Specification

STANDARD SPECIFICATION FOR ROAD AND BRIDGE WORKS
His Majesty's Government of Nepal

MINISTRY OF PHYSICAL PLANNING AND WORKS
DEPARTMENT OF ROADS
STANDARD SPECIFICATIONS
FOR
ROAD AND BRIDGE WORKS
BHADRA, 2057/AUGUST, 2000
Final Review and Compilation by

Nepal Engineering Consultancy Services Center Ltd.
(NEPECON)
(An undertaking of HMG/Nepal)
Anamnagar, Kathmandu, Nepal
GPO Box 4672(KTM), Tel. No. 225493, 268126, Fax: 977-1-268125
SECTION 200 SITE CLEARANCE

Page 2–0
PREFACE
The present document "Standard Specifications for Road and Bridge Works" is the revised and upgraded
version of the existing DOR's Standard Specifications for Road and Bridge Works published in 1973. Previously
some of their Sections were updated by M/S Transroute Consultants in association with M/S SILT Consultant
(P) Ltd. Remaining Sections were updated and some Sections were added by M/S SILT Consultants (P) Ltd.
independently, but they were not operational, because further updating and revision were required. This
document is an outcome of necessary revision and updating as required for making it operational.
NEPECON wishes to express its sincere thanks to Department of Roads, Central Road Laboratory for
entrusting this important job.
The revision and upgrading of these Specifications was not possible without sincere efforts of Mr. Shree
P. Agrahari, SDE, Team Leader, Mr. Bhagwan Shrestha, SDE, Mr. Achyut Bhatta, Senior Engineer, Dr. Bishwa
R. Shahi, Engineer, Mr. Manoj Shrestha, Engineer, Dr. Udhab Shrestha, Engineer and Mr. Kishan K. Sijapati,
Computer Operator. NEPECON appreciates their sincere efforts and expresses its gratitude to them. Similarly
NEPECON owes a debt of gratitude to Nepal Bureau of Standard and Metrology and M/S Silt Consultants (P)
Ltd. for their cooperation in fulfillment of this task.
Acknowledgements
Acknowledgements are made to the following publications and documents which have been consulted during
reviewing of the these Specifications for road and bridge works.
1. The Bureau of Indian Standard (BIS) Hand book - 1996

2. The British Standards Institution (BSI) Catalogue - 2000
3. Annual Book of ASTM Standards Vol.00.01 (Index) - 1986
4. AASHTO Specifications Part I - 1986
5. AASHTO Materials Part II - 1986
6. Specifications for Road and Bridge Works:
Published by Indian Roads Congress - 1998
7. IS Codes
8. BS Codes
9. Specifications for Bridge Upgrading and Maintenance Project (BUMP)
10. Technical Specifications of Lamhi Tulsipur - Road Project
11. Nepal Standards
12. Following literatures published by M/S Maccaferri :
(i) Technical characteristics of gabion structures
(ii) Flexible gabion structures in earth retaining structures
Notes :
(1) In these Specifications references are made to various codes. In case of their disagreement, when
referred to, they shall be in the hierarchy as given below.
(i) NS (ii) IRC (iii) IS (iv) BS (v) ASTM (vi) AASHTO (vii) Others
(2) If any works are not covered under these Standard Specifications or require modifications to some of the
Specifications, appropriate specifications or modifications to the relevant Standard Specifications may
be drafted in Special Specifications to suit the nature of the works. Such specifications or modifications
shall need approval by the competent authority, before they are implemented.
TABLE OF CONTENTS
Contents Page
No.
SECTION 100–GENERAL
101 OFFICES FOR ENGINEER 1–1
102 ACCOMODATION OF TRAFFIC 1–1
103 PUBLICLY AND PRIVATELY OWNED SERVICES 1–4
104 SURVEY AND SETTING OUT 1–5
105 ACCESS TO ABUTING PROPERTIES 1–6
106 DIVERSION BRIDGES 1–6
107 MAINTENANCE OF ROAD 1–7
108 NOTICE BOARD 1–8
109 ENVIRONMENTAL PROTECTION WORKS 1–8
110 PHOTOGRAPHS 1–12
111 SUPPLY OF VIDEO CASSETTES 1–13
112 NOTES ABOUT MEASUREMENT AND PAYMENT 1–13
113 NATIONAL SPECIFICATIONS 1–14
114 EQUIVALENCY OF STANDARDS 1–15
115 UNITS OF MEASUREMENT, ABBREVIATIONS AND TERMINALOGY 1–15
116 PROGRAMME 1–17
SECTION 200–SITE CLEARANCE
201 CLEARING AND GRUBBING 2–1
202 DISMANTLING CULVERTS, BRIDGES, OTHER STRUCTURES AND PAVEMENTS 2–4
SECTION 300–BLANK
SECTION 400–FENCING
401 SCOPE 4–1
402 MATERIALS 4–1
403 INSTALLATION OF POSTS AND STANDARDS 4–2
404 INSTALLATION OF WIRE 4–3
405 INSTALLATION OF GATES 4–3
406 MEASUREMENT 4–4
407 PAYMENT 4–4
SECTION 500–QUALITY CONTROL
501 SCOPE 5–1
502 CONTRACTOR RESPONSIBLE FOR THE QUALITY OF THE WORKS 5–1
503 QUALITY CONTROL SYSTEM 5–1
504 QUALITY ASSURANCE PLAN 5–2
505 TESTING PROCEDURES AND SETS OF TESTS 5–3
506 LABORATORY TRIALS TO CONFIRM COMPLIANCE WITH SPECIFICATIONS 5–3
507 SITE TRIALS OR TRIAL SECTIONS 5–4
508 CONTROL TESTING DURING CONSTRUCTION 5–6
509 ACCEPTANCE TESTS FOR COMPLETED WORKS OR PARTS OF THE WORKS 5–6
510 RECAPITULATIVE SCHEDULE OF TESTS 5–7
511 LABORATORY 5–13
TABLE OF CONTENTS
Contents Page
No.
SECTION 600–MATERIALS AND TESTING OF MATERIALS

601 SCOPE 6–1
602 QUALITY OF MATERIALS 6–1
603 SOURCES OF MATERIALS 6–1
604 INSPECTION AND ACCEPTANCE OF MATERIALS 6–2
605 MATERIALS AND MANUFACTURED ARTICLES 6–2
606 DEFECTIVE MATERIALS 6–3
607 TRADE NAMES AND ALTERNATIVES 6–3
608 FOREIGN MATERIALS 6–3
609 GENERAL: CLASSIFICATION OF MATERIALS 6–4
610 DEFINITION OF GENERAL TYPES OF MATERIALS 6–7
611 SIEVES 6–7
612 SOILS AND GRAVELS 6–8
613 STONE, AGGREGATE, SAND AND FILLERS 6–9
614 CEMENT 6–10
615 LIME 6–11
616 LIME TREATED MATERIALS 6–11
617 CONCRETE 6–12
618 BITUMINOUS BINDERS 6–13
619 BITUMINOUS MIXETURES 6–15
620 REINFORCING STEEL 6–16
621 TESTING OF WELDS 6–16
622 PAINTS FOR STRUCTURAL STEELWORK 6–17
623 BRICKS 6–18
624 MORTAR 6–18
625 REINFORCED CONCRETE PIPES 6–18
626 HIGH DENSITY POLYTHENE PIPES 6–18
627 GEOTEXTILES 6–18
628 TIMBER FOR STRUCTURAL WORKS 6–19
629 PAINT FOR ROAD MARKING 6–19
630 MANHOLE COVERS AND FRAMES 6–19
631 PRECAST CONCRETE CHANNELS 6–19
632 CAST IRON DRAINAGE GRATINGS 6–19
633 GABION 6–19
634 MEASUREMENT AND PAYMENT 6–19
SECTION 700–PIPE DRAINS, PIPE CULVERTS AND CONCRETE CHANNELS
701 PIPE DRAINS AND PIPE CULVERTS 7–1

702 CONCRETE CHANNELLING 7–5
703 COMPLETION OF DRAINAGE WORKS 7–7
TABLE OF CONTENTS
Contents Page
No.
SECTION 800–QUARRIES, BORROW PITS, STOCKPILE AND SPOIL AREAS
801 GENERAL 8–1

802 DEFINITIONS 8–1
803 LOCATING MATERIAL SOURCES 8–2
804 SAFETY AND PUBLIC HEALTH REQUIREMENTS 8–4
805 ACCESS ROADS AND TRAFFIC CONTROL 8–4
806 SITE CLEARANCE AND REMOVAL OF TOPSOIL AND OVERBURDEN 8–4
807 SELECTION, MIXING AND STOCKPILING OF MATERIALS 8–5
808 PRE-SELECTION OF MATERIALS 8–5
809 PROCESSING 8–6
810 MATERIAL UTILISATION 8–8
SECTION 900–EARTHWORKS
901 SCOPE 9–1

902 DEFINITIONS AND GENERAL REQUIREMENTS 9–1
903 CLASSIFICATION OF EXCAVATED MATERIALS 9–3
904 EXPLOSIVES AND BLASTING 9–4
905 EXCAVATION IN CUTTING 9–6
906 EXCAVATION BELOW EMBANKMENTS AND BELOW
FORMATION LEVEL IN CUTTINGS 9–7
907 EXCAVATION FOR FOUNDATION 9–8
908 REFILING OF FOUNDATION PITS AND TRENCHES, REMOVAL
OF SUPPORTS AND FILLINGS TO STRUCTURES 9–10
909 FORMING OF EMBANKMENT AND OTHERS AREAS OF FILL 9–11
910 COMPACTION OF EMBANKMENTS AND OTHER AREAS
OF FILL/BACKFILL 9–13
911 COMPACTION TRIALS 9–14
912 BENCHING 9–15
913 EARTHWORKS TO BE KEPT FREE OF WATER 9–15
914 WATERCOURSES 9–15
915 FILLING EXISTING WATERCOURSES 9–15
916 PROCESS CONTROL 9–16
918 PAYMENT 9–17
SECTION 1000–SUBGRADES
1001 SCOPE 10–1

1003 PREPARATION AND SURFACE TREATMENT OF FORMATION 10–2
1004 CAPPING LAYERS 10–4
1005 MECHANICAL STABILISATION 10–4
1006 LIME STABILISATION 10–8
1008 PAYMENT 10–15
TABLE OF CONTENTS
Contents Page
No.
SECTION 1100–ROADWORKS OVERALL REQUIREMENTS
1101 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY

OF PAVEMENT COURSES 11–1
1102 ADVERSE WEATHER WORKING 11–4
1103 USE OF SURFACES BY CONSTRUCTIONAL TRAFFIC 11–5
1104 CARE OF WORKS 11–5
SECTION 1200–SUBBASE, BASE, HARD SHOULDER AND GRAVEL WEARING COURSE

1201 MECHANICALLY STABLE SUBBASE 12–1
1202 GRADED CRUSHED STONE BASE AND SUBBASE 12–4
1203 WATER BOUND MACADAM BASE AND SUBBASE 12–9
1204 SHOULDERS 12–14
1205 GRAVEL WEARING COURSE 12–16
1206 TELFORD BASE (BLOCK PITCHING) 12–20
SECTION 1300–BITUMINOUS SURFACE AND BASE COURSE
1301 GENERAL REQUIREMENTS FOR PRIME COAT, TACK COAT, SURFACE DRESSING,
PENETRATION MACADAM, SAND SEAL AND SLURRY SEAL 13–1
1302 PRIME COAT AND TACK COAT 13–4
1303 SURFACE DRESSING 13–8
1304 PENETRATION MACADAM. SEMI- GROUT 13–16
1305 SAND SEAL 13–21
1306 SLURRY SEAL 13–24
1307 GENERAL REQUIREMENTS FOR ASPHALT CONCRETE, SAND ASPHALT,
EMULSION AGGREGATE MIX AND COLD ASPHALT 13–27
1308 ASPHALT CONCRETE 13–34
1309 SAND ASPHALT 13–37
1310 EMULSION AGGREGATE MIX 13–40
1311 COLD ASPHALT 13–46
SECTION 1400–KERBS AND FOOTPATHS

