through the full width of concrete with slope of about 1 vertical: 20 horizontal
towards the draining face.
The spacing of weep holes shall generally be 1 m in either direction or as
shown on the drawing with the lowest at about 150 mm above the low water
level or ground level whichever is higher or as directed by the Engineer."
SECTION 2800 REPAIR OF STRUCTURES.
Clause 2809 Delete "Dismantling of Concrete wearing coat" and substitute:
"Dismantllng of Existing ConcretelBltumlnous Wearing Coat, Expansion
Joints"
Clause 2809.1 Commencement of dismantling.
Add as sub para (i) as below:
(i) The concrete wearing coat as well as the bituminous overlay shall be
removed from the existing bridges.
Renumber the sub para (i), (ii), (iii) as (ii), (iii) & (iv)
Clause 2809.2 This Clause shall read as follows:
The removal operations shall be carried out mechanically using pavement
breakers and compressors. Removal shall be done carefully to avoid damage to
any part of the existing structure. In delicate locations for example around
spouts, removal shall be done by manual methods. After removal, the concrete
deck surface shall be closely inspected for identifying any distress such as
cracks, pockets of loose or honeycombed concrete etc. The deck surface shall
be thoroughly cleaned with special efforts to remove any loose material.
Expansion joints and spouts shall be removed carefully so that deck concrete is
not damaged.
Clause 2809.3 Precautions during dismantling work
Add the following at the end
'Dismantling material shall not be stacked on the deck nor shall it be thrown
below the bridge. It shall be neatly piled at points designated by the Engineer
with all lifts and lead upto 1000m. Materials, which can be used or auctioned,
shall be stored in neat piles at locations designated by Engineer with all lifts and
lead upto 2000m."
Clause 2812 Measurement for Payment
Add the following to the end of the Clause.
nA
g) Dismantling of wearing coat shall be measured in cubic metre ofiYolume/of
\
'17 -2

,< -
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the wearing coat dismantled.


Clause 2813 Rate
Add the following to the end of the Clause.
The contract unit rate for dismantling the wearing coat shall include the cost of
all materials, labour, tools and plant, traffic management, signage, safety
precautions and other incidental expenses including removal of existing
expansion joints for the satisfactory completion of the work as per these
specifications.
FOLLOWING NEW CLAUSES SHALL BE ADDED
Clause 2814 Dismantling of damaged structures andlor part of existing structures
The work shall be executed in accordance with Technical Specifications
Section 200 clause 202.
All damaged concrete brick woMstone work in coping wing walls, returns,
piers and abutment and caps shall be thoroughly inspected to identify the
extent of dismantling. The decision of Engineer shall be final. Care shall be
taken to avoid damage to any part of the existing structure. Dismantling work
for part of deck slab railing and kerbs shall be done carefully such that the
existing reinforcement, which will project into the new work, is not damaged or
lost. Reinforcement shall be cleaned thoroughly. FP slab shall be removed
carefully and stoned at a suitable distance for use after the upgradation of the
bridge is complete as per details in drawings.
Dismantled material shall not be stacked on the deck nor shall it be thrown
below the bridge. It shall be neatly piled at points designated by the Engineer
with all lifts and lead upto 1000m. Materials, which can be used or auctioned,
shall be-stored in neat piles at locations designated by Engineer with all lifts
and lead upto 2000m.
Water shall be sprayed to reduce the dust while the dismantling work is in
progress. Dismantling work shall not be carried out at night, dcin'ng storms or
heavy rain.
Goggles and gas masks shall be worn at the time of dismantling. Leather
gloves shall be worn by the workers. Screens made of G.I. sheets shall be
placed wherever necessary to prevent the disintegrated pieces from flying.
Damage caused to any component of the bridge structure during removal
operations shall be restored by the Contractor at his cost. The service lines, if
any, shall be disconnected Idiverted before dismantling work commences.
Clause 2814.1 Dismantling of existing railings, kerbs, footpath slabs, approach slabs
and damaged concrete i n wing wallslreturns, piers and abutments
Railing, kerbs, concrete (P.C.C.) parapet erected in place of damaged railing,
footpath slabs, approach slabs and damaged concrete in wing walls/returns,
piers and abutments of the existing structures shall be dismantled as shown in

carefully and stored at a suitable distance for use in future.

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
4/6 Laning of Karur - Madurai Sections of NH-7

Clause 2814.2 Dismantling of exlsting slab


The depth of cutting of the existing deck slab shall be as shown in the
drawings. Dismantling shall be done in accordance with Standard
Specification section 200
Clause 2814.3 Dismantling of existing damaged stone1 brick masonry i n pier, abutment,
wing wallslreturns, parapet, etc.
Damaged stonelbricks masonry in pier, abutment, wing wallslreturns and all
stonelbrick parapet shall be dismantled as shown in drawings or as directed by
the Engineer.
Ciause 2814.4 Dismantling of existing wing wall for construction of adjacent one lane
-
bridge a) StonelBrick masonry b) Concrete
Part of existing stonelbrick masonrylconcretewing wall shall be dismantled for
construction of adjacent 1 lane bridge as shown in drawings and Specification
No. 2814 above or as directed by the Engineer.
Clause 2814.5 Measurement for Payment
The work of dismantling structures shall be paid for in units by taking
measurements before and after as applicable.
i. Railing and kerb together linear metre
ii. Footpath slab square metre
iii. Approach slab cubic metre
iv. Dismantling bricklstone masonry1
v. concrete (plain 8 reinforced) cubic metre
Clause 2814.6 Rate
The contract unit rate for the various items of dismantling shall be paid in full
for carrying out the required operations including full compensation for all
labour, materials, tools, equipment, safeguards and incidentals necessary to
complete the work. These will also include excavation and backfilling where
necessary to the required compaction and for handling, salvaging, piling and
disposing of the dismantled materials within all lifts and up to a lead of 1000m.
Clause 2815 Providing New Wearing Coat With Profile Corrective Course For New
Cross Camber 1/60
Clause 2815.1 Scope
In order to have a cross slope of 1160 in all existing bridges whether the cross-
section is retained or widened, profile corrective course of Semi-Dense
Bituminous Concrete (SDBC) shall be laid over the structural deck slab after
the top has been exposed by removing the existing wearing coat (refer to
clause 2809). The existing wearing coat will be basically of PCC with or
without surface reinforcement, but can also have top bituminous overlay, which
had been provided subsequently as a leveling course.

Final Detailed Project Report. Vol. V :Technical Specifications lLPage


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Contract Package -NS 82 (TN)


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Clause 2815.2 Construction Operations


The profile corrective course of SDBC of variable thickness has to be laid over
the existing carriageway. For T girder bridges, which are not being widened,
the maximum thickness of profile corrective course will be at the existing
Centre Line. For slab bridges, which are being widened, the maximum
thickness of profile corrective course will be at the kerb toward the central
verge because of unidirectional camber.
Slab bridges are being widened with slab extensions. The top of extended slab
will have a cross slope of 1/60 and no profile corrective course will be required
for the widenedlextended portion of the slab bridge.
A tack coat confirming to standard specification clause 503 shall be applied
over the exposed surface of deck slab before the application of SDBC. In
addition, tack coat has to be provided on new concrete surface of widened
portion.
The SDBC shall follow standard specification clause 508.
Bituminous concrete confirming to standard specification clause 509 shall be
laid as component of wearing coat over the SDBC in the existing bridge portion
and directly over concrete on the new widened concrete slab. Tack coat has to
be provided on new concrete surface
The Mastic Asphalt (MORTH specification clause no. 515) shall be overlaid as
the other component of wearing coat on the bituminous concrete
Clause 2815.3 Measurement for Payment
The profile corrective course (PCC) shall be measured in cubic metres, as
running continuously through. The tack coat shall not be measured. The work
of wearing coat shall be measured in square metres.
Clause 2815.4 Rate
The contract unit rate for profile corrective course shall include the cost of tack
coat and shall also cover cost of all materials, labour, tools, plant and
equipment required for mixing, transporting and placing in position, vibrating
and compacting and finishing as per this section or as directed by the
Engineer, including all incidental expenses, sampling and testing, quality
assurance and supervision'
Clause 2816 Reinstating The Existing Damaged Handrails, Kerbs, Etc
Clause 2816.1 Scope
For repair of kerb, raillrailing post etc., cement sand mortar (1:3) shall be
applied. Missing reinforcement if any shall be compensated before application
of mortar.
Damaged rails of the railing shall be replaced by rails of same size and
reinforcement as given in MORTH drawings. Both the above operations shall
be done as per relevant provisions of MoRTH Technical specification clause
2703.3 & 2703.4

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Clause 2816.2 Measurement for Payment


The measurement shall be done in linear metres of railings repaired.
Clause 2816.3 Rate
The contract unit rate 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.
Clause 2817 Provision of New Drainage Spouts And Repair of Existing Drainage
Spouts
,
Clause 2817.1 Provision of new drainage spouts:
For all existing bridges that are being widened and changed to unidirectional
camber drainage spouts shall be provided as shown in the drawings.
The work of new drainage spout shall be executed in accordance with
Technical Speclficatlon Section 2700 Clause 2705
Clause 2817.1.1 Measurement for Payment
The measurement for pmvision of new drainage spouts shall be done in
number of drainage spouts provided.
Clause 2817.1.2 Rate
The contract unit rate for each drainage spout shall include the cost of all
labour, material, tools and plant required for completing the work as per the
specifications. It shall also include the cost of closure of existing drainage
spouts and providing flow drainpipes with all fixtures up to the point of ground
drains wherever shown on the drawings.
Clause 2817.2 Closure and sealing of existing drainage spouts:
The work shall be done after the wearing coat is removed. The grating shall be
dismantled and the existing spouts shall be removed carefully with minimum
damage to surrounding concrete.
The pocket formed shall be sufficiently large to ensure good flow and
compaction of concrete in the hole. The area around the spout covered by the
grating shall be provided with PMC slurry
Before commencing application of PMC slurry brush topping, the prepared
concrete substrata shall be thoroughly soaked with clean water. Before priming
it should be ensured that any free surface water is removed. The material shall
be applied in accordance with manufacturer's recommendations. Suitable steel
rods shall be placed vertically in the drainage spout and then concreting shall
be done in the hole. And then the steel shall be embedded in the concrete
poured over the grating area
The specifications for polymer modified cementitious topping & mortar shall be
as per of Additlonal Technical Specifications A-3 (1.7).
Clause 2817.2.1 Measurement for Payment
, - ' , ":. .
The closure of drainage spouts shall not be measured. \.