1401 CONCRETE KERBS 14–1
1402 CONCRETE/STONE FOOTPATHS 14–2
1403 BRICK PAVING IN FOOTHPATHS 14–3
1404 BITUMINOUS FOOTPATHS 14–4
1405 CYCLE TRACKS 14–5
SECTION 1500–TRAFFIC SIGNS, ROAD MARKING, ROAD MARKER STONES AND

DELINEATORS
1501 PERMANENT TRAFFIC SIGNS 15–1

1502 ROAD MARKINGS 15–2
1503 ROAD MARKER STONES 15–10
1504 DELINEATOR POSTS 15–12
TABLE OF CONTENTS
Contents Page
No.
SECTION 1600–PILING FOR STRUCTURES
1601 SCOPE 16–1

1602 GENERAL 16–1
1603 TYPES OF PILES 16–1
1604 PENETRATION AND BEARING VALUE 16–1
1605 PRECAST CONCRETE PILES 16–2
1606 DELIVERY, HANDLING AND STORAGE OF PILES 16–2
1607 DRIVING EQUIPMENT 16–2
1608 PILE DRIVING 16–4
1609 CUTTING AND LENGTHENING OF PILES 16–5
1610 PILE HEAVE 16–5
1611 CAST-IN-SITU PILES 16–5
1612 BORED AND CAST-IN-SITU PILES 16–6
1613 DRIVEN SHELL CAST IN SITU PILES 16–13
1614 PILE TESTS 16–15
1615 PILE RECORDS 16–17
1617 PAYMENT 16–18
SECTION 1700–WELL FOUNDATION
1701 SCOPE 17–1
1702 GENERAL 17-1
1703 CUTTING EDGE AND CURB 17-1
1704 STENING 17-2
1705 SINKING 17-2
1706 BOTTOM PLUGGING 17-4
1707 SAND FILLING 17-5
1708 TOP PLUG 17-5
1709 MEASUREMENT 17-5
1710 PAYMENT 17-6
SECTION 1800–FALSEWORK, FORMWORK & SURFACE FINISH FOR CONCRETE
STRUCTURES
1801 SCOPE AND DEFINITIONS 18–1

1802 GENERAL 18–1
1803 FALSEWORK 18–1
1804 FORMWORK FOR CONCRETE 18–5
1805 SURFACE FINISH ON FORMED SURFACES 18–8
1806 FINISHES ON UNFORMED SURFACES 18–10
1807 REMEDIAL WORK TO DEFECTIVE SURFACES 18–11
1809 PAYMENT 18–12
SECTION 1900–BEARINGS AND EXPANSION JOINTS
1901 EXPANSION JOINTS 19–1

1902 BEARINGS 19–11
TABLE OF CONTENTS
Contents Page
No.
SECTION 2000–CONCRETE FOR STRUCTURES
2001 SCOPE 20–1
2003 MATERIALS FOR CONCRETE 20–1
2004 THE DESIGN OF CONCRETE MIXES 20–7
2005 MIXING CONCRETE 20–12
2006 TRANSPORTATION OF CONCRETE 20–14
2007 PLACING OF CONCRETE 20–14
2008 COMPACTION OF CONCRETE 20–17
2009 CURING OF CONCRETE 20–18
2010 PROTECTION OF FRESH CONCRETE 20–19
2011 CONCRETING IN HOT WEATHER 20–19
2012 CONSTRUCTION JOINTS 20–19
2013 RECORDS OF CONCRETE PLACING 20–20
2014 REINFORCEMENT 20–21
2015 CONCRETE FOR SECONDARY PURPOSES 20–23
2016 EARLY LOADING 20–24
2018 PAYMENT 20–25
SECTION 2100–PRESTRESSED CONCRETE

2101 SCOPE 21–1
2102 GENERAL 21–1
2103 CEMENT AND CONCRETE CLASSES FOR PRESTRESSED CONCRETE
STRUCTURES 21–1
2104 TENDON SHEATHS 21–1
2105 ANCHORAGES 21–2
2106 PRESTRESSING TENDONS 21–2
2107 INSTALLATION OF PRESTRESSING TENDONS 21–2
2108 JACKS FOR PRESTRESSING 21–3
2109 TENSIONING OPERATIONS 21–4
2110 BONDING AND GROUTING 21–5
2111 REJECTION OF PRESTRESSED WORK 21–6
2112 TESTING PRESTRESSED WORK 21–7
2114 PAYMENT 21–7
SECTION 2200–STRUCTURAL STEELWORK
2201 GENERAL 22–1
2202 MATERIALS 22–1
2203 FABRICATION: GENERAL REQUIREMENTS 22–1
2204 FABRICATION OF BOLTED STRUCTURES 22–11
2205 CASTINGS AND HEAT TREATMENT 22–16
2206 WELDED CONSTRUCTION 22–17
2207 FIELD ERECTION REQUIREMENTS 22–23
2208 ASSEMBLING AND BOLTING 22–24
2209 PROTECTION AGAINST CORROSION 22–26
2211 PAYMENT 22–32
TABLE OF CONTENTS
Contents Page
No.
SECTION 2300–TIMBER CONSTRUCTION
2301 SCOPE 23–1

2302 MATERIAL 23–1
2303 CONSTRUCTION 23–2
2304 TESTS AND STANDARDS OF ACCEPTANCE 23–3
2306 PAYMENT 23–3
SECTION 2400–MISCELLANEOUS STRUCTURES
2401 GABIONS 24–1

2402 CRIB WALLS 24–7
2403 SLOPE STABILISATION AND SURFACE EROSION PROTECTION 24–9
2404 SUB-SURFACE DRAINS 24–16
2405 DRILLED SUB-SURFACE DRAINS 24–19
2406 SCOUR PROTECTION AND RIVER TRAINING WORKS 24–20
SECTION 2500–BRICKWORKS FOR STRUCTURES
2501 SCOPE 25–1

2503 SOAKING OF BRICKS 25–2
2504 LAYING OF BRICKS 25–2
2505 JOINTS 25–2
2506 JOINTING WITH EXISTING STRUCTURES 25–2
2507 CURING 25–2
2508 SCAFFOLDING 25–3
2509 CONDITION OF EQUIPMENT 25–3
2510 FINISHING OF SURFACES 25–3
2511 TEST AND STANDARD OF ACCEPTANCE 25–4
2513 PAYMENT 25–4
SECTION 2600–MASONRY FOR STRUCTURES
2601 SCOPE 26–1

2604 ASHLAR 26–3
2605 BLOCK-IN-COURSE 26–3
2606 SQUARE RUBBLE - COURSED OR BROKEN COURSES 26–3
2607 RANDOM RUBBLE - COURSED OR UNCOURSED 26–3
2608 DRY RANDOM RUBBLE 26–4
2609 COMPOSITE RANDOM RUBBLE 26–4
2610 TEST AND STANDARD OF ACCPETANCE 26–4
2612 PAYMENT 26–4
TABLE OF CONTENTS
Contents Page
No.
SECTION 2700–REPAIR OF STRUCTURES
2701 SCOPE 27–1
2702 GENERAL 27–1
2703 REPAIR OF MINOR DEFECT IN REINFORCED CONCRETE 27–1
2704 PLACEMENT OF CONCRETE FOR BRIDGE DECKS 27–2
2705 REPLACEMENT CONCRETE FOR THE SIDES AND SOFFITS OF DIAPHRAGMS,
AND SOFFITS OF DECKS 27–3
2706 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN 27–7
2707 EPOXY MORTAR FOR REPLACEMENT OF SPALLED CONCRETE 27–12
2708 EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE 27–14
2709 CEMENT GROUTING 27–15
2710 GUNTING/SHORTCRETE 27–16
2711 REPLACEMENT/RECTIFICATION OF BEARING 27–18
2712 DISMANTLING OF CONCRETE WEARING COAT 27–19
2713 PAINTING OF STEEL BRIDGES 27–20
2714 PROTECTION OF STEEL STRUCTURES AGAINST CORROSION 27–26
2715 REPAIR OF STEEL BEARINGS 27–27
2717 PAYMENT 27–31
SECTION 2800 BIO–ENGINEERING WORKS
2801 SCOPE 28–1

2802 PROVISION OF SEEDS 28–1
2803 PROVISION OF PLANT CUTTINGS 28–3
2804 NURSERY CONSTRUCTION 28–8
2805 NURSERY OPERATION AND MANAGEMENT 28–11
2806 FINAL SLOPE PREPARATION FOR BIO-ENGINEERING 28–15
2807 SITE PLANTING AND SOWING 28–18
2808 JUTE NETTING WORKS 28–30
2809 GABION WIRE BOLSTERS, SUB-SOIL DRAINS AND WIRE NETTING 28–33
2810 SITE PROTECTION 28–37
2811 SITE AFTERCARE AND MAINTENANCE 28–39
SECTION 2900–MAINTENANCE WORKS

2901 SCOPE 29–1
2902 RESTORATION OF RAIN CUTS 29–1
2903 MAINTENANCE OF EARTHEN SHOULDERS 29–1
2904 MAINTENANCE OF GRAVEL SHOULDERS AND GRAVEL CARRIAGEWAY 29–2
2905 BITUMINOUS PATCH WORKS 29–3
2906 MAINTENANCE WITH SLURRY SEAL 29–5
2907 MAINTENANCE WITH SURFACE DRESSING 29–7
2908 MAINTENANCE WITH SAND SEAL 29–7
2909 MAINTENANCE WITH FOG SEAL 29–7
2910 REPAIR OF BRICK SHOULDERS/FOOTHPATHS 29–8
TABLE OF CONTENTS
Contents Page
No.
SECTION 3000–SUB-SURFACE GEOTECHNICAL INVESTIGATIONS
3001 SCOPE 30–1
3002 FIELD INVESTIGATION 30–1
3003 METHOD OF EXPLORATIONS 30–2
3004 LABORATORY TESTING 30–11
3005 WATER SAMPLES 30–12
3006 CONCLUSIONS AND RECOMMENDATIONS 30–12
3008 PAYMENT 30–12
APPENDIX 30.1 (3 PAGES)
SECTION 3100–MISCELLANEOUS WORKS

3101 SCOPE 31–1
3102 PRECAST MEMBERS 31–1
3103 OPEN JOINTS, FILLED JOINTS, BOARD FILLERS AND SHEET PACKING 31–1
3104 WEARING COAT 31–2
3105 RAILINGS 31–3
3106 APPROACH SLAB 31–5
3107 DRAINAGE SPOUTS 31–6
3108 UTILITY FACILITIES 31–7
3109 WEEP HOLES 31–7
3310 FILTER MATERIALS 31–8
SECTION 100 - GENERAL
Page No.
101 OFFICES FOR ENGINEER 1–1

102 ACCOMODATION OF TRAFFIC 1–1
103 PUBLICLY AND PRIVATELY OWNED SERVICES 1–4
104 SURVEY AND SETTING OUT 1–5
105 ACCESS TO ABUTING PROPERTIES 1–6
106 DIVERSION BRIDGES 1–6
107 MAINTENANCE OF ROAD 1–7
108 NOTICE BOARD 1–8
109 ENVIRONMENTAL PROTECTION WORKS 1–8
110 PHOTOGRAPHS 1–12
111 SUPPLY OF VIDEO CASSETTES 1–13
112 NOTES ABOUT MEASUREMENT AND PAYMENT 1–13
113 NATIONAL SPECIFICATIONS 1–14
114 EQUIVALENCY OF STANDARDS 1–15
115 UNITS OF MEASUREMENT, ABBREVIATIONS AND TERMINALOGY 1–15
116 PROGRAMME 1–17
SECTION 100 - GENERAL
101 OFFICES FOR ENGINEER
The Contractor shall provide and maintain offices for the use of the Engineer and his staff if
provided in the contract.
102 ACCOMODATION OF TRAFFIC
(1) Scope
This Clause covers the construction and maintenance of the necessary detours and
diversions, barricades and signs, and everything necessary for the safe and easy
passage of all public traffic during the construction period and also the removal of
diversions as they become redundant including bringing up the area under use into its
original condition.
The Contractor shall take precaution regarding safety at road works. The Contractor
shall strictly adhere to the stipulations of the latest publication of the document
“ SAFETY AT ROAD WORKS : A Code of Practice for Signing at Road works”
published by the Traffic Engineering and Safety Unit of the Design Branch of the
Department of Roads.
(2) General Requirements
The Contractor shall at all times carry out works on the road in a manner creating least
interference to the flow of traffic. For all works involving improvements of the existing
road, the Contractor shall provide and maintain a passage for traffic either along a part
of the existing carriageway under improvement, or along a temporary diversion
constructed close to the road. The Contractor shall take prior approval of the Engineer
regarding traffic arrangements during construction.
The Contractor may be allowed to stop traffic temporarily. The period of such closure
shall be as agreed by the Engineer. For this the Contractor shall submit the time and
period of the closure to the Engineer at least 14 days in advance, to enable the
Engineer to issue the relevant notices.
(3) Temporary Diversions
(a) Provisions of Diversions
Where some portions of the existing road cannot be used by through traffic,
diversions as may be required to deviate traffic from such portions shall be
constructed.
(b) Survey Beacons and Monuments
Diversions shall be constructed so as not to damage or displace

trigonometrical survey beacons and road monuments. In exceptional cases
SECTION 100 GENERAL Page

1–1
where this is not possible, arrangements shall be made to have survey

beacons suitably referenced before they are displaced.
(c) Access to Properties

Access to properties which fall within or adjoining the area over which work is
being carried out shall be provided in the manner as existed before the start of
the work.
(d) Temporary Works
If diversions are provided they shall include the construction of temporary
gates, grid gates, fences, drainage works, and other incidentals considered
necessary.
(e) Public Services
Arrangements shall be made for the continuity of all public services such as
power lines, telephone lines, water mains, sewerage, drainage, etc., if the
existing services are likely to be affected.
(f) Width of Diversions
The usable width for accommodation of two-way traffic shall not be less than 6
m. Where diversions consist of two separate one-way lane the minimum
usable width of each lane shall not be less than 3.5 m.
(g) Temporary Drainage Works
All necessary temporary drainage works required for proper surface run-off,
such as side drains, catchwater drains, temporary cross-drainage structures,
etc. shall be constructed.
0 (h) Earthworks for Diversion
Diversions shall be shaped and graded making full use of all material that can
be obtained from side cut or from the immediate vicinity within the road
reserve. If sufficient material cannot be obtained in this manner, material shall
be imported from other sources. Where necessary, cuttings shall be made to
obtain a satisfactory vertical alignment. All necessary clearing including the
removal of all trees and stumps shall be performed. Where the sub-grade is
not sufficiently compacted in its natural condition, it shall be compacted as
specified in Section 900 prior to the commencement of the earthworks.
All fill material shall be compacted to a density of at least 90% of maximum dry
density
(i) Maintenance of Diversions

All diversions shall be maintained in a safe and smooth trafficable condition.
Whenever required the diversions shall be bladed by means of graders to
provide a smooth riding surface free of corrugations. All potholes shall be
promptly repaired. Diversion shall be watered to keep down dust from traffic or
in order to facilitate the proper blading of the surface. All drainage works shall
be maintained in good working order and kept unblocked.
SECTION 100 GENERAL Page 1 –

2
(j) Removal of Diversions
When traffic is routed permanently into the new road following the completion
of construction, the diversions which are no longer required shall be removed
and the ground reinstated to its original condition.
(4) Accommodation of Traffic Where the Road is Constructed in Half Widths
Where by reason of difficult terrain or for any other reason, the construction of
diversions is not possible, the road shall be constructed in half width, allowing traffic to
use that half of the road not under construction at the time. The lengths of the half
width for construction shall be kept to a minimum, with a provision for traffic travelling in
opposite directions to pass at frequent intervals.
The works in one half width of the road shall be so arranged that the traffic will have
free one-way movement in another half during construction period. That half of the road
which is being used for traffic, shall be maintained free of corrugations and potholes.
Wherever possible the Contractor shall ensure that the whole road width is open at
night. Should the road not be in a safe trafficable condition for two-way traffic over the
whole width, at the end of each day’s work the Contractor shall supply adequate
flagmen, signs, barriers and the necessary staff at his own cost to ensure a reasonable
free flow of traffic alternately in each direction.
Materials and equipment stored on or adjacent to the existing roadway shall be so

placed and the work at all times shall be so conducted, as to cause no obstruction of
the traveling public and traffic.
(5) Traffic Safety and Control
The Contractor shall provide, erect and maintain such barricades, including signs,
markings, flags, lights and flagmen as may be required for the information and
protection of traffic approaching to or passing through the section of the road under
improvement and/or diversions. Barricades, traffic signs and warning boards shall be
provided as per the Traffic Signs Manual (Latest Publication) published by the
Traffic Engineering and Safety Unit of the Design Branch of the Department of Roads.
The barricades erected on either side of the carriageway/portion of the carriageway

close to movement of traffic, shall be of strong design to resist violation, and be painted
as per the said Traffic Sign Manual. On both sides, suitable regulatory and/or warning
signs shall be installed for the guidance of the road users. On each approach, at least
two signs shall be put. The location of these signs shall be in accordance with the
Code of Practice published by the Traffic Engineering and Safety Unit of the
Department of Roads (Latest Publication).
In some locations steel drums may also be placed. These drums shall be white-
washed, blasted with sand and provided with retroreflective tape strips, red on the left
hand side facing on coming traffic and white on the right hand side as appropriate. The
minimum size of these tapes shall be 0.01 sq.m. The drums shall be maintained in a

3
clean and effective condition and no stones or any other warning device shall be
placed on top of the drums.
(6) Measurement and Payment
Unless otherwise provided in the contract, no separate measurement and/or payment

shall be made for all materials and works required under this Clause. All costs in
connection with the work specified herein shall be considered to be included with other
related items of the work in the Bill of Quantities.
103 PUBLICLY AND PRIVATELY OWNED SERVICES
(1) If any privately owned service for water, electricity, drainage, etc., passing through the
site is affected by the works, the Contractor shall provide a satisfactory alternative
service in full working order to the satisfaction of the owner of the services and of the
Engineer before terminating the existing service.
(2) Drawing and scheduling the affected services like water pipes, sewers, cables, etc.
owned by various authorities including Public Undertakings and Local Authorities
included in the contract documents shall be verified by the Contractor for the accuracy
of the information prior to the commencement of any work.
(3) Notwithstanding the fact that the information on affected services may not be
exhaustive, the final position of these services within the works shall be supposed to
have been indicated based on the information furnished by different bodies and to the
extent the bodies are familiar with the final position. The Contractor must also allow for
any effect of these services and alternations upon the works and for arranging regular
meetings with the various bodies at the commencement of the contract and throughout
the period of the works in order to maintain the required co-ordination. During the
period of the works, the Contractor shall agree if the public utility bodies vary their
decisions in the execution of their proposals in terms of programme and construction,
provided that, in the opinion of the Engineer, the Contractor has received reasonable
notice thereof before the relevant alterations are put in hand.
(4) No clearance or alterations to the utility shall be carried out unless ordered by the
Engineer.
(5) Any services affected by the works shall be restored immediately by the Contractor
who must also take all measures reasonably required by the various bodies to protect
their services and property during the progress of the works.
(6) The Contractor may be required to carry out the removal or shifting of certain
services/utilities on specific orders from the Engineer for which payment shall be made
to him. Such works shall be taken up by the Contractor only after obtaining clearance
from the Engineer and ensuring adequate safety measures.
(7) No separate measurement and payment shall be made for the work of temporarily
supporting and protecting the publicly and privately owned services and/or for
construction and maintenance of new services in lieu of them
104 SURVEY AND SETTING OUT

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(1) During the period of Commencement of works the Contractor shall resurvey the Base
Lines, Traverse Points, Bench Marks and confirm the co-ordinates and levels of the
stations. He shall immediately notify the Engineer of any discrepancies and shall agree
with the Engineer any amended values to be used during the contract, including
replacements for any stations missing from the original stations.
(2) The Contractor shall check, replace and supplement as necessary the station points
and agree any revised or additional station details with the Engineer.
(3) All stations and reference points shall be clearly marked and protected to the
satisfaction of the Engineer.
(4) Where a Station Point is likely to be disturbed during construction operations, the
Contractor shall establish suitable reference stations at locations where they will not be
disturbed during construction. No old station shall be covered, disturbed or destroyed
until accurate reference stations have been established and details of such stations
have been approved by the Engineer.
(5) The Contractor shall establish working Bench Marks tied with reference stations soon
after taking possession of the site. The coordinates and the elevations of the reference
stations shall be obtained from the Engineer. The working Bench Marks shall be at the
rate of four per kilometer and also near all major/medium structure sites. Regular
checking of these Bench Marks shall be made and adjustments, if any, got agreed with
the Engineer and recorded.
(6) The Contractor shall be responsible for the accurate establishment of the center lines
based on the Drawing and data supplied. The center lines shall be accurately
referenced in a manner satisfactory to the Engineer. The reference points shall be
established at every 30 m interval in plain/rolling terrain and 10 m interval in hill terrain,
with marker pegs and chainage boards set in the right of way. A schedule of reference
dimensions shall be prepared and supplied by the Contractor to the Engineer.
(7) The existing profile and cross-sections shall be taken jointly by the Engineer and the
Contractor. These shall form the basis for the measurements and payments. If in the
opinion of the Engineer, design modifications of the center lines and/or grade are
advisable, the Engineer shall issue detailed instructions to the Contractor and the
Contractor shall perform modifications in the field, as required, and modify the levels
on the cross-sections accordingly.
(8) Accurate control of lines and levels shall be provided by the Contractor at all stages of
the construction. In respect of roads itself, control shall be at least 10 m interval or
such close interval as may be directed by the Engineer. The lines and levels of
formation, side slope, drainage works, etc. shall be carefully set out and frequently
checked. Care shall be taken to ensure that correct gradients and cross-sections are
obtained everywhere. Wherever necessary, but particularly on completion of the
subgrade, subbase and the base, the Contractor shall re-establish center line pegs at
sufficiently close intervals to determine the edges of base and surfacing accurately.

5
(9) The Contractor shall provide the Engineer with all necessary assistance for checking
the setting out, agreement of levels and any other survey or measurement which the
Engineer needs to carry out in connection with the contract during the entire period of
contract. Such assistance shall include:
(a) provision of suitably qualified surveyors to work under the direction of the
Engineer as required.
(b) provision of all necessary support for these surveyors including assistants,
chainmen, labours, handtools, pegs and materials.
(c) Provision of survey equipment(Precision automatic levels, theodelite and

distomat) as required by the Engineer for survey works.
No separate measurement and/or payment shall be made for the work required under
this Clause. All costs in connection with the work specified herein shall be considered
included in the related items of the work specified in the Bill of Quantities.
105 ACCESS TO ABUTTING PROPERTIES
For the duration of the works the Contractor shall at all times provide convenient access to
paths, steps, bridges or drives for all entrances to property abutting the site and maintain them
clean, tidy, and free from mud or objectionable matter.
106 DIVERSION BRIDGES
(1) Temporary diversion bridges shall be provided by the Contractor as required by the
contract. Where the Contractor is required to prepare Design Drawing and
Specifications of the structure, he shall submit his proposal to the Engineer for his
approval at least 28 days before construction commences. These proposals shall be
accompanied with sufficient ground and information to enable the Engineer to decide
on the stability of the structures.
(2) The Contractor shall maintain the temporary bridges in a condition satisfactory to the
Engineer so long as required.
(3) On completion of the works, the Contractor shall obtain the approval of the Engineer
before removing the temporary bridges. The materials arising from the removal shall
become the property of the Contractor or of the Employer as designated in the
contract. In the case of the materials becoming the property of the Employer, they
shall be removed to the Employer's premises and neatly stacked at no cost to the
Employer.
Construction and maintenance of diversion bridges for the required period quantified in
months shall be paid as per contract price on lump sum basis. Alternatively, if specified
in the contract, construction of the diversion bridges shall be paid as per contract unit
rates of respective items and maintenance work shall be paid as per days work