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Clause 2817.2.2 Rate


The rate for such closing shall be deemed to have been included in the cost of
new drainage spouts provided in the widened portion.
Clause 2817.3 Extension of existing drainage spouts:
For bridges that are not being widened, the existing drainage spouts are to be
retained with minor repairs. The work shall be carried out as shown in the
drawing. The concrete surrounding the spout in the soffit of the slab shall be
chipped out. An extension collar of specified size shall be attached to the
existing pipe as shown in the drawing. The chipped out area shall then be filled
with 1:4 cement sand mortar over which a 10mm thick layer of PMC repair
mortar shall be applied.
Clause 2817.3.1 Measurement for Payment
Drainage spout repair shall be measured in numbers
Clause 2817.3.2 Rate:
The contract unit rate for each drainage spout shall include the cost 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 drainpipes in
girder bridges with all fixtures up to the point of ground drains wherever shown
on the drawings.
Clause 2818 Repair t o Honeycombed, Spalled Concrete:
Honey combed, spalled concrete should be cleaned and cleared (plaster
removed) before the start of repair operation. If necessary, should be cleaned
vigorously with wire brush.
The work shall be executed in accordance with Technical Specification
Section 2800 and special Specification A-3 (1.4 & 1.5).
Clause 2818.1 Measurement for Payment
Measurement for application of PMC mortar for specified thickness shall be
per square metre of surface area of application:
Clause 2818.2 Rate
The contract unit rate for application of PMC mortar for specified thickness
including cement mortar 1:4 wherever required, shall include cost of all
materials, labour, tools and plant, placing in position, testing and other
incidental expenses including surface preparation for the satisfactory
completion of the work as per these specifications and as shown in the
drawings.
Clause 2819 Sealing of Cracks In Concrete:
The work is to seal all cracks in slab, girders and substructures
The work shall be executed in accordance with Technical Specification
Section 2800 Clause 2803,2804 and Additional Technical Specification A-
3 ( I .I& 1.2).
P
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Clause 2819.1 Measurement for Payment


Fine Crack:
Measurement for sealing of fine crack by application of PMC mortar for
specified thickness along with application of PMC slurry for proper bondage of
old concrete and PMC mortar shall be linear metre of crack.
Wide crack:
Measurement for sealing of cracks and injection shall be made by weight of
cement consumed in kg for cement grouting.
For provision of nipples required for grouting, the payment shall be for number
of nipples inserted
Clause 2819.2 Rate
Fine Crack:
The contract unit rate for application of PMC 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
satisfactory completion of the work as per these specifications and as shown in
the drawings.
Wide crack:
The contract unit rate for sealing of cracks and injection of cement grout shall
include cost of all materials, labour, tools and plant, placing in position, testing,
curing and other incidental expenses for the satisfactory completion of the
work as per these specifications
Injection nipples are being paid separately.
Clause 2820 Voids in Soffit of Girder
Portions of the soffits of the girder wherever voids are anticipated shall be
chipped off so that films forming external soffit surface are removed exposing
the reinforcement. Loose concrete sticking with the reinforcement shall be
removed using appropriate tool and equipment. Polymer modified concrete
15mm thick shall be applied and after that cement plaster 1:4 shall be applied
so as to have the entire soffit in one straight line.
The work shall be executed in accordance with Additional Technical
Specification A-3 (1.3)
Clause 2820.1 Measurement for Payment
Measurements for reshaping of soffit of girder with PMC and Cement Plaster
(1:4) shall be square metre of surface area of application.
Clause 2820.2 Rate
The contract unit rate for application of PMC 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
satisfactory completion of the work as per these specifications and as s w n in

Final Detailed Project Report. Vol. V : Technical Specifications Page 8laf +w"
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the drawings.
Clause 2821 Sealing of Wide Cracks at Junction of Wing Wall and Abutment Wlth
Brick Bats and Finishing with 1:3 Cement Mortar.
Wide cracks of different degreelextent due to separation of masonry/PCC
substructure such as wing wall abutments etc. shall be sealed by cement grout
after filling the gap followed by the application of sealing material. The work
shall be executed in conformity with Technical Specification Section 2800
Clause 2806 and Additional Technical Specification A 3 (1.2). Gaps shall
be sealed by filling sized stoneslbrick bats and finishing with cement plaster
(1:3).
Clause 2821.1 Measurement for Payment
Measurements for sealing of cracks and injection shall be made by weight of
cement consumed in kg for cement grouting. For provision of nipples required
for grouting, the payment shall be for number of nipples inserted.
Clause 2821.2 Rate
The contract unit rate for sealing of gap, cracks and injection of cement grout
shall include cost of all material including the gap filling material, labour, tools
and plant, placing in position, testing, curing and other incidental expenses for
the satisfactory completion of the work as per these specifications.
Clause 2822 Repair of Spalling Due to Weathering /Loss of Cover
The work is to repair spalls or loss of cover in abutment, pier substructure and
gaps. This shall be executed in accordance with Technical Specification
Section 2807 and Additional Technical Specification A-3 (1.6 (a) & (b))
and 1.7
Clause 2822.1 Measurement for Payment
Measurement for guniting shall be square metre of area of application.
Clause 2822.2 Rate
The contract unit rate for guniting shall cover cost of all materials, labour, tools,
plant, placing in position, tasting, curing and surface preparation and other
incidental expenses for the satisfactory completion of work as per
specification. It shall also include the cost of the provision of steel weld mesh
as per specification.
Clause 2823 Providing and Inserting Nipples for Cement Injections
The work shall include providing and inserting nipples with approved fixing
compound after drilling holes, and affer operation, cutting and removing
nipples and sealing the holes.
Clause 2823.1 Measurement for Payment
Measurement for Payment for making provision of nipples required for groutim-
shall be for number of nipples inserted
'/lt
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FRFNDI-~~~~,,~, mr;lb;l;lmlm

Clause 2823.2 Rate


The rate will include cost of cement nipples, admixture fixing compound, all
material and labour in drilling fixing and cutting af&erthe job and removal and
sealing the holes including the cost of drilling equipment, cost of drill, bits and
spares wastage etc.
Clause 2824 Casting of Approach Slab with M-30 Grade.Concrete
Approach slabs are to be provided for the new widened carriageway of
bridges. In addition, approach slabs, which are cracked or otherwise damaged,
shall be recast.
The work shall be executed in accordance with Technical Specification
Section 2700 Clause 2704. The approach slab shall be laid over lean
concrete as per drawing. The base shall be consolidated by ramming with
water.
Clause 2824.1 Measurement for Payment
The measurement shall be in cubic metre
Clause 2824.2 Rate
The contract unit rate for approach slab shall include the cost of all labour,
material, tools and plant and other cost necessary for completion of 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.
Clause 2825 Expanded Metal Sheet
Expanded metal sheet of size 75 mm x 200 mm, 3.25 mm wide and 3.15 mm
thick @ 2.141 kg1sq.m shall be provided over the steel plate placed at the
expansion joint and welded.
Clause 2825.1 Measurement for Payment
This provision of expanded metal sheet shall not be measured and shall be
deemed to have been included in the cost of provision of expansion joints.
Clause 2825.2 Rate
The contract unit rate shall include provision, placing in position of the sheet as
per drawing and specifications, and welding also.
SECTION 2900 PIPE CULVERTS
Clause 2904 Bedding for Pipe
Delete the word 'rammed" in line 6 of paragraph (i) and substitute it with 'by
Rollerlor plate vibrator."
Clause 2907 Backfilling
The Second sentence of this clause shall be replaced as below:

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SECTION 3000 MAINTENANCE OF ROAD


Clause 3001 General
This Clause shall be read as under:
"The Specifications shall apply to all items of road 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 the relevant Specifications to
the required level, grade and lines using approved 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, a
reference is made to the 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."
Clause 3002 Restoration of rain cuts
Clause 3002.4 Delete & replace with
"The items shall be measured in km-monthsn
Clause 3002.5 This Clause shall be read as under
'The contract unit rate for maintenance of road shall be inclusive of this item
of work"
Clause 3003.4 This Clause shall be deleted.
Clause 3003.5 This Clause shall be read as under
"The contract unit rate for maintenance of road shall be inclusive of this item
of work"
Clause 3004.4 This Clause shall be deleted.
Clause 3004.5 This Clause shall be deleted.
Clause 3005 This Clause shall be deleted.

\-
Final Detailed Project Report. Vol. V : Technical Specifications Page 84 of 116
Contract Package -NS 82 (TN)
h

rq Additional Technical Specifications


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q*..(mi-ea~hm~ll

ADDITIONAL TECHNICAL SPECIFICATIONS

A-I REINFORCED EARTH, REINFORCED SOIL, MECHANICALLY STABlLlSED


EARTH STRUCTURES
1.I SCOPE
This work shall consist of Design, Engineering, Procurement and Construction of the
Reinforced Earth Structures, Reinforced Soil, Mechanically Stabilised Earth or
Similar Soil Reinforcing systems including supervision as per Appropriate
technology. The different types of structures shall be consists of Pre-cast concrete
facia slabslpanels or hollow blocks, or as advised by the approved system
manufacturer and Reinforcing elements such as galvanized steel strips, or
Geosynthetic (geogridslgeotextiles) with accessories, fittings, drainage materials and
backfill material.
1.2 DESIGN AND ENGINEERING
The scope of work shall cover the supply of detailed design, engineering, submission
of working drawings by the approved specialized supplierlmanufacturer/agency for
the works of Reinforced Earth Structures, Reinforced Soil, Mechanically Stabilised
Earth or Similar Soil Reinforcing systems.
The design shall ensure internal and external stability of the reinforced soil wall,
meeting the requirements of B.S. 8006-1995. The maximum Reinforcing element
design load under working condition for 100 years design life shall be assessed by
applying serviceability limits and ultimate limits, whichever is lower, as stipulated in
B.S. 8006-1995.
Complete design calculations and Cross sections showing layout of reinforcement
and other details such as drainage arrangements shall be provided. Cross sections
shall be provided for approximately every 2m change in the height of the reinforced
soil wall, and keeping in the view changes in reinforcement layout.
The designs and drawings shall be got approved from the Engineer before execution
of work.
A technical representative of the approved supplierlmanufacturershall be present on
site throughout during the casting and erection phases to ensure that the quality of
the works performed by the Contractor is in accordance to the specifications.
All expenses relative to his presence on site shall be borne by the Contractor.
REINFORCING ELEMENT
The reinforcing elements shall be hot dip galvanised steel strips, or Geosynthetics
Material (ie, geogrid reinforcement or geotextiles reinforcement),or any other
proprietary material which may be approved by the engineer and as indicated in the
L4
-
drawinas.

- /-
1.3.1 Hot Dip Galvanised Soll Reinforcing Strips and Tie Strips
A
High adherence hot dip galva

h
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Shapes and dimensions of these elements shall be as shown on the approved


drawings. Tie strips and high adherence reinforcing strips shall be hot rolled. Their
physical and mechanical properties shall conform to European norm EN 10025 or
equivalent IS 2062. Reinforcing the tie strips shall be hot-dip galvanized (not less
thqn 1 4 0 ~to
) conform to the minimum requirements of I S 0 standard 1460 and 1461
equivalent to IS 4559
Reinforcing and tie strips shall be cut to the lengths and tolerance shown on
approved drawings. Holes for bolts shall be punched in the locations shown. They
shall be carefully inspected to ensure they are true to size and free from defects that
mqy impair their strength or durability.
1.3.1.1 Fasteners
*
-
Bolts and nuts shall be hexagonal in shape and high strength screw, conforming to
European norm E25100 Class 10.9 or equivalent IS. They shall be 12mm in
diameter 30mm in length hot-tip galvanized in conformity with ASTM A153 or
,- equivalent IS.
'
a
%' 1.3.2 Geosynthetics.
The geosynthetic material shall be dimensionally stable and able to retain its
geometry under construction stresses and have resistance to damage during
construction, to ultraviolet degradation, and all forms of chemical and biolqgical
degradation encountered in reinforced soil structures. These effects must be
determined by testing and analysis as it may cause deterioration of either the
geosynthetics tensile strength and the geosyntheticlsoil stress transfer mechanisms
within the structure.
All quality control strength of geosynthetics must represent minimum average roll
values (MARV) only (97.5% confidence limit). For testing of the tensile strength of th
geosythetic material. ASTMD4595 shall be performed every 5000 square meters
and test data for each lot of material shall accompany shipments. Samples of
geosynthetics to be used for the project shall be submitted along with documentation
notarized by the manufacturer that the material meets the project specification.
Approval of the material by the ownerlowner's engineer will be required prior to
delivery of the material to site.
Since geosynthetics are manufactured from plastics (polymers), which are visco-
elastic in nature, they are susceptible to creep or long term deformation within the
structures in post construction stages. Creep of polymer is primarily dependent on
the soil ambient temperatures. The manufacturers of geosynthetics materials must
be able to supply creep test datalresults for the period of minimum 10 years over a
tevperature of 40C minimum. (Facing temperature attained in most tropical Indian
climates/locations where geosynthetics is connected to the modular block or facia
papel). The post construction strains in geosynthetics must be restricted below 1.O%
for approach highway retaining walls and 0.5% for abutments (mixed or pure type) to
mget serviceability state requirements.

r* The manufacturer Isupplier of geosynthetics material must conduct site specific .,


tests to assess the potential for construction damage and strength loss in
,
-
A gepsynthetics based on the quality of backfill soil, compaction equipment and ~ f h r t @
\

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* Contract Package -NS 82 (TN)
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utilized and type of geosynthetic proposed for use. The same shall be accounted in
the design as partial factor of safety from construction Iinstallation damages.
Specific chemical compatibility tests to account for adverse effects of pH, chemical,
aqueous solutions of salts, acids and alkalics etc. at soil ambient temperature of
40% (facing temperature) for site specific backfill soils shall be conducted and
accounted in the design as partial factor of safety from chemical degradation on
geosynthetics.
Special measures must be adopted to ensure that risk from fire hazards and thereby
release of toxic fumes are eliminated and the same be accounted for in the detailed
proposal for ensuring structural integrity of the construction.
-
The manufacturer/supplier of the geosynthetic precast concrete facing system
(blocklpanel) as appropriate, must conduct test results to sustainable the choice of
interaction properties (direct sliding and bond coefficients) with site-specific backfill
materials in design calculations.
In no cases must interaction coefficients more than 0.9 and 0.8 respectively be used
in the design for the backfill properties specified in this documents in accordance to
GRI-GG5 test requirements for geogrids and in accordance GR1 -GT6 test
requirement for geotextile.
No joining along principal stress direction in geosynthetics (with fasteners or
connectors) shall be permitted.
1.3.2.1 Geogrid Relnforcement
The geogrid shall be made from high molecular weight, high tenacity polyester (PET)
or high-density polyethylene (HDPE).
Polyester geogrids shall be manufactured by the weaving in tension process and
coated with a protective latex or PVC to maximise the resistance to creep,
hydrolysis, pH and enhance durability during construction and in service. Minimum
mass per unit area (ASTM 05261) of polyester geogrids shall be 225 gsm. The roll
width shall be minimum 5.0 m.
High density polyethelene geogrids shall be manufactgured by extruded, drawn
sheets and by punched and orientation process in one direction so that the resulting
ribs shall have a high degree of molecular orientation, which is continued through the
integral transverse bar. It shall contain adequate stabilisers to enhance stability to
environmental stress cracking (ESC), photo oxidation (UU exposure) and thermal
oxidation. HDPE geogrids must process 100% junction efficiency of QC strength (in
accordance to GR1-GG2-87 test requirements) between longitudinal ribs and
transverse bars for efficient load transfer mechanism. Minimum mass per unit area
(ASTM D5261) of HDPE geogrids shall be 500 gsm. The roll width shall be minimum
5m.
1.3.2.2 Geotextlle Reinforcement
Geotextile shall be made from woven high quality polypropylene (PP) or polyester
(PET) fibres. They shall be manufactured from weaving process. The manufacturer
of geotextile by this process will give rise to warp direction (the direction of fabric is
being made, or long direction), weft or fill direction (the cross direction,. or S&

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direction), and selvedge (edges of the fabric where the weft yarns reverse direction
and gather the outer warp yarns on each side of the fabric).
The geotextile must possess maximum resistance to creep, hydrolysis,
environmental stress cracking (ESC), photo oxidation (UU exposure), thermal
oxidation and installation damages as per ASTM guidelines. Geotextile must
possess sufficient permeability of prevent build-up of hydrostatic pressures in the
reinforced soil mass. Minimum mass per unit area (ASTM D5261) of geotextile shall
be 350 gms.
1.3.2.3 Partial Factors
Partial factors as specified in BS 8006: 1995 shall be used to calculate the long term
design strength of geosynthetic materials of any type proposed to be used as
reinforcement.
Table-1 Default Partial Factors

HDPE based Woven PET


Calculation of 100 years geogrids geogrids based based
long term design strength geotextiles geotextiies
(TD) in accordance with BS
8006:1995 requirements
I I I
1 Partial FOS for creep No Default factors allowed for values of partial factor for
deformation [Tfl,] creep. Manufacturer shall provide values certified by

I I I independent testing /certifying agency.

Partial factor for creep at 40C shall be used for determining


I
the long-term design strength and in evaluating long term
strain of goesynthetic reinforcement in retaining walls and
abutments, as specified in BS 8006-1995.
2 Partial FOS for 1.O 1.O 1.O 1.O
variations in (use only (use only (use only (use only
manufacture from MARV) MARV) MARV) MARV)
control specimens (fm
11)
3 Partial FOS for 1.10 1.10 1.15 1.15
extrapolation of creep
test data (fm 12) ( I 0 years (10 years (10 years (10 years
creep test creep test creep test creep test
results at results at results at results at

damage (susceptibility

, --7

Final Detailed Project Report. Vol. V : Technical Specifications Page 88'of 116
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In all cases, the long term design strength (LTDS) shall be calculated by using the
values of material partial factor of safety based on 100 years service design life. All
partial factors for any type of geosynthetic material proposed in the reinforced soil
systems shall be provided by the manufacturer, and these shall be certified by a
competent independent certifying agency. Provision of such certificate is required
before approval for the material is accorded by the Engineer.
In the absence of values of partial factors as per BS 8006-1995, as specified above,
the minimum partial factors as given in table -1 shall be used in the design, as
default values, except for creep. No default value for partial factor for creep shall be
allowed and it is mandatory for the geosynthetic material supplier to provide certified
values of partial factors for creep as per BS-8006-1995 requirements.
1.3.2.4 -
Certification, Stress Strain Properties
Mechanical properties of the geogrid shall be verified in accordance with EN-DIN
18200 or equivalent standard by both internal quality assurance testing and external
quality control and assurance by an independently authorized and accredited
laboratory. Tensile strength and strain of geogrid shall be tested in accordance with
EN IS0 10319 or equivalent standard.
A British Board of Agreement certificate shall be submitted stating that the geogrid is
certified for use as a soil reinforcement geogrid.
The production of the geogrid shall be EN IS0 9001 certified.
Strain at nominal strength (wide width tensile strength) as per EN DIN IS0 10319 (or
equivalent standard) shall be:
longitudinal = max. 12.5%
transverse = rnax. 12.5%
The total warp strain (including creep) at 10,000 hrs loading shall not exceed 8% at
50% of ultimate tensile strength.
1.4 FAClA MATERIAL
The Facia material shall be Pre-cast Reinforced concrete slabslpanels, or Pre-cast
cement concrete hollow blocks or any other proprietary material that may be
approved by the engineer and as indicated in the drawings.
1.4.1 Precast Reinforced Concrete SlabsIPanels.
Pre-cast Reinforced Concrete Slabs I Panels shall conform to the details and
dimensions shown on the approved drawings. The grade of Concrete shall be
minimum M-35 and shall conform to the requirements contained in Section-1700
'Structural concretenof the MoRTH Specifications.
Reinforcement shall be placed as shown on the drawing and shall conform to the
requirements specified in Section-1600 of the MoRTH Specifications.
1.4.1 .I Casting
The elements shall be cast on a flat area. Connecting pins, PVC pipes and lifting
\
anchors etc., shall be set in place to the dimensions and reinforcing elements guides
shall be set on the rear face, prior to casting. The concrete in each unit shall be
I

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Clause 1806 Tensioning Equipment


Add the following at the end of para 2:
"Jack and Pump shall be calibrated by an approved laboratory prior to use
and then at intervals not exceeding three months."
Clause 1807 Add the following at the end of this Clause:
The Contractor shall submit fabrication drawings, detailing prestressing
cables, anchorages, couplers, chairs and supports, templates or forms
holding anchorage assemblies etc. for Engineer's approval at least one month
before commencement of work in superstructure. Stressing schedules shall
be prepared by the Contractor and submitted to Engineer for approval.
Clause 1808 Add the following at the end of clause1808:
Where directed by the Engineer the Contractor shall perform krll-scale site
test to determine the adequacy of grout mix, equipment and grouting method.
The Contractor shall submit a method statement detailing the test procedure.
Clause 1816 Joints In Construction With Pre-Cast Units
Add new clause:
Joints between a series of precast concrete units which are to be prestressed
together by post-tensioning shall be such as to ensure even transfer of
compression from one unit to another.
Whatever be the method of jointing, the holes of the prestressing steel shall
be accurately made and shall meet one another in true alignment at ends.
Jigs shall always be used. Care shall be taken to ensure that the jointing
material does not enter the duct or press the sheath against the prestressing
steel.
Jointing by application of mortar on the face of a unit and then placing another
unit against it shall not be permitted
Suitability and effectiveness of the method should be got confirmed from a
suitably designed mock-up.