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provided in the Bill of Quantities. The contract price and/or rates shall be the full and
the final compensation to the Contractor as per Clause 112.
107 MAINTENANCE OF ROAD
(1) The Contractor shall be responsible for undertaking all routine maintenance of the
existing road and all bridges on the road from the day the road is officially handed-over
to the Contractor until the issue of Defects Liability Certificate by the Engineer. The
Contractor shall also carry out all routine maintenance of the completed works from the
time of their substantial completion until the Defects Liability Certificate is issued.
The Contractor shall also maintain roads that he uses for construction or access and
the use of such roads shall be identified in advance to the Engineer for inspection prior
to use.
The routine maintenance of the road shall include besides other, trimming vegetation,
cleaning all culverts, ditches, borrow pits, road side drainage, drainage channels and
any other obstructions including minor landslide (up to 20 m 3 at one spot, with
unlimited number of spots), cleaning road signs and checking and undertaking the
repair of guardrails and other road safety structures, cleaning including removal of
obstructions of bridge decks and bridge deck of drainage elements, cleaning and
checking of expansion joints and bearings, cleaning bearing shelves and weep holes,
removing accumulated debris and vegetation around and between piers and
abutments, repairing parapets, clearance on the road to allow free flow of traffic and
reinstatement of any damaged or deteriorated carriageway, and protection of adjoining
works. In case of road Section where the surface is in badly damaged condition, the
maintenance of existing road surface shall be maintained by potholes patching using
gravel, reprofiling and regrading as instructed by Engineer. The surface shall be
maintained to ensure longitudinal and transverse profile. All the damages to the road
carriageway and shoulder shall be repaired with the material of equal or higher
standard than the original surfacing.
The Contractor shall perform the maintenance works as often as required to keep the
carriageway, shoulders, and adjoining structures in proper working order to the
During the period of commencement of works the Contractor shall mobilize labour and
equipment to make an immediate start on the maintenance of the existing road. The
location and scope of the maintenance work shall be as directed by the Engineer and
shall include clearing out of ditches, and culvert, filling of potholes, regrading and
profiling of badly deteriorated stretches and removal of minor slides or other
obstruction on the road.
Existing ditches shall, where shown on the Drawing, be cleared by removing vegetable
growths and deposits. The sides shall be trimmed throughout and the bottoms
uniformly graded and the ditches kept clean and trimmed and maintained so long as
required. Material removed from the existing ditches shall be disposed off at the
places as directed by the Engineer.

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Should at any time the Engineer gives any instruction for the up keep of a section of
the road/site and the Contractor does not respond in 48 hours, the Engineer shall be
empowered to instruct others to carry out the works. Any costs involved by this action
shall be deducted from any money due to the Contractor.
Maintenance of road in defects liability period quantified in months shall be paid as per
contract price on lumpsum basis. Maintenance of road during
construction/rehabilitation period quantified in km-months shall be paid as per contract
unit rate. The contract price and/or unit rate shall be the full and the final compensation
to the Contractor as per Clause 112.
108 NOTICE BOARD
The Contractor shall erect notice boards (1.8m×1.2m) at each end of the site giving details of
the contract in the format and wording as directed by the Engineer. These boards shall be
erected within 14 days after the Contractor has been given the Possession of Site.
The Contractor shall not erect any advertisement sign board on or along the work without the
written approval of the Employer.
All sign boards shall be removed by the Contractor by the end of the Defects Liability Period.
109 ENVIRONMENTAL PROTECTION WORKS
The environment has been defined to mean surrounding area including human and natural
resources to be affected by execution and after completion of works.
The Contractor shall take all precautions for safeguarding the environment during the course of
the construction of the works. He shall abide by all prevailent laws, rules and regulations
governing pollution and environmental protection. In particular, the Contractor shall fully comply
with the environmental protection mitigation measures specified in the Latest Publication of
“Environmental Management Guidelines” published by the Department of Roads.
The Contractor shall prohibit employees from unauthorised use of explosives, poaching wildlife
and cutting trees. The Contractor shall be responsible for the action of his employees.
Environmental protection works, among others, shall also include the following:
(1) Borrow/Quarry Sites
The Engineer shall have the power to disallow the method of construction and/or the
use of any borrow/quarrry area, if in his opinion, the stability and safety of the works or
any adjacent structure is endangered, or there is undue interference with the natural or
artificial drainage, or the method or use of the area will promote undue erosion.

8
All areas suspectible to erosion shall be protected as soon as possible either by

temporary or permanent drainage works. All necessary measures shall be taken to
prevent concentration of surface water and to avoid erosion and scouring of slopes
and other areas. Any newly formed channels shall be backfilled.
Borrows/quarries shall be located away from the population centers, drinking water
intakes, cultivable lands and drainage systems. The cutting of trees shall be minimised.
Temporary ditches and/or settling basins shall be dug to prevent erosion. The
undesirable ponding of water shall be prevented through temporary drains discharging
to natural drainage channels.
Earthwork operations shall be strictly limited to the areas to be occupied by the

permanent works and approved borrow areas and quarried unless otherwise permitted
by the Engineer. Due provision shall be made for temporary drainage. Erosion and/or
instability and/or sediment deposition arising from earthwork operations not in
accordance with the Specifications shall be made good immediately by the Contractor.
The Contractor shall obtain the permission of the Engineer before opening up any
borrows pits or quarries. Such borrow pits and quarries may be prohibited or restricted
in dimensions and depth by the Engineer where:
(i) they might affect the stability or safety of the works or adjacent property;
(ii) they might interfere with natural or artificial drainage or irrigation;
(iii) they may be environmentally unsuitable.
The Contractor shall not purchase or receive any borrow materials from private
individuals unless the source of such materials has been approved by the Engineer.
At least 14 days before he intends to commence opening up any approved borrow pit
or quarry, the Contractor shall submit to the Engineer his intended method of working
and restoration. These shall include but not be limited to:
(i) the location, design and method of construction of any access track;
(ii) the volume and nature of materials to be removed;
(iii) the sequence and method of excavation of materials;
(iv) measures for controlling runoff and sediment from the site during operations;
(v) proposals for site restoration including approximate finished levels, drainage,
erosion and sediment control, slope stabilization and revegetation, including
reinstatement of any access track.
Operation of borrow pit or borrow area shall not be permitted until the method of
working for that particular pit or area has been approved by the Engineer in writing.
Restoration shall be to the satisfaction of the Engineer.
(2) Disposal of Spoil and Construction Waste

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Materials in excess of the requirements for permanent works and unsuitable materials
shall be disposed off in locations and in the manner as agreed with the Engineer. The
locations of disposal sites shall be such as not to promote instability, destruction of
properties and public service systems. Exposed areas of such disposal sites shall be
suitably dressed and be planted with suitable vegetation.
The Contractor shall plan his works in such a way that there is no spillage of POL
products to the surface or sub-surface water.
(3) Provision and Maintenance of Camps, Offices, Stores, Equipment Yards and
Workshops
Various works defined under this item are related to provision and maintenance of
camps for workmen and employees, Contractor's site offices, stores equipment yards
and workshops. These camps must be adequate, rain-proof, spacious, airy and
hygienic with proper lighting and materials storage facilities. The area shall be kept
neat and clean.
Space allocated for storage of materials such as cement, gabion wire, reinforcing wire
etc. shall in general be damp-free, rain-proof and away from petroleum products
storage.
Permission may be granted by the Engineer to erect suitable camps within the right of
way free of charge, if such establishments do not cause obstructions to traffic,
nuisance to works execution and adverse effect to the environment.
Written information must be given to and approval be taken from the Engineer
regarding proper establishment and maintenance of such camps. Failure in
compliance with Engineer's instruction in respect of overall standard will lead to
reduction or with holding of payment.
(4) Provision and Maintenance of Toilets
Provision of toilets for labour and employees shall be made to avoid public nuisance as
well as pollution of water courses and air. The Contractor shall construct suitable septic
tanks and/or soak pits along with room of pit-type latrines. Sufficient water must be
provided and maintained in the toilets. Proper methods of sanitation and hygiene
should be employed during the whole project duration.
(5) Provision of Potable Water
The Contractor shall supply potable water alongwith commencement of work to

Contractor's staff and workmen both at camps and construction-sites. This
arrangement shall be enforced to avoid proliferation and generation of various water
borne diseases.
The Contractor shall inform the Engineer regarding sources, installation and operation
of supply of potable water within a week after the supply is commenced.
(6) Provision of First Aid/Medical Facilities

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Provision of first aid/medical facilities shall be made alongwith commencement of work

to provide quick medical service to injured/sick workmen, and employees. Services
shall also include on-the-way service and other arrangements required for taking them
to the nearest hospital in case of emergency.
The scope of work shall include service of at least one part-time experienced health
worker/health assistant with a minimum of once a week full time site visit as work
assignment. The Contractor shall also supply and provide adequate medicines and
facilities required for standard first aid.
The Contractor shall inform the Engineer regarding the medical facility within a week
after its establishment and operation.
(7) Crushing Plants
Crushing plants shall be located away from the population centers, water intakes and
establishment of sensitive echo system. Suitable dust control device shall be fitted to
the crusher to control emission of dust from the plant.
Hot Mix Plants and Batching Plants
Hot-mix plants and batching plants shall be located away from the population centers.
The Contractor shall take every precaution to reduce levels of noise, vibration, dust
and emission from his plants.
No bituminous material shall be discharged into drains. Nearby trees, vegetation and
property shall be protected during spraying of bitumen.
(9) Hazardous Materials
The Contractor shall not store hazardous materials near water surfaces. The
Contractor shall provide protective clothing or appliances when it is necessary to use
some hazardous substances.
High concentration of airborne dust resulting in deposition and damage to crops and
water resources shall be avoided. The Contractor shall take every precaution to control
excessive noise resulting in disruption to wildlife and human population.
Only controlled explosives methods shall be applied and used in construction works.
(10) Reinstatement of Environment
The Contractor shall arrange and execute works as well as related activities in such a
way that environmental conditions are reinstated. He may be required to carry out
filling, removal and disposal works alongwith plantation of grass and trees as directed
by the Engineer at his own costs at identified locations to reinstate environment.
Written instruction/approval shall be given by/sought from the Engineer regarding

reinstatement of environment both during and after completion of works and upto the
end of Defects Liability Period.

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No separate measurement and payment shall be made for the works described in this
Clause.
110 PHOTOGRAPHS
(1) The Contractor shall supply negatives and unmounted positive colour prints of
photographs, of such portions of the works in progress and completed, as may be
directed by the Engineer. The negatives and prints shall not be retouched. The
negative of each photograph shall be the property of the Employer and shall be
delivered to the Engineer with prints. No prints from these negatives shall be supplied
to anyone without the written permission of the Engineer.
The photographs shall be of two categories:
(a) progress photographs (9 photographs, each of them shall have 4 prints and
the negative supplied monthly)
(b) record photographs (9 photographs, each of them shall have 4 prints and the
negative supplied monthly)
Both categories of photographs shall be properly referenced to the approval of the
Engineer and on the back of each print shall be recorded the date of the photograph
and the direction in which the camera was facing, and identifying description of the
subject, and the reference.
The Contractor shall supply four prints of each photographs which shall be taken at
locations and times determined by the Engineer.
Photographs taken for the record purposes as ordered by the Engineer shall be
supplied with four prints, having on the reverse of one print the signature of the
Contractor and the Engineer for the purpose of attestation. If required, the Contractor
may at his own expense have an additional print similarly attested for his retention.
(2) Payment
Payment shall be made at the contract unit rate which shall be the full and the final
payment to Contractor as per Clause 112.
111 SUPPLY OF VIDEO CASSETTES
(1) The work consists of taking video film of important activities of the work as directed by
the Engineer during the currency of the contract and editing them to a video film of
playing time between 60 minutes and 180 minutes as directed by the Engineer. It shall
contain narration of activities in English and/or Nepali by a competent narrator. The
edition of the video film and the script shall be approved by the Engineer. The video
cassettes shall be of acceptable quality and the film shall be capable of producing
colour pictures.
(2) Measurement