SECTIONZOOO BEARINGS
Clause 2001 Description
Add the following as paragraph 2 of this clause:
Within 180 days of award of work, the Contractor shall submit detailed
specifications, designs and drawings including installation drawings and
maintenance manual, for the approval of the Engineer. Designs shall also
include review and modifications of designs and drawings of bearing
pedestals and other elements required for installation. The installation of
bearings shall be carried out under the supervision of the manufacturer of the
bearings.

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placed without interruption and shall be compacted by the use of an approved
h

e
- vibrator supplemented by such hand-tamping as may be necessary to ensure that
the concrete reaches into the comers of the forms and prevent formation of air
pockets or cleavage planes.
h
1.4.1.2 Curing
The pre-cast elements shall be cured for a sufficient length of time as approved by
the Engineer so that the concrete develops the required compressive strength. Only
fresh potable water shall be used for curing.
h
1.4.1.3 Removal of Forms
The forms shall remain in place until they can be removed without damaging the
elements. The scheme of removal of formwork shall be as per relevant MoRTH
Specifications.
h
1.4.1.4 Scribing
The date of manufacture and batch number shall be clearly scribed on the rear face
of each unit.
1.4.1.5 Concrete Finish
h

- The front (exposed) face of the elements shall have the finish approved by the
Engineer and painted with cement based waterproof paint. The rear face shall have
the-finish of unformed surface and shall be roughly screened to eliminate open
pockets of aggregates.
h
1.4.1.6 Tolerance
A All elements shall be manufactured within the following tolerances:

n All dimensions within : -


+ 5 mm
h
Evenness of the front face : f 5 mm over 1500 mm
Difference between lengths
of two diagonals 10 mm max.
Thickness : k5mm

A
1.4.1.7 Handling, Storage and Transporting
All elements shall be handled, stored and transported in such a manner as to
eliminate the danger of chipping, cracking, fracture and excessive bending stresses.
Elements in storage shall be supported on firm blocks to be located adjacent to the
reinforcing elements to avoid their bending.

h
1.4.1.8 Acceptability
Acceptability of the precast elements shall be determined on the basis of
compression tests, as per MoRTH Specifications and visual inspection. A minimum
of one sample of 6 cubes shall be taken for each lot of 5 cubic metre of concrete or
part thereof produced per day. 50% of these cubes shall be cured in the same
manner as the elements and tested to determine when the elements can be placed
n

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in the structure. Elements shall be acceptable for placement in the structure if the
strength at 7 days, or before, exceeds 75% of the 28 days requirements.
1.4.1.9 Rejection
Elements shall be subject to rejection in case of failure to meet any of the
requirements specified above. In addition, defects indicating imperfect moulding,
honey combing or open textured concrete, shall be sufficient cause for rejection
I.4.2 Precast Cement Concrete Hollow blocks.
The facia material of geosynthetic reinforced soil retaining wall shall be modular
concrete block units, as alternate to discrete slab1 panel facing.
Pre-cast Cement Concrete blocks shall conform to the details and dimensions shown
on the approved drawings. In case of hollow blocks, the outer side of the block have
a minimum thickness of 95mm and inner side 50mm. The hollow area shall not
exceed 40% of the cross sectional area of the block. The grade of Concrete shall be
minimum M-35 as per IRC guide lines and the minimum depth (perpendicular to wall)
of these units shall be 300mm
I.4.2.1 Casting
Modular concrete facing units will be manufactured by dry casting process by fully
automatic block making machine to ensure consistent quality of concrete,
dimensional tolerance, good finish and aesthetic appearance.
I.4.2.2 Curing
The pre-cast blocks shall be cured for a sufficient length of time as approved by
Engineer so that the concrete develops the required compressive strength. Only
fresh potable water shall be used for curing. Steam curing is desirable
1.4.2.3 Scribing
The date of manufacture and batch number shall be clearly scribed on the rear face
of each unit.
1.4.2.4 Concrete Finish
All units shall be sound and free of cracks or other defects that would interfere with
the proper placing of the unit or significantly impair the strength of permanence of the
construction. Any block units with cracks or chips observed during construction shall
be rejected from use
1.4.2.5 Tolerance
Modular concrete block units dimensions shall not differ more than 2 2.5mm except
height, which shall differ more than 2 1.5mm.
Modular concrete block units shall match the colour, surface finish and dimension for
height, width, depth and batter not exceeding Iin 40 to vertical.
I.4.1.6 Handling, Storage and Transporting

in storage shall be supported on firm blocking.

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1.4.1.7 Acceptability
Acceptability of the pre-cast element shall be determined on the basis of
compression tests, as per MoRTH Specifications and visual inspection. A minimum
of one sample of 6 cubes shall be taken for each lot of 5 cubic meters or part thereof
producer per day. 50% of these cubes shall be cured in the same manner as the
elements and tested to determine when the elements can be placed in the structure.
Elements shall be acceptable for placement in the structure if the strength at 7 days,
or before, exceeds 75% of the 2 M a y requirements.
1.5 BACKFILL MATERIAL
The Backfill Material used in the Reinforced Earth Structures, Reinforced Soil,
Mechanically Stabilised Earth and similar soil reinforcing systems shall be granular
material, free from organic or otherwise deleterious materials and shall conform to
the following mechanical and physicalchemical requirements.
1.5.1 Mechanical requirements
Sieve Size Percentage Passing
250mm 100 %
100mm >75 %
# 200 el5 %
Plasticity Index shall not exceed 6.
Coefficient of uniformity Cu = (D6OlDIO) 2 2
The fill material shall have a peak effective friction angle of not less than 32Otested
as per Annexure C, BS-8006-1995.
1.5.2 Physical-chemical requirements
In case metal reinforcements being used, fill materials with a resistivity of 5000 Qcm
or more, are readily acceptable, based on a standard test as directed by the
Engineer.
Materials with resistivity less than 1000 Qcm are inadequate and shall not be used
except as specified in Clause15.4 below.
Materials with resistivity between 5000 and 1000 Rcm are acceptable provided that
in water extracted from soil-water mix, the content of chlorides does not exceed 200
ppm, the content of sulphates does not exceed 1000 ppm, and pH value is in the
range of 5 to 10.
The foundation soil physical-chemical requirements shall also meet the above
criteria. If not, special consideration will be given to the design of Reinforcing
element and Facia material.
1.5.3 Testing
For every 300 Cu.m of backfill material, or whenever the approved source is
changed, one sieve analysis and one measurement of resistivity shall be carried out
for acceptance.

1 . .
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+ 1.5.4 Materials not conforming t o the above


Materials not conforming to the above requirements may be used with the written
consent of Engineer after carrying out tests. Such materials shall be tested for their
functional properties to ensure that they are consistent with the parameters used in
the design calculations.
CONSTRUCION OPERATIONS
The construction of Reinforced Earth Structures, Reinforced Soil, Mechanically
Stabilised Earth or similar soil reinforcing systems shall carried out in accordance
with the specifications and in conformity with the lines, grades, design and
dimensions shown on the approved drawings.
Excavation
The Plan area of the of Reinforced Earth Structures, Reinforced Soil, Mechanically
Stabilized Earth or similar soil reinforcing systems shall be excavated in accordance
with the requirements of General and Special Specifications and in reasonably close
conformity to the limits and construction stages as shown on the approved drawings.
Foundation Preparation
The foundation shall be graded level for a width equal to or exceeding the length of
reinforcing elements or as shown on the drawings. Prior to wall construction, if
required by the Engineer, the foundation shall be compacted with a smooth wheel
vibratory roller. Any foundation soils found to be unsuitable shall be removed and
replaced.
Levelling Concrete
A levelling course of concrete pad shall be provided under walls and seat beams (for
bridge abutments). Such concrete shall have a minimum grade of M-15 (150

-
~ g l c m ~ Maximum
). size of aggregates shall be 20 mm. The pad shall be cured for
24 hours at least before placing of the panels
1.6.5 Erectlon of Facia Material along with Reinforcing element
.- ,'
The erection of Reinforced Earth Structures, Reinforced Soil, Mechanically Stabilised
h
Earth or similar soil reinforcing systems shall be of pre-cast concrete facia
slabslpanels or hollow blocks and reinforcing elements which may be of galvanized

-
e

1.6.5.1
steel strips, or Geosynthetics and in conformity with the lines, grades, design and
dimensions shown on the approved drawings.
Concrete facia slabslpaneis and Reinforcing steel strips.
Pre-cast concrete slabslpanels shall be placed vertically with the aid of a light crane.
For erection, panels are handled by means of lifting devices set into the upper edge
of the panels. Panels shall be placed in successive horizontal lifts in the sequence
shown on the drawings as backfill placement proceeds.
Shapes and dimensions of the reinforcing elements shall be as shown on the
approved drawings. Protective coating material shall be got approved by engineer.
As fill materials is placed behind a panel, the panels shall be maintained in vertical
position by means of temporary wooden wedges placed in the joint at the junction4

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the two adjacent top rows of panels during construction. As construction proceeds,
and a fourth row is erected, the lowest row of wedges can be removed and so on.
Fillers of vertical joints between panels shall be flexible open cell polyurethane foam
strips or non-woven fabric strips (the latter used as joint cover instead of filter) as
approved by the Engineer. Bearing pads for horizontal joints between panels shall
be made of elastomer with vulcanised EPDM.
1.6.5.2 Cement Concrete block units with Geogrld reinforcement
These units will be dry stacked (without mortar) one over the other in a running bond
configuration, vertically. Adjacent units shall be connected by dowels or shear pins to
ensure positive connection with the reinforcing geosynthetic. Tongue and groove
type connections are also acceptable. Hollow area in the blocks shall be filled with
aggregate of 10 to 18mm nominal size during constructions.
Dowels or pins used by the retaining wall supplier to interconnect block units shall
consist of a non-degrading polymer or galvanized steel and be made for the use with
the block unit supplied.
All materials shall be installed at the proper elevation and orientation as shown in the
wall details on the construction plans or as directed by the Engineer. The drawings
shall govern in any conflict between the two requirements.
Broken chipped, stained or otherwise damaged units shall not be placed in the wall
unless they are repaired and the repair method and results are approved by the
Engineer.
The spacing between primary reinforcing geosynthetic shall not be more than
600mm or two block units, whichever is greater.
Overlap of the geogrid in the design strength direction shall not be permitted. The
design strength direction is that length of geogrid reinforcement perpendicular to the
wall face and shall consist of one continuous piece of material. Adjacent sections of
geogrid shall be placed in a manner to assure that the horizontal coverage shown on
the plans is provided. A minimum 100mm overlap shall be allowed between
adjacent roll widths.
Geogrid reinforcement should be installed under tension. A nominal tension shall be
applied to the reinforcement and maintained by staples, stakes or hand tensioning
until the reinforcement has been covered by at least 200mm of soil fill.
Backfill Placement and Compacting
The reinforcing elements shall be laid free from all kinks, damage and displacement
during deposition, spreading, leveling and compaction of the fill. The programme of
filling shall be such that no construction plants runs directly on the reinforcement.
Water of minimum resistivity exceeding 700 ncm shall be used for compaction.
Compaction of backfill material shall be 100% P.D. for 1 metre depth below road
crust and 95% of P.D. for remaining portion of fill materials.
All construction plant having a mass exceeding 1000 kg shall be kept at least 1.5m
away from the face of slope or wall. In this area (upto 1.5m from the face of slopear
wall), following compaction plant shall be used:

,,-

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Vibratory roller having a weight per meter width of roll not exceeding 1300
kg, with total weight not exceeding 10,000 kg.

- Vibratory plate compactor of maximum weight 1000 kg.


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 mm, to achieve compaction of 95%
of maximum laboratory dry density where measured as per IS: 2720 (Part 8).
Temporary fonwork 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.
Drainage Fill Placement.
Drainage fill shall be placed to the minimum finished thickness and widths shown on
the construction plans or as modified by the Owner's Engineer.

-
A

A
The drainage collection pipe shall be a perforated or slowed PVC or corrugated
HDPE pipe. The pipe and drainage aggregate may be wrapped with a geotextile
that will function as a filter. Outlets shall be provided at suitable locations.
1.6.8 Cap Block Placement.
The cap block and or top concrete block unit shall be bonded to the modular

-
concrete block units below using cap adhesive.
1.7 GUARANTEE
The guarantee period for all types of Reinforced Soil Retaining Structures shall be
ten (10) years from the date of completion of flyover, underpass, overpass,
interchange, bridge works irrespective of defect liability period specified elsewhere in
the tender document. The contractor(s) shall furnish the guarantee bond as directed
by the Engineer-in-Charge.
MEASUREMENT FOR PAYMENT
The measurement for Reinforced Earth Structures. Reinforced Soil, Mechanically
Stabilised Earth or similar soil reinforcing systems shall be of Reinforced Soil
Retaining Wall shall be measured as follows:

a) Measurement for Facia Material (Panellslab or Blocks) shall be in Sq. metres.


This shall be measured on each face of the ramp and closing wall from top of
the levelling concrete to bottom of the crash barrier.

b) Measurement of Backfill Placement and Compacting shall be in Cu. metres.


-
A

--
This shall be measured separately by taking cross sections
4
original position before the work starts and after its completio

m
Contract Package -NS 82 (TN)
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The payment for Excavation, Foundation concrete, Reinforcing element, fasteners,


filter media, drainage layer, drainpipe, wping beam and other accessories shall not
be made separately. It is deemed to have been included in the Facia Material rates
for these items.
However the payment for friction slab, Crash barrier and Sub-grade shall be
measured and paid under the respective items.
RATES
The contract unit rates for the items of Facia Material and Backfill Placement shall be
the payment in full for carrying out the required operation including full compensation
for:

a) Cost of detailed design, engineering and preparation of working drawings


b) Patentee charges (if any) and supervision by the specialized supplier
/manufacturer /agency.

c) Cost of all labour charges, material wst, all transportation costs and storage
of the same.

d) Cost for necessary temporary form works, scaffolding, traffic diversion and all
leads and lifts.
Rate for Back fill shall also 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 reinforcement as shown in the drawings.

.%,

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A-2 VOID FORMER


1.I General
Void formers are to be sppplied with suitable end blockers to seal the void former
ends.
Specialised form work shall be manufactured by use of form lining materials with ring
stiffeners as per design requirements. The form lining may either be Marine
Plywood, PVCIHDPE sheet or steel sheet of appropriate thickness and the ring
stiffeners should preferably be of structural steel sections. Manufactured void
formers shall be absolutely leak proof.
1.2 Scope
The contractor may use PVCl HDPE pipes, Galvanised corrugated light metal tubes
of required sizes from nlarket or specially manufactured for use as void formers.
However, the specificatians & design for such pipes1 tubes shall be submitted for
approval of Engineer.
The Void Formers shall be strong enough to withstand all pressure, ramming and
vibration during placing of concrete and handling I erection stresses. The void
formers shall be placed gnd tied in position so that they are not displaced during
concreting.
All the steel surfaces shall be painted with Zinc Rich Paint in accordance with
Section 1900 of the Technical Specification, before use of Void Formers.
Standard R.C.C. Hume pipes are not to be used as void formers.
The contractor shall furnish the design and drawing along with detailed specifications
of the proposed Void Formers for approval of Engineer before taking up the work.
1.3 Rate
The payment for void former shall not be made separately. It is deemed to have
been included in the concrete rates for voided slab, which shall include cost of
supply of void formers, transport, fitting fixing in position and all other incidental
expenditure complete.

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A-3 REPAIR PROCEDURE, UPGRADATION AND MATERIAL SPECIFICATION


1.O General
Various types of distress in concrete superstructure and substructure manifesting in
the formation of horizontal cracks, vertical cracks and spalling are generally
observed. The constructional inadequacy in the form of honeycombing and spalling
of soffit concrete near drainage spout outlet are also found.
Apart from these, the bridges are to be provided with uni-directional camber, crash
barriers in lieu of railing and new expansion joints specially when the slab bridges
are widened.
For various types of defects, the repair methodology, its procedure and the material
specification and the specification and procedure for providing new expansion joint,
crash barrier and wearing coat are outlined in the succeeding Para.
1.l Fine Cracks
There can be fine visible cracks in bridges. If the cracks are 0.5mm wide or less,
these cracks are to be repaired with PMC mortar. The location of the cracks can be
seen during repair and widening works. In order to avoid increase in corrosion,
rectification of the cracks by cutting grooves in the concrete and sealing the grooves
with PMC repair mortar after cleaning and applying PMC sluny on the freshly cut
surfaces at all locations is recommended.
1.1.1 Procedure
The size of the groove, which should be cut along the whole length of visible cracks,
shall be 20 x 10mm. Depth of the groove is 10mm while the width of the groove is
20mm, which however, should be symmetrically placed along the crack. In case
reinforcement is met within a depth of 6mm, the depth should be limited to the depth
of the reinforcement from the surface. It is preferable to cut the groove
perpendicularly to the surface but a deviation of 15 degrees in either direction may
be permitted.
After cutting the groove it shall be cleaned properly to ensure a dust free clean
surface and a coating of PMC sluny be applied over the freshly cut surfaces.
The PMC repair mortar shall be used to fill the 20 x IOmm groove while the sluny
coating is still wet, after a lapse of 30 minutes from the time of application of the
slurry, the PMC repair mortar shall be applied and compacted to ensure complete
filling of the groove. The tilling up of the groove shall be finished flush with the
existing concrete surface. After the finishing operation, the filled up groove should
be properly covered with impermeable sheet whose edges are to be sealed by
taping.
Curing of the finished surface will be the same as that stated for curing of PMC
repair mortar (See C1.1.7). Care should be taken to cut the groove with sharp edge
instrument to avoid damage to the structure.
1.1.2 Material SpecMcatlon
Specification of PMC material is provided at 1.1.7

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1.2 Wide cracks


Wide cracks having width more than 0.5 mm have been found in some of the bridge
components. Moreover, these wide cracks are also found in MasonryIPCC
substructure, such as wing walls, abutments and piers. While locating them and to
repair specially the wing walls, it is to be decided whether the old wing wall will be
functional after widening, if so they need to be repaired.
The basic repair methodology consists of injection of cement grout in the wide cracks
after most of the visible gaps have been sealed by applying sealing mortars. The
repair should be in conformation with clause 2806 of MORTH specification.
However, the general procedure is briefly described
1.2.1 Procedure
The wide gaps should be chased so that grooves are formed which may be 10 x 5
mm in size. After cleaning the surface with wire brush and compressed air, 15mm
-
dia nipples are to be fixed in 150 200mm deep holes with suitable sealing material.
The nipples should have maximum spacing 500 - 600mm. The chased groove also
should be filled up with suitable sealing material. Neat cement along with soluble
glass (Sodium Nitrate) forms excellent quick setting sealing compounds.
Grouting of cement slurry should be done by mechanical pumps. The details of
procedure should be in conformity with clause 2806 of MORTH specification except
for sub clause 2806.6
1.2.2 Material Specification
Material specification should be in accordance with clause 2806.1 of MORTH
specification.
1.3 Repair of Voids in Girder Soffit
1.3.1 General
In case of voids in the girder soffits are identified, the repair technique shall be as
follows. The repair shall be done by low permeability polymer modified cement repair
mortar. The thickness of the PMC repair mortar shall be limited to 15 mm. For
repairing voids more than 15 mm, the lowerlinner layer should be filled with cement-
sand mortar 1:4 prior to application of PMC repair mortar.
Portions of the soffits of the girders to be repaired are to be chipped off, so that the
film forming the external soffit surface are removed exposing the reinforcement. All
loose concrete sticking with the reinforcement shall be removed using appropriate
tools and equipment.
Depending on the depth of voids, cement sand mortar 1:4 is to be applied, before the
application of PMC mortar 15mm thick so that the soffit of the girder is in a straight
line i.e., the soffit should not have protrusion or depressions.
All concrete film in the soffit of girders and weak concrete
reinforcement will be removed by using appropriate tools and
reinforcement bars are exposed, the breaking shall continue
diameter prior to further treatment.