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The measurement for this item shall be by number of sets of edited master cassettes
supplied each with four copies thereof.
(3) Payment
The contract unit rate shall include all expenses for making video films with the help of
a professionally competent photographer, editing, narration and supplying the final
edited master cassette alongwith four copies thereof.
112 NOTES ABOUT MEASUREMENT AND PAYMENT
(1) Measurement
Unless specified, all measurements shall be based on standard practices of

measurement in engineering works.
The tolerances specified in these Specifications are for evaluation of accuracies only
based on which the work shall be accepted or rejected. However, the measurement of
the work performed within the limits of tolerances shall be the measurement of actual
work done in place, if their dimensions are less than what have been specified or
instructed by the Engineer. If the actual work done in place is more than what has been
specified or instructed by the Engineer, but within the limit of tolerances, the
measurement shall be the measurement of the work what has been specified or
instructed by the Engineer.
(2) Payment
Unless specified in the contract, the contract unit rates and/or prices for items as set
out in the Bill of Quantities are the full and the final compensation to the Contractor for:
 supply of all materials necessary to complete the item as per relevant

specifications;
 use of materials, labours, tools, equipment, machines and other resources as
per need;
 all handling, packing charges and transportation;
 cost of supervision, quality assurance, temporary and ancillairy works;
 site commissioning;
 maintenance and making good;
 all duties and obligations as set out in the contract;
 general works such as setting out, clearance of site before setting out and after
completion of works
 the preparation of detailed work programme
 providing samples of various materials proposed to be used
 the detailed Design and Drawing of temporary works
 testing of materials
 any other details as required by the contract
 cost of all operations like storing, erection, moving into final position, etc.
necessary to complete and protect the work till handing over to the Employer;
 the cost for safeguarding the environment

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 all incidental costs, not covered under above stated.
Where the Bill of Quantities does not include the items mentioned in Section 100, no
separate payment shall be made for such works. The costs in connection with the
execution of the works specified herein shall be considered to be included in the
related items of other works specified in the Bill of Quantities or shall be considered to
be incidental to the works specified . Items specified in this Section and included in the
Bill of Quantities shall be paid at the contract unit rates as agreed and shown in the Bill
of Quantities.
113 NATIONAL SPECIFICATIONS
Certain Specifications issued by various national or other widely recognised bodies are
referred to in these Specifications. Such Specifications shall be defined and referred to as
National Specifications.
The Contractor may propose that the materials and workmanship be defined in accordance
with the requirements of other equivalent National Specifications and he may execute the
works in accordance with such National Specifications as may be approved by the Engineer. A
copy of the National Specification, together with its translation into the English language if the
National Specification is in another language, shall be submitted to the Engineer along with the
request for its adoption.
In referring to National Specifications, the following abbreviations are used:
NS Nepal Bureau of Standards and Metrology

IS Indian Standards
IRC Indian Road Congress (i.e. Recommended Code of Practice by IRC)
ASTM American Society of Testing and Materials
BS British Standards
BSCP British Standard Code of Practice
AASHTO American Association of State Highway and Transportation Officials
ISO International Organisation for Standardisation
EN European Norm
NFP French Norm
Alongwith the commencement of the contract, the Contractor shall provide in his site office at
least one complete set of all National Specifications referred to in these Specifications, if they
are for the Sections applicable to the works. This set shall be made available for use by the
Engineer.
114 EQUIVALENCY OF STANDARDS
Wherever reference is made in these Specifications to specific standards and codes to be met
by the materials, plant, and other supplies to be furnished, and work to be performed or tested,
the provisions of latest current edition or revision of relevant standards and codes in effect shall
apply. Other authoritative standards which ensure a substantially equal or higher performance
than the specified standards and codes shall be accepted subject to the Engineer’s prior
review and approval. Differences between the standards specified and the proposed
alternative standards shall be fully described by the Contractor and submitted to the Engineer
at least 28 days prior to the date when the Contractor desires the Engineer’s approval. In the

14
event that the Engineer determines that such proposed deviations do not ensure substantially
performance, the Contractor shall comply with the standards and codes specified.
115 UNITS OF MEASUREMENT, ABBREVIATIONS AND TERMINOLOGY
(1) Units of Measurement
The Symbols for units of measurement are used in these Specifications as they are
given below.
µ micron = m x 10 -6
mm millimetre
m metre
km kilometre
sq. mm. or mm² square millimetre
sq.m. or m² square metre
sq. km. or km² square kilometre
ha hectare
3
cu. m. or m cubic metre
lit or l litre
rad radian
°C degrees Celsius
kg kilogram
g gram = kg x 10 -3
mg milligram = kg x 10 -6
mg/l milligram per litre
t tonne = kg x 10 3
kg/ m3 kilogram per cubic metre
3
t/ m tonne per cubic metre
N newton
N/m² newton per square metre
Lin. m Linear metre
Max Maximum
Min Minimum
Symbols of other units, if not covered above, shall be as per SI system set out in ISO
31/1.
(2) Abbreviations
The following abbreviations are used in these Specifications.
ACV Aggregate Crushing Value

AIV Aggregate Impact Value
ALD Average Least Dimension
BA Bitumen Affinity
BOQ Bill of Quantities
CBR California Bearing Ratio

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CR Crushing Ratio
dia Diameter
FI Flakiness Index
hr Hour
LAA Los Angeles Abrasion Value
LS Linear Shrinkage
MC Moisture Content
MDD Maximum Dry Density
min Minute
no Number (units), as in 6 no.
No Number (order) as in No 6
OMC Optimum Moisture Content
OPC Ordinary Portland Cement
PI Plasticity Index
PL Plastic Limit
PM Plasticity Modulus (PI x % passing 0.425 mm sieve)
ROW Right of Way
SE Sand Equivalent
sec Second
SG Specific Gravity
SI International Standard Units of Measurements
SSS Sodium Sulphate Soundness test, loss on 5 cycles
STV Standard Tar Viscosity
TS Tensile Strength
UC Uniformity Coefficient
UCS Unconfined Compressive Strength
VIM Voids in Mix
w/c Water cement ratio
wt Weight
% Percent
(3) Terminology
The term "the Specifications" shall be construed as the Standard Specification and the
Special Specification all together.
(4) The Sections, Clauses and/or Sub-clauses mentioned in these Specifications deem to
apply those of these Specifications only, if otherwise not specified.
116 PROGRAMME
The Contractor shall provide all information needed for fulfilment of the programme and
required in accordance with the Conditions of Contract including the sequence in which he
intends to work including implementation of quality assurance plan. If the Contractor requests a
change in the sequence and such change is approved by the Engineer, the Contractor shall
have no claim as per the Conditions of Contract for delay arising from such revisions to the
programme.
The programme for the construction and completion of the works shall be established using
CPM/PERT techniques or equivalent. The programme shall be detailed enough to give, in
addition to construction activities, detailed network activities for the submission and approval of
materials, procurement of critical materials and equipment, fabrication of special

16
products/equipments if any and their installation and testing, and for all activities of the
Engineer that are likely to affect the progress of work. The Contractor shall update all activities
in accordance with the Conditions of Contract on the basis of the decision taken at the periodic
site review meetings or as directed by the Engineer.
The programme shall also include the Contractor's general requirements for any road closures
pursuant to Clause 102 to be agreed in principle with the Engineer. Such agreement shall not
relieve the Contractor of his responsibility to obtain specific approval for each closure or series
of closures.
Any proposal for night working shall also be stated in the programme.

17
SECTION 200 - SITE CREARANCE
Page No.
1 201 CLEARING
AND GRUBBING 2–1
202 DISMANTLING CULVERTS, BRIDGES, OTHER STRUCTURES AND PAVEMENTS 2–4
SECTION 200– SITE CLEARANCE
201 CLEARING AND GRUBBING
(1) Scope
This Section covers the clearing and grubbing necessary for the construction of the
works covered by the contract. Conservation of the top soil and flora is also covered
under this Section.
(2) Description of Work
(a) Clearing
Clearing shall consist of the cutting, removing and disposal of all trees,
bushes, shrubs, grass, weeds, other vegetation, anthills, rubbish, fences, top
organic soil not exceeding 150 mm in thickness and all other objectionable
material, resulting from the clearing and grubbing. It shall also include the
removal and disposal of structures that obtrude, encroach upon or otherwise
obstruct the work.
The moving of a certain amount of soil or gravel material may be inherent to or

unavoidable during the process of clearing and no extra payment shall be
made for this. Clearing shall include the removal of all rocks and boulders of
up to 0.15 m3 in size exposed or lying on the surface.
(b) Grubbing
In the roadway all trees upto 300 mm girth, stumps and roots shall be removed
to a depth of not less than 900 mm below the finished road level and a
minimum of 500 mm below the original ground level whichever is lower.
Except in borrow areas the cavities resulting from the grubbing shall be
backfilled with approved material and compacted to a density not less than the
density of the surrounding ground.
(c) Conservation of Top Soil
Where suitable topsoil exists within the limits of the area to be cleared and
grubbed, the Contractor shall, if ordered by the Engineer, remove the topsoil
together with any grass and other suitable vegetation. If not used immediately,
the topsoil shall be transported and deposited in stockpiles for later use.
(d) Conservation of Flora
Where provided for in the contract, certain designated flora encountered in the
road reserve and borrow areas shall be carefully protected by the Contractor.
In his tendered rate for Site Clearance, he shall include for the careful removal
SECTION 200 SITE CLEARANCE Page 2–1

and planting of the flora in a protected and fenced-off area and, on completion
of the road, for the replanting of the flora in suitable positions in the road
reserve in accordance with the Engineer’s instructions.
(3) Execution of Work
(a) Areas to be Cleared and Grubbed
Stumps, embedded logs, roots and all other vegetable growth and
accumulated rubbish of whatsoever nature and all other objectionable material
shall be completely removed to a depth as specified in Sub-clause 201 (2) (a)
and (b).
Normally the portions of the road reserve that fall within the limits of the road
prism, as well as certain borrow areas shall be cleared and/or grubbed.
Where the road reserve is to remain unfenced, the full width of the road
reserve shall be cleared and/or grubbed except for such trees designated by
the Engineer to be left standing and uninjured.
The Contractor shall mark the boundaries of the area for clearing and
grubbing and seek the approval of the Engineer before commencement of the
work. The Engineer shall designate in detail the exact areas to be cleared and
grubbed and the time at which it shall be done.
(b) Cutting of Trees
The Contractor shall take the necessary precautions to prevent damage to

structures and other private or public property. If necessary, trees shall be cut
in sections from the top downwards. The branches of trees to be left standing
shall be trimmed so as not to intrude into a space of 7 m above the roadway.
Such individual trees as the Engineer may designate and mark in white paint
shall be left standing and uninjured. In order to minimize damage to trees that
are to be left standing, trees shall be felled towards the center of the area
being cleared, if so required by the Engineer.
Authority for cutting trees must be obtained from the Ministry of Forests who
may require that trees be numbered, measured and marked in the presence of
officials from the Ministry of Forests. Cutting of such trees shall then be carried
out by the Contractor and the timber stored at designated locations within the
Right of Way.
Felling and cutting of trees on the site and pilling them off the site shall
conform to the requirements of the Ministry of Forest.
All tree trunks and branches in excess of 150 mm in diameter shall be cleaned
off, secondary branches cut into suitable length and stacked at sites indicated
by the Engineer. Such timber shall not be used by the Contractor for any
purpose and shall remain the property of the Employer.

All timber except such timber as can be used and all brush, stumps, roots,
rotten wood and other refuse from the clearing and grubbing operations shall
be completely removed from within the Right of Way.
(c) Dealing with Anthills
Where anthills are encountered within the limits of the road prism, they shall
be excavated to a depth of not less than 750 mm below the finished road level
and the material carted to spoil. Cavities resulting from the clearance of anthill
material shall be backfilled with approved material and compacted to a density
not less than that of the surrounding ground.
Where directed by the Engineer, the area covered by anthills shall be treated,
after excavation and before backfilling of cavities, with an approved ant control
chemical. Payment for such treatment shall be made in the manner specified
in the contract.
(d) Disposal of Material
Material obtained from clearing and grubbing shall be disposed off in borrow
pits or other suitable places and be covered up with soil or gravel as directed
by the Engineer. The burning of combustible material shall not, normally, be
permitted and may only be done with the prior written approval of the
Engineer.
Where fences have to be taken down, fencing wire shall be neatly wound into
reels and all such wire, together with all fence posts and other serviceable
material from structures, etc., shall be stacked at sites indicated by the
Engineer.
(e) Reclearing of Vegetation
When portions of the road reserve, borrow or other areas have been cleared
in accordance with the Specifications, but in the course of time, vegetation
grows again during construction, the Engineer may, if he considers it
necessary, order that the area be recleared.
Before the bottom layer of the embankment is made, the Contractor shall grub
up and remove any vegetation that may in the meantime have grown on the
surfaces previously cleared and grubbed. Such reclearing of areas previously
cleared include the removal and disposal of grass, shrubs and other
vegetation in the same manner as for the first clearing operation. No separate
payment shall be made for reclearing of vegetation.
(4) Measurement
Clearing and grubbing executed as per this Specification shall be measured in square
meter.

Cutting trees including removal of stumps and their roots of girth above 300 mm and
backfilling to required compaction shall be measured in number according to the sizes
given below:
(a) Above 300 mm to 600 mm
(b) Above 600 mm to 900 mm
(c) Above 900 mm to 1800 mm
(d) Above 1800 mm
For this purpose girth shall be measured at a height 1 meter above ground.
Cutting of trees upto 300 mm girth including removal of stumps and roots and
backfilling of holes with compaction shall not be measured separately.
(5) Payment
Clearing and grubbing and cutting trees shall be paid at their respective contract unit
rates which shall be the full and the final compensation to the Contractor as per Clause
112. The contract unit rate for cutting of trees of girth above 300 mm shall also include
handling, salvaging, piling and disposing off the cleared materials with all leads and
lifts.
202 DISMANTLING CULVERTS, BRIDGES, OTHER STRUCTURES AND PAVEMENTS
(1) Scope
This work shall consist of removing as hereinafter set forth existing culverts, bridges,
pavements, buildings and other structure like guard-rails, kerbs, manholes, catch
basins, inlets, walls, drains etc., which are in place but interfere with the new
construction or are not suitable to remain in place, and salvaging and disposing off the
resulting materials and back filling the resulting trenches and pits.
(2) General
(a) Only those structures designated by the Engineer, or shown on the Drawings,
shall be demolished or removed.
(b) Dismantling and removal operations shall be carried out in such a way that the
adjacent pavement, structures are left intact and in place. All operations
necessary for the removal of any existing structure which might endanger new
construction shall be completed prior to start of new work.
(c) Existing culverts, bridges, buildings and other structures which are within the
road and which are designated for removal, shall be removed upto the limits
and extent specified on the Drawing or as indicated by the Engineer.
(d) Materials that are to be salvaged shall be carefully removed and stockpiled
near the site at a location designated by the Engineer. Materials which are to

be salvaged or used in the reconstructed work and have been damaged or

destroyed as a result of the Contractor's operations, shall be repaired or
replaced by the Contractor at his expense. Materials that are not to be
salvaged and stockpiled, shall become the property of the Employer. In
general, piling, piers abutments and pedestals shall be removed to at least
300 mm below ground level measured at the face unless a different depth is
designated or specified. Existing reinforcement that is to be incorporated in
new work shall be protected from damage and shall be thoroughly cleaned of
all adhering material before being embedded in new concrete.
(e) When pipe culverts, wooden culverts, gabion walls or other structures with a
salvaged value are removed, care shall be exercised in their safe removal.
The material involved shall be kept intact without damage. The Contractor
shall be responsible for the satisfactory removal of such structures in a usable
condition.
(f) Salvaged reinforced concrete pipes, corrugated steel pipes, wooden boxes or
other structures shall be stored at places as directed by the Engineer or
shown on the Drawing. Structures or portions thereof which are specified in
the contract for reerection shall be stored in separate piles.
(g) Timber or lumber from old structures which is designated by the Engineer as
materials to be salvaged shall have all nails and bolts removed therefrom and
shall be stored in neat piles in locations suitable for loading.
(h) All operations necessary for the removal of any existing structure which might
endanger new construction shall be completed prior to the start of new work.
(i) All salvaged or unsalvaged materials shall be the property of the Employer.
(j) All materials obtained from dismantling operations which, in the opinion of the
Engineer, cannot be used or auctioned shall be disposed off.
(3) Dismantling Culverts and Bridges
The structures shall be dismantled carefully and the materials shall be so removed as
not to cause any damage to the serviceable materials to be salvaged. The part of the
structure to be retained and other structures nearby shall be safeguarded against any
damages.
Where existing culverts/bridges are to be otherwise incorporated in the new work, only
such parts of the existing structure shall be removed as are necessary and directed by
the Engineer to provide a proper connection to the new work. The connection edges
shall be cut, chipped and trimmed to the required lines and grades without weakening
or damaging any part of the structure to be retained.
Steel structures shall, unless otherwise provided, be carefully dismantled in such a

manner as to avoid damage to members thereof. The structure shall be removed in a
condition suitable for re-erection unless otherwise shown on the Drawing. All members
shall be match-marked by the Contractor with white lead paint before dismantling; end

pins, nuts, loose plates, etc., shall be similarly marked to indicate their proper location;
all pins, pin holes and machined surfaces shall be painted with a mixture of white lead
and tallow and all loose parts shall be securely wired to adjacent members or packed
in boxes.
(4) Dismantling Other Structures and Pavements
In removing pavements, kerbs, gutters, walls and structures like catchpits, outlets, etc.,
where portions of the existing construction are to be left in the finished work, the same
shall be removed to an existing joint or cut and chipped to a true line with face
perpendicular to the surface of existing structure. Sufficient removal shall be made to
provide connections with the new work as directed by the Engineer. All pavements,
base courses in carriageway and shoulders, etc. designated to removal shall be
broken to pieces whose volume shall not exceed 0.02 cubic meters and stockpiled at
designated locations if the materials are to be used later or otherwise arrange for
disposal.
(5) Back-filling
Holes and depressions caused by dismantling operations shall be backfilled with

excavated or other approved materials and compacted to required density as directed
by the Engineer.
(6) Measurement
Prior to commencement of dismantling, the work of dismantling structures shall be

measured in the units given below:
Type of Work Unit

(i) Dismantling brick/stone masonry/
concrete (plain and reinforced) cu.m.
(ii) Dismantling gabion cu.m.
(iii) Dismantling steel structures tonne
(iv) Dismantling timber structures cu.m.
(v) Dismantling pipes, guard rails,

kerbs and gutters lin. m.
(vi) Utility services lump sum
(vii) Pavement cu.m.

(viii) Dismantling pipe culverts no.
(ix) Dismantling pitching and rip raps sq. m.

Associated works like disposal, stockpiling, marking and numbering, etc. shall not be
measured separately.

(7) Payment
The various dismantling works shall be paid at their respective contract unit rates
which shall be the full and the final compensation to the Contractor as per Clause 112
and for the cost of all operations involved for completion of this item.

SECTION 400 - FENCING
Page No.
401 SCOPE 4–1

402 MATERIALS 4–1
403 INSTALLATION OF POSTS AND STANDARDS 4–2
404 INSTALLATION OF WIRE 4–3
405 INSTALLATION OF GATES 4–3
407 PAYMENT 4–4
SECTION 400 - FENCING
401 SCOPE
This Section covers the erection of new fences along the boundaries of the road reserve
and/or camp site as indicated on the Drawing or directed by the Engineer.
It shall also include the erection and later removal of temporary fences other than temporary
fences for bypasses. Except for when the Engineer allows otherwise, new fences as well as
temporary fences shall be erected before construction on a particular portion of the road where
work is commenced with.
402 MATERIALS
(1) Posts, Stays, Standards and Droppers
Posts, stays, standards and droppers shall be of the type and size indicated on the
Drawing. Concrete posts shall comply with the requirements of IS 4996 and the mild
steel posts shall comply with the requirements of IS 226.
(2) Bolts for Stay
Bolts shall be galvanized steel bolts of the required length and diameter. The diameter
shall not be less than 12 mm. All the necessary bolts, together with nuts and washers,
shall be supplied with each post.
(3) Wire
(a) Barbed Wire
Barbed wire shall comply with the requirements of NS: 168/2045 and shall be
of mild steel grade, double strand, unidirectional twist wire, each strand 2.50
mm diameter for use at any height above ground. The wire shall be either
lightly galvanized or fully galvanized, as specified in the Bill of Quantities.
Barbs shall be manufactured from 2 mm galvanized wire and shall be spaced

at not more than 162 mm apart.
(b) Smooth Wire
Smooth wire shall comply with the requirements of N.S. 163/2045 and shall be
of the type specified below:
 Straining wire shall be 4 mm diameter, lightly galvanized wire.

 Fencing wire shall be high tensile grade, 2.24 mm diameter wire,
either lightly or heavily galvanized, as specified in the Bill of
Quantities.
SECTION 400 FENCING Page 4 

1
 Tying wire shall be 2.50 mm diameter, mild steel, lightly galvanized

wire for tying fencing wire to standards and droppers, and 1.6 mm
diameter, mild steel, lightly galvanized wire for tying netting and mesh
wire to fencing wire.
(4) Wire Netting
Wire netting shall be heavily galvanized mild steel wire with a minimum diameter of l.8
mm and hexagonal mesh of 60 X 80 mm or as shown on the Drawing.
The width shall be as shown in the Drawing.
(5) Gates
Gates shall be manufactured to the dimensions shown on the Drawing.
Gates shall be complete in every respect, including hinges, washers, bolts and locking
chain attached to the gate.
(6) Manufacturing Tolerances for Wire
Nowhere the actual diameter of the wire shall be less than the specified diameter by
more than the following tolerances:
Specified diameter Tolerances
up to 1.5 mm (+/-) 0.03 mm

above 1.5 mm up to 2.5 mm (+/-) 0.04 mm
above 2.5 mm (+/-) 0.05 mm
403 INSTALLATION OF POSTS AND STANDARDS
Straining posts shall be erected at all ends, corners and bends in the line of fences and at all
junctions with other fences. Straining posts shall not be spaced further apart than shown on
the Drawing. The height of posts above ground shall be such that the correct clearance
between the lowest wire and the ground can be obtained.
Posts shall be accurately set in holes and where shown on the Drawing be provided with
concrete bases to the dimensions shown on the Drawing.
Holes shall be dug to the full specified depth of the posts. Where due to the presence of rock
the holes cannot be excavated by means of hand or pneumatic tools and the Contractor has to
resort to the use of explosives, he shall be paid separately for the drilling and blasting
operations required.
Corner, gate, end and straining posts shall be braced by means of stay or anchors, as shown
on the Drawing or as directed by the Engineer. Pipe stays shall be bolted to the posts.
Standards shall be firmly planted into the ground at the spacing shown on the Drawing or as
directed by the Engineer. The spacing of standards between any two straining posts shall be

2
uniform and not greater than that shown on the Drawing. In rock or hard material standards
shall be either driven or set in holes drilled into the rock. The size of drilled holes shall be such
that a tight fit is obtained. Care shall be exercised when driving standards in order to prevent
buckling or damaging them.
All posts and standards shall be accurately aligned and set to plumb. After posts and standards
have been firmly set in accordance with the fore-going requirements, the fence wire shall be
attached thereto at the spacing shown on the Drawing.
404 INSTALLATION OF WIRE
All fencing wire shall be wired to the sides of standards or posts in order to prevent the wires
from being displaced and becoming loose. The wire shall be carefully stretched and hung
without sag in true alignment. It shall not be stretched so tightly that it breaks or the end,
corner, straining or gate posts are pulled up.
Each strand of fencing wire shall be securely fastened in the correct position to each standard
with soft galvanized binding wire. The binding wire for each horizontal fence wire shall pass
through a hole or notch in the standard to prevent slipping of the fence wire in a vertical
direction, while the ends of the wire shall be wrapped at least four times around the fencing
wire to prevent it from moving in a vertical direction.
At end, corner, straining and gate posts the fencing wire shall be securely wrapped twice
around the posts and secured against slipping by tying the end tightly around the wire by
means of at least six snug, tight twists.
Splices in the fencing wire shall be permitted if made in the following manner using a splice
tool. The end of each wire at the splice shall be carried at least 75 mm past the splice tool and
wrapped snugly around the other wire for not less than six complete turns, the two separate
wire ends being turned in opposite directions. After the splice tool is removed the space left by
it in the splice wire shall be closed by pulling the wire ends together. The unused ends of wire
shall be cut close so as to leave a neat splice.
The gaps between gate posts and the adjacent straining posts shall be fenced off with short
fencing wires or as shown on the Drawing.
Droppers shall be tied to each fence wire with soft binding wire in the required position as
specified for standards, to prevent slipping in a vertical direction. The spacing of dropers
between any two straining posts shall be uniform. Anchoring to structures shall be done as
shown on the Drawing.
The completed fences shall be plumb, true to line with all posts, standards and stays firmly set. The
height of the lower fencing wire above the ground at posts and standards shall not vary by more than 25
mm from their prescribed relative vertical positions.
405 INSTALLATION OF GATES
(a) Gates shall be installed at the positions indicated in the Drawing. The gates shall be hung on
gate fittings in accordance with the requirements shown on the Drawing. Gates shall be so erected that
they swing in a horizontal plane at right angles to the gate posts, clear of the ground in all positions. At
pedestrian and security fences the double swing gates shall not leave a gap of more than 5 mm
between them when closed and single swing gates shall not leave a gap of more than 5 mm from the
gate post when closed.