Final Detailed Project Report. Vol. V : Technical Specifications Page 99 of 116


Contract Package 4 S 82 (TN)
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1.3.2 Reinforcement Preparation


All exposed reinforcement shall be cleaned in accordance with the following:
a Where exposed reinforcement is sound and does not show any signs of heavy
corrosion or pitting other than typical rusting, it shall be mechanically cleaned
to remove rust and loose mill scale.
b Where exposed reinforcement shows signs of heavy corrosion deterioration, it
shall be cleaned by grit blasting or by proprietary rust removing compound
1.3.3 Reinforcement Priming
Within one hour of preparing and cleaning, the reinforcement shall be coated with a
primer. The primer shall be PMC slurry using Tapecrete PI51 as polymer latex or
approved equivalent polymer latex.
The primer shall be brush applied on to the cleaned reinforcement ensuring that the
full surface area is in accordance with the manufacturer's recommendation.
1.3.4 Concrete Surface Prlming for Bond
Before commencing to apply PMC repair mortar or the inner cement sand mortar,
the prepared concrete substrata shall be thoroughly soaked with clean water. Free
surface water shall be removed before priming. The primer shall be PMC slurry using
MISClCO Technologies Ltd.'s Tapecrete PI51 polymer latex or approved equivalent
The priming agent shall be well worked into the irregularities according to the
manufacturer's recommendations.
The repair material should be applied before the priming agent sets. The area
coated as one time must be restricted to allow for this provision and any area, which
becomes set shall be recoated as per manufacturer's instruction.
1.3.5 Cementitlous Repair Mortar
The repair mortar shall be high build polymer modified cementitious repair mortar.
The PMC repair mortar shall be of appropriate general specification for use in
vertical and overhead application.
The total thickness of mortar shall be applied in one layer not exceeding 15mm
without sagging or slumping. The material shall be applied in accordance with the
manufacturer's recommendations.
The mixing shall be carried out using forces action mixes or with slow speed drive
mixer (400 - 500 rpm) fitted with a spiral paddle. In no circumstances shall water be
used in the PMC repair mortar mix. Re-mixing and re-tampering shall not be
permitted
The material shall be applied by gloved hand or trowel to the prepared and primed
surface of the substructure and be well worked inside paying particular attention to
packing behind and between the reinforcement. In order to make up the total height
of the girder up to the original soffit level, the balance portion of the girder depth shall
be made up with 1:4 cement sand plaster. Refer to Para 1.7.1 for specifications of
PMC mortar i.e., special specification 1.7.

Final Detailed Project Report. Vol. V : Technical Specifications Page 100 of 116
Contract Package -NS 82 (TN)
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o.amn- mw

1.4 Spalllng or Honeycombing In Deck Slab with Light Exposure of Reinforcement


(Less than half the diameter of relnforcement vislble or dlscolouratlon of soffit)
1.4.1 General
For some bridges, spalling and honeycombing have been observed specially near
the drainage waterspout. The basic repair for this defect is to provide a 5 to 8 rnm
thick PMC repair mortar layer afler removing the loose concrete, plaster etc. The
peripheral edge may be cut upto 10mm deep and the material removed to give a
proper demarcation line. If such spalling or honeycombing is observed in the
cantilevered portion of deck of girder bridges, a drip course covered with PMC repair
mortar may be provided to stop the back flow of rainwater.
1.4.2 Procedure
The honeycombedlspalled surface after removing plaster, if any, should be cleaned
vigorously with steel wire brush. PMC slurry coat should be provided on the
prepared surface after the surface has been pre-wetted with water. The surface
should be moist but without any free water. For further details refer to 'Concrete
surface priming for Bond" and "Cementitious Repair MortaP under Para 1.7 ante.
A drip course 10'x 12 mm size is to be formed at the outer edge of the soffit of the
cantilevered deck slab. PMC repair mortar 5mm thick shall be applied on the drip
course. Refer to Para 1.7 for details of specification of PMC materials
1.5 Spalllng or Honeycombing In Deck Slab with Heavy Exposure of
Reinforcement. (More than half the diameter of relnforcement visible)
1.5.1 General
This type of distress has been observed in couple of bridges. The large spalting
might have been initiated due to honeycombing, a bad construction defect. In many
cases, inadequate length of drainage spout has been responsible for wetting the
locality with drained rainwater and in addition due to the growth of vegetation. This
happens particularly in pier caps.
The repair technique suggested is the application of Cement Sand mortar 1:4, before
the application of PMC mortar 15mm thick so that the soffit is in a straight line.
1.5.2 Procedure for repair
All concrete film in the soffit and weak concrete sticking to the reinforcement shall be
removed by using appropriate tools and equipment. Where the reinforcement bars
are exposed, the breaking shall continue so as to expose half the diameter prior to
further treatment. PMC slurry shall be applied over the prepared surface. After
application of PMC slurry, the repair shall be carried out as per section 1.3.
1.6 Pier and Abutment Substructure Affected by Weathering and Loss of
PointlnglPlaster
1.6.1 General
Generally, there are no cases where these defects have been identified. However,
during the construction period, if the defects are noticed, the following methodology
shall be used for repairing the same.

Final Detailed Project Report. Vol. V : Technical ~pecifikations Page 101 of 116
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1.6.2 Case (a) Weathering


1.6.2.1 Basic Principles
Guniting or shotcreting of affected portion of masonry of abutment and pier is being
suggested in such cases. (Guniting and shotcreting are the two different names for
the same operation).
- The purpose of guniting of the bridge is to increase its life from general weathering
and for counteracting weathering effects also. There are distinct weathering signs in
the old masonrylcementconcrete substructure portion.
The guniting thickness for vertical faces of substructure should be at least 40mm and
should be strengthened by providing a steel weld mesh 50 x 50 x 10 gauge all along
vertical faces of substructure.
1.6.2.2 Procedure
The steel wire mesh has to be placed in position keeping the mesh within 10 -
15mm from the surface, which will be curved for the cutwater portion. Suitable fixing
pins are to be inserted between the masonry mortar joint so that the mesh can be
kept in proper position. The inserts can even be spaced quite apart but ensuring that
the weld mesh is not disturbed during guniting, which is also termed as shotcreting.
Depending on the expertise of the guniting personnel, the thickness of 40mm may be
built in one layer but it must be ensured that no void is created behind the gunite built
up thickness. The presence of void can be found by hollow hammering sound after
the gunite has attained strength say after 3 days.
I.6.2.3 Material Specification
For details and specification of gunite refer to clause 1.8
1.6.3 Case (b) Loss of PointinglPlaster
For loss of pointinglplaster cement mortar 1:3 will be used on exposed surface after
removal of old plasterlpointing and preparation of surface thereof.
1.7 Specification for Materials and Mix Formulations for PMC Material System
1.7.1 General
The acrylic polymer latex to be used for system shall be TAPECRETE P 151
manufactured by MIS ClCO Technologies Ltd. Equivalent products of MIS FOSROC
and MISSlKA are also acceptable.
1.7.2 Specification for Acrylic Polymer Latex
The polymer latex, which is to be used, should consist of water based acrylic and
copolymer dispersion and special purpose chemicals. (TAPECRETE PI51 of MIS
FRC Composites (I) Pvt. Ltd. or any approved equivalent may be used for this
+
purpose). The polymer solid contents shall be 30 1 percent. The particles shall be
nearly spherical shape with a diameter of 0.35 2 0.05 micrometer. The manufacturer
shall certify to the above requirements about solid content and grain size. In order to
-.
keep control over the quality, the manufacturer shall provide infrared absorption
spectrum analysis for the materials (polymer latex) to be supplied to them.

. -.
Final Detailed Project Report. Vol. V : Technical Specifications Page 102 of 116
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The integral waterproofing compound which is to be used for underlying layer of


cement sand mortar shall conform to IS: 2645 No. 1 manufactured by MIS Structural
Waterproofing Co. Pvt. Ltd. or approved equipment.
Portland Cement conforming to IS: 8112 shall be used for production of polymer
modified cement repair mortar and polymer modified cementitious coating system,
which is to be used as a bonding medium with concrete substrate.
Tapecrete P I 51, an acrylic polymer latex shall be used as the polymer for modifying
and improving the properties of cement. The same product is to be used for various
purposes such as in a slurry form with cement to form a bondinglprirning medium
and with sand to firm PMC repair mortar. However, no additional water is to be
added to PMC slurry or PMC repair mortar as the water which is present in the latex
is sufficient for cement hydration and for this reason the latex cement ratio remains
constant for all applications.
The sand, which is to be used for constituting the PMC repair mortar, should be
Silica sand as the basic material, which is categorized in two groups:
a) Coarse Silica Sand
b) Fine Silica
The grading of the above groups should follow the limits provided below:

In the event of using local sand, the sand to be used must satisfy the limits of
deleterious materials and the requirements of soundness as given in Clause. 3.2.1
and 3.6 of IS: 383 respectively. Confirmatory tests shall be conducted by the
contractor and sample kept for comparison by the Public Works Department
-
Cement Sand Mortar
For repair of spallings, where the depth of spalling exceeds 15mm cement-sand
mortar 1:4 layer have been recommended after the application of PMC repair mortar,
15mm thick.
The composition of the cement sand mortar shall be as follows

Final Detailed Project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
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--munn /,!: ;,'&A
m ~ ~ - 0 m O R

COMPOSITION PARTS BY WEIGHT

Cement 100
Sand 400
ClCO No. 1 or equivalent 3
Water Variable

The amount of water will depend on the environment condition and is therefore
variable.
In case where two layers of cement-sand mortar are to be used, the second layer
shall be provided after a lapse of 24 hours from the time of application of the first
layer. Conventional practice or surface preparation for good bonding shall be
adopted for all layers.
Conventional curing of the cement sand mortar layer by application of water spray
should be followed for at least 2 days.