3
(b) The Contractor shall, on completion of each Section of fencing, remove all cut-offs and
other loose wire or netting so as not to create a hazard to grazing animals or a
nuisance to the owners of the ground.
406 MEASUREMENT
The fencing shall be measured in linear metres inclusive of all excavations, installation of posts
and standards, barbed wires, painting if any, entry gates and other requirements necessary to
complete the work as per this Specification.
407 PAYMENT
The fencing, measured as stated above, shall be paid at the contract unit rate which shall be
the full and the final compensation to the Contractor as per Clause 11

4
SECTION 500 - QUALITY CONTROL
Page No.
501 SCOPE 5–1

502 CONTRACTOR RESPONSIBLE FOR THE QUALITY OF THE WORKS 5–1
503 QUALITY CONTROL SYSTEM 5–1
504 QUALITY ASSURANCE PLAN 5–2
505 TESTING PROCEDURES AND SETS OF TESTS 5–3
506 LABORATORY TRIALS TO CONFIRM COMPLIANCE WITH SPECIFICATIONS 5–3
507 SITE TRIALS OR TRIAL SECTIONS 5–4
508 CONTROL TESTING DURING CONSTRUCTION 5–6
509 ACCEPTANCE TESTS FOR COMPLETED WORKS OR PARTS OF THE WORKS 5–6
510 RECAPITULATIVE
SCHEDULE OF TESTS 5–7
511 LABORATORY 5–13
STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS
SECTION 500 - QUALITY CONTROL
501 SCOPE
This Section covers the Quality Control System and procedures, Quality Assurance Plan,
programme of tests, trials, and general procedures for acceptance as well as laboratory
arrangements and related facilities which are required for the selection and control of the
quality of materials and workmanship.
502 CONTRACTOR RESPONSIBLE FOR THE QUALITY OF THE WORKS
All materials incorporated and all workmanship performed shall be strictly in conformity with the
requirements of the Specifications and the Contractor shall be responsible for the quality of the
works in the entire construction within the contract.
The Contractor shall provide, use and maintain on the Site, throughout the period of execution
of the contract, a laboratory with adequate laboratory equipment operated by competent staff
for carrying out tests required for the selection and control of the quality of materials and for the
control of workmanship in accordance with these Specifications. The list of laboratory
equipment to be procured and laboratory facilities to be provided shall be got approved from
the Engineer. The Contractor shall assume that tests shall be required on all materials to be
used in the works and on all finished works or part of works.
503 QUALITY CONTROL SYSTEM
The Quality Control System comprises the methods, procedures and organisation for the
Quality Control of the works. The Contractor shall implement the Quality Control System in the
following sequences:
(1) Sequence
(a) Compliant testing for materials including laboratory trials,
(b) Compliant testing for methods and equipment prior to the commencement of
the work, including site trials or trials sections,
(c) Control testing during construction,
(d) Acceptant testing on completed works or parts of the works.
The Contractor shall carry out all necessary tests and shall report to the Engineer the
results of such tests before submitting materials and/or finished works or part of works
to the Engineer for approval in accordance with this Specification. In certain
circumstances, tests may be carried out at the place of manufacture as per the
Conditions of Contracts.
For satisfying himself about the quality of the works, quality control tests shall be
conducted by the Engineer himself or by any other agencies deemed fit by the
SECTION 500 QUALITY CONTROL Page 5 –

1
Engineer. Additional tests may also be conducted where in the opinion of the Engineer
such tests are needed.
Before commencement of the work, the Contractor shall demonstrate a trial run of all
construction equipment for establishing their capability to achieve the laid down
Specifications and tolerances to the satisfaction of the Engineer.
(2) The supply, testing and monitoring shall be in compliance with a Quality Assurance
Plan, Clause 504 and the provisions in the contract.
504 QUALITY ASSURANCE PLAN
The Contractor shall submit to the Engineer for his approval, the Quality Assurance Plan (QAP)
which shall be based on the detailed Programme of the Works as per Clause 116 of these
Specifications.
The Quality Assurance Plan shall include the following :
(1) The Quality Control Schedule Comprising of:
(a) The recapitulative test schedule and testing programme detailing the list of
tests for compliance, laboratory trials, site trials and trials Sections,
construction control tests and their frequencies, tests for acceptance of the
completed works with their dates.
(b) Recapitulative list of "critical" acceptance testing procedures, for equipment or

parts of the works which corresponds to the tasks on the Critical Path
according to the construction Programme.
(c) Estimate of the number of tests to be carried out, list and number of
appropriate equipment to conduct them, list of tests to be conducted outside
the site laboratory, if any, identification of the outside laboratory where
proposed to carry out the test.
(d) List of staff assigned to the laboratory, their position and responsibilities in the
quality control procedures, their qualification and experience, general
description and detailed organisation of the laboratory activities.
(2) The list of sources of materials and/or of manufactured articles, their main
characteristics, their identification mode as provided by the supplier when required; the
programme of supply and procurement of material and/or manufactured articles in
accordance with the Programme pursuant to Clause 116.
(3) The list of tests and quality control procedures to be implemented by the Sub-
contractors, if any, pointing out the "critical" acceptance testing procedures relating to
the Sub-contracted works, which correspond to the tasks on the Critical Path included
in the Sub-contracted works.
The Contractor shall implement the Quality Control in compliance with the approved
QAP.

2
The Engineer's approval of the QAP shall not relieve the Contractor from his
responsibility of the quality of the Works as per the Conditions of Contract and these
Specifications nor shall the Engineer's approval of the QAP exempt the Contractor of
any procedure to inform the Engineer in writing or request for the Engineer's approval
or reapproval as specified in the Conditions of Contract and/or in these Specifications
The Contractor shall monitor and update the QAP on the basis of the decisions taken
at the periodic review meetings or as directed by the Engineer and in accordance with
the programme of the works as per Clause 116 and the Conditions of Contract.
505 TESTING PROCEDURES AND SET OF TESTS
For ensuring the quality of the work, the materials and the workmanship shall be subjected to
testing in accordance with procedures, sets of tests and frequencies as specified in Section
600 and respective Sections of these Specifications. The specified testing frequencies are not
restrictive. The Engineer shall direct for the tests to be carried out as frequently as deemed
necessary that the materials and workmanship comply with their Specifications.
Sets of tests to be carried out on the materials and the workmanship as specified in these
Specifications are recapitulated in Clause 510. Where no specific testing procedure is
mentioned in the Specifications, the tests shall be carried out as per the prevalent accepted
engineering practice or directions of the Engineer.
506 LABORATORY TRIALS TO CONFIRM COMPLIANCE WITH SPECIFICATIONS
(1) Filling and Pavement Materials
Laboratory trials shall be carried out by the Contractor on filling and pavement
materials proposed to be used in the works in their natural state. The laboratory trials
shall establish a relationship between their specified requirements of the end product
and properties which can be determined in the field for construction control purposes.
Laboratory mixes and site trials for bituminous mixes shall be carried out in
accordance with the requirements of the Section 600.
The mixed materials, the composition of which meets the specified requirements and is
accepted by the Engineer, shall then be used in the site trials carried out in accordance
with Clause 507 to ensure that all specified requirements of the completed pavement
courses can be achieved.
The Contractor shall submit the proposals for the site trails to the Engineer at least two
weeks before he intends to use the mixed materials in the site trials in accordance with
Clause 507.
(2) Concrete

3
Laboratory trials for concrete mixes as specified in Clause 2004 shall be carried out by
the Contractor to demonstrate that the composition of the mixes proposed for the
concrete meets the requirements of the Specifications.
The compositions of concrete mixes which meet the specified requirements and are
accepted by the Engineer shall be then used in the site trials carried out in accordance
with Clause 507.
507 SITE TRIALS OR TRIALS SECTIONS
(1) Earthworks and Pavement Materials
Site trails for laying and compaction shall be carried out by the Contractor on all
earthworks and pavement materials proposed for the works, using the same
constructional plant and methods proposed by the Contractor for use in the works. The
trials shall demonstrate the suitability of the method and equipment for laying and
compacting the material to the specified density and confirm that other specific
requirements of the completed earthwork or pavement work can be achieved.
Each trial area shall be at least 100 metres long and to the full construction width and
shall be laid to the specified depth for the material. It may form a part of the works
provided it complies with the required Specifications. Any areas, which do not comply
with the Specifications, shall be removed and new trial shall be made.
The Contractor shall allow in his programme for conducting such site trials and for
carrying out the appropriate tests on them in accordance with the Quality Assurance
Plan. The trials on each pavement layer shall be undertaken at least 21 days ahead of
the commencement of the related work.
The Contractor shall compact each section of the trial over the range of compactive
effort the Contractor is proposing. The data in respect of the following shall be recorded
for each level of compactive effort at each site trial :
(a) The composition and grading of the material before the site trial.
(b) The composition and grading of the material including the lime or bitumen
content.
(c) The moisture content at the time of compaction and the optimum moisture
content for the specified compaction.
(d) The type, size, tyre pressures, frequency of vibration and the number of
passes made by the compaction equipment.
(e) The maximum dry density or target density as appropriate measured on a

sample before and at intervals through the site trials.
(f) The density achieved.
(g) The compacted thickness of the layer.

4
(h) Any other relevant information as directed by the Engineer.
At least, eight sets of tests shall be made by the Contractor on each 100 metres length
of trial section for each level of compactive effort. If all eight sets of results over the
range of compactive effort proposed by the Contractor meet the specified requirements
for the material, the site trial shall be deemed successful. The above data recorded in
the trial shall become the agreed basis on which the particular material shall be
provided and processed to achieve the specified requirements. If required, the QAP
shall be updated or modified on the basis of these data.
If, during the execution of the works, the construction control tests indicate that the
requirements for a material are not being consistently achieved, then work on that layer
shall be stopped until the cause is investigated by the Contractor. Such investigation
may include further laboratory and site trials on the materials to determine a revised set
of data as stated above which when agreed, shall be the basis on which all
subsequent material shall be provided and processed to achieve the specified
requirements.
(2) Concrete
Site trials for concrete mixes as specified in Clause 2004 shall be carried out by the
Contractor to demonstrate the suitability of his mixing equipment. During the site trials,
compliance with the Specifications for weighing equipment, storage of ingredients,
means of transport for concrete, placing, compaction and curing shall be checked by
the Engineer.
During the site trial a full scale sequence including placing and compaction of concrete
shall be carried out on a part of the works which will represent particular difficulties due
to the presence of reinforcement, obstructions or others.
The Contractor shall allow in his programme for conducting the site trials and for
carrying out the appropriate tests, including the time required to obtain compressive
strength test results at 28 days. The Contractor shall inform in writing the Engineer at
least two weeks before the date he proposes to use the concrete mixes in the site trials
with all relevant data including the trial programme, the results of the laboratory trial
tests for the proposed concrete mixes and compliance tests results of all constituents
i.e. cement, aggregates, water and admixtures, if any.
(3) Production of Materials and Crushing Plant
Full scale site trials corresponding to one day production shall be carried out by the
Contractor on all type of materials to be processed using the crushing plant, related
devices and methods to demonstrate the suitability of the equipment to provide
materials of the characteristics and performances specified in these Specifications.
At each stage of the processing, materials shall be sampled, and the following
characteristics shall be determined in the laboratory and recorded :
(a) the grading of the material