Mix Formations
PMC SLURRY
Component Parts by Weight
Cement 100
Ta~ecretePI51 or eauivalent 50

PMC BRUSH TOP COATING


Cement 100
Tapecrete Pi51 50
Fine Silica Sand 100

PMC REPAIR MORTAR


Cement 100
Tapecrete PI51 50
Coarse Silica Sand 150
Fine Silica Sand 150

PMC FILLER
Cement 100
Tapecrete PI51 50
Concrete Sand 350

1.7.4 Curing of PMC Work


This specification describes the curing procedures to be followed for various PMC
systems.
The curing procedures outlined apply to normal weather condiqns. Take
precautions to avoid drying. PMC work should be carried out a temperaqe below

Final Detailed Project Report. Vol. V : Technical Specifications


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Under unusual weather conditions e.g. high humidity andlor high wind velocity or
imposed constraints special curing procedures shall be followed. Approval,
therefore, shall be obtained from the Engineer-in-charge.
Air-drying shall be considered to take place only during unfavourable uninterrupted
weather conditions existing throughout the recommended drying period. Some
judgement shall be made in this respect and if conditions are deemed unfavourable
for drying to occur, then drying must be prolonged for the full-recommended period
after the weather clears.
1.7.4 Curing of PMC Repair Mortar and Filler
As PMC work proceeds, precautions shall be taken to prevent rapid drying of the
PMC repair mortar and PMC filler. This is usually accomplished by covering the
filled surfaces with an impermeable sheet shortly after the work has been done. The
edges of the impermeable sheet should be suitably taped
The sheet shall be kept in place until further work is carried on over the filler or in the
case where the filler will be exposed to heavy abuse, the sheet shall be kept in place
for 24 hours.
No foot traffic or further work shall be allowed over the filler until 12 hours from the
time of the completion of the work.
All the areas repaired using cementitious materials specified above shall be fully
cured in accordance with good practice for PMC application as given under general
specifications for PMC material systems
For the first day the repaired concrete patch shall be protected from harsh
environment by laying a polythene sheet over it taping down the edges.
1.7.5 Curing PMC Brush top Coatings and PMC Sluny
In unexposed and exposed areas the initial airdrying of 2 to 12 hours shall be
followed by moist curing for 24 hours by spraying or another approved curing
method. No curing compound is to be used.
Following moist curing, the coating shall be allowed to air dry for at least 3 days prior
to the application of finishing coat.
1.8 Specification for Guniting (Shotcretlng)
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
Ordinary Portland cement conforming to IS: 269 shall be used for guniting.
Sand for guniting shall comply with the requirements stipulated in IS: 383. In general,
sand should neither be too coarse to increase the rebound nor too fine to increase
the slump. Sand should preferably have a moisture content between 3 and 6%.
The grading of sand shall lie within the limits given below

1
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. -1
# I
Final Detailed Proiect Report. Vol. V : Technical Specifications " Page105of116
Contract ~ a c k a ~ 82 e -(TN)
~ ~
GREW
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. hlnt Ventue With
,,,,om a\wr,a,,.,
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IS Sieve Designation % Passing the Sieve

4.75 mm 95 - 100

2.36mm 65 - 90
1.18mm 45 - 75
600 microns 30 - 50
300 microns 10-22
150 microns 2-8
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 1 of IS 9012. The percentage of coarse
aggregate may normally be kept as 20 to 40% of the total aggregate and the mix
shall be suitably designed. Waterlcement 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% and 0.1%. The quick setting compound shall be added at the nozzle
with water just before guniting.
The cement and sand shall be batched and mixed and conveyed through a hosepipe
with the help of compressed air. A separate line shall bring the water u'nder
pressure. The cement, sand 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 kglcum. The strength of
gunite shall not be less than 25 Mpa. For effective guniting the nozzle shall be kept
60 to 150 cm away from the surface, preferably 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.
Test panels simulating actual field conditions shall be fabricated for conducting pre-
construction testing. The procedure for testing the cubes or cylinders taken from the
panels stipulated in clause 6 of IS: 9012 shall be followed. It should be ensured from
tests that strength of about 30 MPa at 28 days is available for the mortarlconcrete
mix.
The defective concrete shall be cut out to the full depth 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 sqm of surface area.
The exposed reinforcement shall be thoroughly cleaned free of rust etc. by wire
brushing. Wherever the reinforcements have been corroded the same shall be
removed ad replaced by additional reinforcement. Before application of gunite a
coat of neat cement slurry should be applied on the surface of the reinforcement.
Sufficient clearance shall be provided around the reinforcement to permit
encasement with sound gunite. Care shall be taken to avoid sand pockets behind
the reinforcements.

Final Detailed project Report. Vol. V : Technical Specifications


Contract Package -NS 82 (TN)
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<, . 4/6 Laning of Karur - Madurai Sections of NH-7
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A thickness of 25 to 40mm of gunite can normally be deposited in one operation. It


would always be necessary to apply guniting on a damp concrete surface.
Where required, welded wire fabrics 5 crn 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
The stipulations given in IS: 9012 regarding applications 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 reused in the work. It would
be desirable that green gunite is moistened as curing requirement for at least 7 days.
Guniting work shall not be done during windy or rainy conditions.

I
Vol. V :Technical Specifications Page 107 of 11
Final Detailed Project Report.
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A4 PAINTING ON STRUCTURES WITH WATER PROOF CEMENT PAINT FOR


PARAPET, RAILING 8 CRASH BARRIER
1.l Material
The waterproof cement paint shall be (conforming to IS: 5410) of approved brand
and manufacture.
The water cement paint shall be brought to the site of work by the contractor in its
original container in sealed condition. The material shall be brought in at a time in
adequate to suffice for the whole work or at least a fortnight's work. The material
shall be kept in the joint custody of the Contractor and the Engineer-in-Charge. The
empties shall not be removed from the site of work till the relevant item of the work
has been completed and permission obtained from the Engineer-in-Charge.
1.2 Preparation of Surface
For New Work, the surface shall be thoroughly cleaned of all mortar dropping, dirt,
dust, algae, grease and other foreign matter by brushing and washing. Pitting in
plaster shall be made good and a coat of water proof cement paint shall be applied
over patches after wetting them thoroughly.
1.3 Preparation o f mix
Cement paint shall be mixed in such quantities as can be used up within an hour of
its mixing as otherwise the mixture will set and thicken, affecting flow and finish,
Cement paint be mixed with water in two stages. The first stage shall comprise of 2
parts of cement paint and one part of water stirred thoroughly and allowed to stand
for 5 minutes. Care shall be taken to add the cement paint gradually to the water and
not vice versa. The second stage shall comprise of adding further one part of water
to the mix and stirring thoroughly to obtain a liquid of workable and uniform
consistency. In all cases the manufacturer's instructions shall be followed
meticulously.
The lids of cement paint drums shall be kept tightly closed when not in use, as by
exposure to atmosphere the cement paint rapidly becomes air set due to its
hygroscopic qualities.
In case of cement paint brought in gunny bags, once the bag is opened, the contents
should be consumed in full on the day of its opening. If the same is not likely to be
consumed in full, the balance quantity should be transferred and preserved in an
airtight container to avoid its exposure to atmosphere.
1.4 Application
The solution shall be applied on the clean and wetted surface with brushes or
spraying machine. The solution shall be kept well stirred during the period of
application. It shall be applied on the surface which is on the shady side of the
building so that the direct heat of the sun on the surface is avoided. The method of
application of cement paint shall be as per manufacturer's specification. The
completed surface shall be watered after the day's work.
The second coat shall be applied after the coat has been set for at least 24 hours. -

~ i n aDetailed
l Project Report. Vol. V :Technical specifi&tions Page 108 gf 'I16
Contract Package -NS 82 (TN)
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Before application of the second or subsequent coats, the surface of the previous
coat shall not be wetted.
For the work, the surface shall be treated with three or more coat of waterproof
cement paint as found necessary to get a uniform shade.
For old work, the treatment shall be with one or more coats as found necessary to
get a uniform shade
1.5 Precaution
Water proof cement paint shall not be applied on surfaces already treated with white
wash, colour wash, distemper dry or oil bound, varnishes, paints, etc. It shall not be
applied on gypsums, wood and metal surfaces.
If water proof cement paint is required to be applied on existing surfaces previously
treated with white wash, colour wash, etc., the surface shall be thoroughly cleaned
by scrapping off all the white wash, colour wash etc., completely. There after, a coat
of cement primer shall be applied followed by two or more coats of water proof
cement paint.
1.6 Measurement for payment
The painting shall be measured in square metre of surface area treated.
1.7 Rate
Rate shall include one prime coat and two coats of the paint over the prime coat
include coat of all labour and materials involved in all operations described above.

Final Detailed Project Report. Vol. V : Technical Specifications Page 109 of 116
Contract Package -NS 82 (TN)
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PAINTING WITH SYNTHETIC ENAMEL PAINT FOR KERB, MEDIAN OPENING 8


OTHER STRUCTURES
1.1 Material
Synthetic enamel paint confirming to IS: 2932 of approved brand and manufacture
and of the required colour shall be used for the top coat and an undercoat of ordinary
paint of shade to match the top coat as recommended by the same manufacturer as
far as top coat shall be used.
1.2 Painting o n New Surface
1.2.1 Preparation of surface
The surface shall be thoroughly cleaned and dusted off. All dirt, mortar droppings
and grease shall be thoroughly removed before painting is started. The prepared
surface shall be received the approval of the Engineer after inspection, before
painting is commenced.
1.2.2 Application
The number of coats including the undercoat shall be as stipulated in the item.
1.2.3 Under Coat
One coat of the specified ordinary paint of shade suited to the shade of the topcoat,
shall be applied and allowed to dry overnight. It shall be rubbed next day with the
finest grade of wet abrasive paper to ensure a smooth and even surface, free from
brush marks and all loose particles dusted off.
1.2.4 Top Coat
Two top coats of synthetic enamel paint of desired shade shall be applied after the
undercoat is thoroughly dry. Additional finishing coats shall be applied if found
necessary to ensure properly uniform glossy surface.
1.2.5 Measurement for payment
The painting shall be measured in square metre of surface area treated.
1.2.6 Rate
Rate shall include one prime coat and two coats of the paint over the prime coat
include coat of all labour and materials involved in all operations described above.
1.3 Lettering and Numbering on New Surface
1.3.1 Scope
The letters and numbers for bridgeslculverts span and number shall be as per IRC-
71971. The size of area for paining shall be varied depend upon the numbers and
letters. The background area and letterslnumbers shall be painted with one prime
coat (under mat) and two coats (top coat) of synthetic enamel paint.
1.3.2 Measurement for payment
The painting of culverts1Bridges numbering and span arrangement shall be
measured in number of each side facing traffic
1.3.3 Rate
Rate shall include the cost of materials, labour and other operation described above
to complete set of letters and numbers required in each side facing traffic.
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A-6 SOLAR POWERED ROAD SAFETY SIGNALS WITH LED MODULES


1.1 Scope
The scope of work includes transporting to site solar powered road safety signals
with LED signal modules for "U": turn IKeep Left IJunction Ahead as per the
specification below
1.2 Signal panel:
Material Glass Fiber Reinforced Polyester conforming to DIN
16911 type 834-834.5
Protection class IP 66 (EN 60 529)
Impact Resistance > 7 Nm (EN 50 014)
Flammability Self extinguishing (UL 94 - VO)
Protective Insulation Fully Insulated ( VDE 0100)
Seal 40 C to + 100 C, Endless Polyurethane Foam
Dielectric Strength > 10 Kvlmm
Water absorption Max. 0.7% (ASTM D 570)
Toxicity Halogen free
Surface > 10 l2ohm (DIN 53482)
Dimensions 600 mm X 420 mm X 220 mm
Number & arrangement of LED8 :-To the satisfaction of Engineer
Pole Galvanized pole with corrosive resistant paint with
alternate black and white stripes. Pole to withstand wind
load
Solar Panel 30 Wp (U Turn) 1 20 Wp (Keep Left) 1 50 WP
(Pedestrian Crossing) I 1 5 Wp (Intersection)
Wattage 84 watt (U Turn) 1 54 watt (Keep Left) 1 132 watt
(Pedestrian Crossing) I 3 6 watt (Intersection)
Battery 40 Ah (U Turn) / 20 Ah (Keep Left) 1 60 Ah (Pedestrian
Crossing) 124 Ah (Intersection)
Foundations As required
1.3 Warranty Requirements in favour of NHAl
1 LEDs 10000 Hrs
2.Battery (SMF Lead 5 Years
Acid
3. Solar Panel 15 years
4.Other accessories The supplier should give an undertaking to change any
',\,
other damaged part within 48 hours of intimation
A

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1.4 Measurement for payment


Supplying & Fixing Solar powered road safety signals with LED modules shall be
measured in number of units fixed.
1.5 Rate
Rate shall include the cost of materials, labour and other operation described above
to complete.

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Final Detailed Project Report.
Contract Package - N S 81 (TN)
4/6 Laning of Karur - Madurai Sections of NH-7
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A-7 SOLAR STREET LIGHTS


1.I Scope
The scope of work includes provision of solar powered double aspect streetlights
with 40 W CFL lamps with solar module and SMF Lead Acid batteries of adequate
capacity for supporting dawn to dusk operation supported on 7 m pole made of
galvanised pole structure with corrosion resistant paint designed to meet 125 KMPH
wind load including foundation work. The unit shall be procured only from agencies
that are empanelled by the Ministry of non-conventional energy sources (MNES) and
the supplier should give warranty in favour of NHAl for the following:
1.2 Warranty requirements
Battery 5 Years
Solar Panel 15 Years
Lights and other The supplier should give an undertaking to change the
accessories burnt out lights and any other accessories within 48
hours of intimation.
1.3 Measurement for payment
Supplying & Fixing Solar streetlights near junctions and other locations shall be
measured in number of units fixed.
1.4 Rate
Rate shall include the cost of materials, labour and other operation described above
to complete.
A-8 DIVERSION OF EXISTING WATER COURSES
1.1 Scope
The work shall consist of excavation of new channels for diverting watercourses
existing along the road way alignment or at cross drainage structures and depositing
the excavated materials for closing the existing channels. The location and the
extent of work to be carried out shall be shown on the Drawings or as directed by the
Engineer.
1.2 Construction Operations
Excavation of new channels and deposition of excavated material shall be carried
out in accordance with Clause 301. The excavation shall be carried out to such
widths and depths and at such locations as shown on Drawings or as directed by the
Engineer. Deposition of the excavated material on the existing channels shall be
carried out in such a manner that the latter gets closed and becomes non-
operational. Any surplus material, if found suitable shall be made use of in
embankment construction or sent to spoil as directed by the Engineer.
1.3 Measurementfor payment - .- ---.
excavation in accordance with Clause 301

Vol. V :Technical Specifications .page 113of 116


Final Detailed Project Report.
Contract Package -NS 81 (TN)
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A-9 CHUTE DRAIN FOR HIGH EMBANKMENT SECTIONS


1.1 Scope
This work shall consist of construction of chute drain on the slope of the road
embankment including erosion protection works at the locations and to dimensions
shown on the Drawings or as directed by Engineer. Schedule of works shall be so
arranged that the drains are completed in proper sequence with roadway to ensure
that no damage is caused due to lack of drainage. The chute drains shall be
constructed for drainage at embankment higher than 5.0m and at locations indicated
by the Engineer. These shall be generally at spacing of 15m on either side unless
otherwise modified by the Engineer.
1.2 Material
The drains shall be of half round pipe of 300-mm dia formed by joining precast
semicircular RCC sections at site as shown in the Drawings. The RCC work shall
conform to the relevant Clauses of these specifications.
The toe wall below ground level shall be of plain cement concrete of M-15 grade
conforming to Clause 1700, as shown in the Drawings
Dumped riprap for erosion protection at ground level shall be hard, unweathered and
durable rubble stone of size 150 to 250 mm.
1.3 Construction Operations
1. Excavation for fixing drain sections: At the locations where the chute drains
are to be installed, a semicircular cut on the side slope of the embankment
along the line of the chute drain shall be made in such a way that the RCC
drain sections could be fixed snugly with their edges flush with the adjoining
embankment slope. The sloping bed of the drain shall be to a regular line
and suitably compacted to provide a firm bed.
11. Fixing RCC drains sections: The ends of the RCC drain sections shall be
specially shaped to form a self centring joint. Fixing of the drain sections
shall start from top of toe wall at the lower end and proceed toward the
upper. The joining space shall be filled with cement mortar (1 cement to 2
sand) mixed sufficiently dry to remain in position when fixed with a trowel or
wooden rammer. Care shall be taken to fill all voids, and excess mortar shall
be removed. All joints shall be made with care with interior surface of RCC
sections. After finishing, the joint shall be kept covered and damp for at least
4 days.
Ill. Toe Wall: The toe wall shall be constructed below ground level at the lower
end of the Chute drain. It shall be plain cement concrete, and shall be
constructed to the required dimensions, all as indicated in the Drawing.
IV. Excavation of trench for the toe wall shall conform to Clause 304. Plain ,
cement concrete (M 15grade) and brick masonrylstone masonry in cement
mortar (1:4) shall be to Clause 1700 and Clause 1300/1400 respectively.
V. Dly Rip Rap: Dry rip rap for erosion protection shall be hard dwaMe rubble
stone of size varying between 150mm and 250mm size in the least d i i b n .

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Final Detailed Project Report. Vol. V :Technical Specifications
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These shall be placed in one layer over the ground level in such a way these
are not easily washed by water flowing through chute.
I.4 Measurement for payment
Chute Drain shall be measured as length of drain sections placed in position in
linear meter. Excavation and preparation of bed for the drain shall not be
measured separately.
Excavation of trench for toe wall shall be measured as structural excavation to
Clause 304.
Toe wall in bricklstone masonry or in plain cement concrete shall be measured in
cum. as per respective Clauses. Dry rip rap shall be measured as volume of
material placed in position in cum
1.5 Rates
Rate for the different items of work shall be paid in full for completing the respective
work including all materials, labor, equipment and incidentals.
A-I 0 UTILITY DUCTS AND CROSSING
1.1 Utility Ducts
Utility ducts should be laid below the footpath, shall comprise 300 mm diameter RCC
NP-2 grade on compacted and appropriately shaped granular bed to the kerb as
shown in the drawing or as directed by the Engineer. Care should be taken to
compact the fill material above and around the duct pipe with power rammer before
finishing the footpath base and surface. This work must be done after casting the
channel kerb of the footpath. Manholes with RR masonry or cement concrete of size
and type as shown in the drawing or as directed by the Engineer shall be provided at
200m intervals. The quantities for the various items included in Manholes
construction will be paid separately
1.2 Utility Crossing
Utility crossing shall be provided at locations approved by the Engineer to
accommodate future cables, pipes etc. of Utility agencies. The work shall comprise
600 mm diameter RCC pipes of NP-4 grade laid on a bed of concrete as shown in
drawing or as directed by the Engineer and shall confirm to IS: 458-2000 and
MoRTH specification Clause 2100.
1.3 Utility Protective Work
The contractor shall carry out the protective work for the underground utilities to be
retained as decided by the engineer. The work shall be taken up with the express
approval of the Engineer and under strict supervision of respective line agencies.
The work shall comprise digging trenches around the underground cables to the size
and depth required to accommodate the RCC half pipes (arches). The grade and
size of the arches shall be as directed by the Engineer and should confirm to the
specifications of full RCC pipe of NP-4 grade. The foundation and bedding concrete
shall confirm to IS: 458-2000 and MoRTH specification Clause 2100.

Final Detailed Project Report. Vol. V : Technical Specifications Page 115of 116
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PART Ill

TECHNICAL SPECIFICATIONS FOR BUILDING WORKS

This part shall comprise the latest "Specifications for Building Works" Volume I to Volume IV, 1995 as
published by the Central Public Works Department, Govt. of India and deemed to be bound into this
document.

Final Detailed Project Report. Vol. V :Technical Specifications


Cnntrad Parkano -NS R 1 TTN\