5
(b) characteristics of the fine fraction : Sand Equivalent (SE); Mica Content; and if
SE<40, Plasticity Index.
(c) characteristics of the coarse fraction : LAA, AIV, ACV, FI, Adhesivity test,
Crushing Ratio.
At least three sets of tests shall be conducted by the Contractor at each stage of the
production. If all the three sets of results over the full sequence of production proposed
by the Contractor meet the specified requirements for the materials, the site trial shall
be deemed successful.
(4) Other Works and Equipment
Site trials for Prestressed Concrete Works, Painting of Structural Steelwork etc. are
detailed in the relevant Sections of these Specifications.
Approval of the Engineer to a set of data recorded in a site trial shall not relieve the
Contractor of his responsibilities to comply with the requirements of these
Specifications
508 CONTROL TESTING DURING CONSTRUCTION
(1) Earthworks and Pavement Materials, Backfill to Drainage and Other

Structures
All earthworks, pavement layers, and backfill to drainage and other structures shall be
subject to control testing (process control) including, if required, testing by the Engineer
in accordance with the Conditions of Contract and Clause 503. The Contractor shall
allow in his programme or sequence of operations for any disturbance or delays
occasioned by such control and testing.
Quality Control procedures are detailed in the relevant Sections of these

Specifications.
509 ACCEPTANCE TESTS FOR COMPLETED WORKS OR PARTS OF THE WORKS
(1) Earthworks and Pavement Materials, Backfill to Drainage and Other

Structures
The Contractor shall request, in writing for the Engineer's approval for each layer of
each section of earthwork, pavement construction and backfill to drainage and other
structures. Such requests shall be made only when the Contractor is fully satisfied that
the section of the works concerned is in the condition required by the relevant
Specifications. Such request shall be accompanied by the tests results required by the
Sub-clause 503 (1) (a), (b), (c) and the relevant Sections of these Specifications.
The Engineer shall thereupon, without undue delay, inspect the Section for any visible
defects including, heaving material (visible during compaction or on proofrolling)

6
segregation, and for the uniformity of the mixing and compaction. If the visual aspects
are satisfactory the Engineer shall test the Section of the works submitted and inform
the Contractor in writing of the results of the tests specifying acceptance or rejection of
the Section or the layer concerned.
Work on a layer shall in no circumstances commence until the preceding layer has
been approved and accepted by the Engineer in writing. The Contractor shall be fully
responsible for protecting and maintaining the condition of the work which has been
submitted for approval.
Should any layer be left unprotected for more than 24 hours subsequent to approval,
the Contractor shall request for reapproval of the layer and the layer shall again be
subject to proofrolling, construction control testing, and tolerance checks in accordance
with these Specifications.
Notwithstanding the Engineer's approval of a layer, the Contractor shall be responsible
for making good any subsequent damage due to traffic, ingress of water or any other
reason and should any damage occur the layer shall again be subject to proofrolling,
construction control testing and tolerance checks in accordance with these
Specifications.
Acceptance tests for other works and equipment are detailed in the relevant Sections
of these Specifications.
510 RECAPITULATIVE SCHEDULE OF TESTS

The tests to be carried out and their frequency for the quality control of the works are detailed
in the relevant Sections of these Specifications.
The following Table 5.1 recapitulates the testing schedule for the main types of works.
Table 5.1: Testing Schedule
PART OR COMPONENT OF THE Section/

WORKS Clause TESTS FREQUENCY
No
PIPE DRAINS, PIPE CULVERTS 700
AND CONCRETE CHANNELS
MATERIALS FOR RE-FILLING THE 701 Identification : Gradation, Plasticity Index, CBR As specified or required by the
TRENCHES In-Situ Density (95% MDD) Engineer
PRODUCTION OF MATERIALS 800
NATURAL AND CRUSHED  Site Trails:  Before starting production
MATERIALS  Other tests on materials  According to the relevant
component of the works
EARTHWORKS 900
FILL MATERIAL  Material Identification, MDD, OMC, CBR  For each new source and in
every 1500 m3 or part of it
COMPACTION  MC  For each new source and in
 Field Density every per 250 m3 or part of it
 One set per 500m2 of each
layer with a minimum 3 test
per Section

7
Table 5.1: (Continued)

No
SUBGRADE 1000
UNTREATED SUBGRADES,
CAPPING LAYERS
MATERIALS 1003  Material Identification, MC MDD, OMC,  For each new material and
& CBR not less than once per 3000
COMPACTION 1004 m² of each layer
 Field Density  Once per 250 m² of each
layer or part of it
MECHANICAL STABILISATION 1005
IN-SITU MATERIAL  Material Identification, MC MDD, OMC,  One test for each new
CBR material and one test per
3000 m² of each layer or
part of it.
STABILISER  Grading, ES (for sand)  One test for each new
source and one test per 500
m3 of additive material or
part of it.
MIXED MATERIAL  MDD,OMC,CBR,MC  One test for each new
material and one test per
400 m² of each layer or part
of it.
COMPACTION  Field Density  Once per 250 m² of each
layer or part of it.
LIME STABILISATION 1006
IN-SITU MATERIAL  Material Identification, MC, MDD, OMC,  One test for each new
CBR material and one test per
3000 m² of each layer or
part of it.
LIME  Quality of Lime  For each consignment
delivered at the site.
MIXED MATERIAL  MDD,OMC,CBR,MC  One test for each new
material and one test per
400 m² of each layer or part
of it.
COMPACTION  Field Density  Once per 250 m² of each
layer or part of it.
SUBBASE, BASE, HARD SHOULDER 1200
AND GRAVEL WEARING COURSE
MECHANICALLY STABLE
MATERIALS FOR SUBBASE 1201
MATERIALS
 Material Identification, MC, Gradation,  Once per 200 m or part of it

3
Plasticity Index, and change in source with a

minimum of 2 tests per
Section
 MDD, OMC  Once per 1000 m3 or part of
it and change of source, with
a minimum of 2 tests per
COMPACTION
Section.
 Field Density and moisture content  Once per 500 m² of each
layer with a minimum of 2
tests per Section.

8

No
GRADED CRUSHED STONE
FOR BASE AND SUBBASE 1202
 Material Identification, MC, Gradation,  Once per 200 m or part of it
3
MATERIALS
Plasticity Index, FI and change in source with a
minimum of 2 tests per Section
 LAA,AIV, Crushing Ratio,  Once per 200 m 3 or part of it
and every change of source
 SSS, CBR  Once per 500 m 3 or part of it
and every change of source
 MDD, OMC  Once per 1000 m3 or part of it &
every change of source, with a
COMPACTION minimum of 2 tests per Section.
 Field Density and moisture content  Once per 500 m² of each layer
with a minimum of 2 tests per
Section.
WATER BOUND MACADAM
BASE AND SUBBASE 1203
 Material Identification, Gradation,  Once per 200 m3 or part of it
MATERIALS Flakiness Index, and change in source with a
minimum of 2 tests per Section
 LAA, AIV  Once per 200 m 3 or part of it
COMPACTION and change in source.
Section.
GRAVEL WEARING COURSE

MATERIALS 1205  Material Identification, Gradation,  Once per 300 m 3 or part of it
Plasticity Index, CBR, LAA, AIV and for each new source
 MDD,OMC  Once per 400 m 3 or part of it
COMPACTION and for each change in sources
Section.
BITUMINOUS SURFACE AND 1300
BASE COURSE
PRIME COAT - TACK COAT 1302
 Quality of Binder  Certificates from suppliers.
MATERIALS
 One set of tests for each 50,000
litres of supply or part of it
CONSTRUCTION  Binder temperature for application  At regular close intervals
 Rate of spread of binder  2 tests per run
SURFACE DRESSING 1303
MATERIAL  Material Identification, Gradation, FI  Once per 50 m 3 or part of it and
change in source
 LAA, AIV, CR  Once per 250 m3 or part of it and
change in source
 Degradability test, SSS  Once per 500 m3 or part of it and
change in source
 Striping Value  One set of 3 specimens for
each source of supply. Then,
when warranted, by change in
the quality of aggregates.

9

No
SURFACE DRESSING 1303
MATERIALS (Continued)
 Quality of Binders  Certificates from suppliers.
litres or part of it of supply.
CONSTRUCTION  Rate of application of Chippings  Two per day
 Binder temperature for application  At close intervals
 Rate of application of Binder.  Two per run
PENETRATION MACADAM
(SEMI-GROUT) 1304
MATERIALS  Material Identification, Gradation,  Once per 100 m 3 or part of it

and change in source
 LAA, AIV, SSS  Once per 500 m 3 or part of it
CONSTRUCTION litres of supply or part of it
 Binder temperature for application  At close intervals
 Rate of application of binder and  Two per run
chippings.
SAND SEAL 1305
MATERIALS  Material Identification, Gradation,  Once per 50 m3 or part of it and

Plasticity Index change in source
CONSTRUCTION  Binder temperature for application  At close intervals
 Rate of application of Binder.  Two per run
SLURRY SEAL
1306
MATERIALS  Material Identification, Gradation,  Once per 50 m 3 or part of it and
change in source
 Sand Equivalent  Once per 200 m 3 or part of it
CONSTRUCTION
 Two per 1000 sq.m
 Rate of application of slurry mixture.
ASPHALT CONCRETE
1308
MATERIALS  Material Identification, Gradation,  Once per 100 m 3 and change in
source
LAA, ACV, SSS, SE  Once per 500 m 3 and change in
source
Flakiness Index  Once per 100 m3 " " "
Quality of Filler  Per 50 tonnes " " "
Penetration test  Daily
 Mixture
Grading and Bitumen Content  Each 100t of mix or part of it
CONSTRUCTION Marshall stability, flow and voids  each 100t of mix or part of it

10
 Control of Temperature  As required
Table 5.1: (continued)

No
SAND ASPHALT 1309
MATERIALS  Material Identification, Gradation,  Once per 100 m3 or part of it and
change in source
Sand Equivalent  Once per 500m3 " " "
Quality of Filler  Per 50 tonnes " " "
 Quality of Bitumen  Certificates from suppliers.
Penetration test  At close intervals as directed by
Engineer.
 Mixture
Grading and Bitumen Content  Each 100tonnes of mix or part of it
Marshall stability,  each 100tonnes of mix or part of it
CONSTRUCTION  Control of temperature  As required
EMULSION AGGREGATE MIX 1310
MATERIALS  Material Identification, Gradation  Once per 100 m 3 or part of it and
change in source
LAA, SSS, SE  Once per 500 m 3 or part of it and
change in source
Quality of Filler  Per 50 tonnes or part of it and
change in source
 Emulsion  Certificates from suppliers.
Water Content  Each 100 tonnes of mix or part of it
Sieve test  Each 100 tonnes of mix or part of it
 Mixture
Grading and Bitumen Content  Each 100 tonnes of mix or part of it
CONSTRUCTION Marshall stability, flow or Duriez test  Each 100 tonnes of mix or part of it
 Compaction  Per 500m² or part of it
COLD ASPHALT 1311
MATERIALS  Material Identification, Gradation,  Once per 100 m 3 or part of it and
change in source
LAA, ACV, SSS, SE  Once per 500 m 3 or part of it and
change in source
Flakiness Index  Once per 100 m 3 or part of it and
change in source
Quality of Filler  Per 50 tonnes or part of it and
change in source
 Emulsion  Certificates from suppliers.
litres of supply or part of it.
Water Content  Each 100 tonnes of mix or part of it
Sieve test  Each 100 tonnes of mix or part of it
 Mixture
Grading and Bitumen Content  Each 100 tonnes of mix or part of it
CONSTRUCTION Marshall stability, flow and voids  Each 100 tonnes of mix or part of it
 Compaction  Per 500 m² or part of it

11
Table 5.1: (continued)

No
CONCRETE 2000
MATERIALS  Cement :  Conservative samples for each
Acceptance tests: supply and not less than every
200 t or part of it.
CONTROL TESTS :  Testing in case of non compliance
Chemical composition of the mixes or storage on site for
Physical properties longer than 1 month
 Aggregates:
Acceptance tests :  Sub-clause 2003 (5)
CONTROL TESTS :  Each delivery and every 100 t or
Grading part of it for fine aggregate and
Silt & clay content 250 t or part of it for coarse
Organic Impurities aggregate
Choride content, sulphate content,  As frequently as required.
Alkali reactivity
Water, Admixtures  Sub-clause 2003 (7) and (8)
CONCRETE
 LAB. TRIALS  Sub-clause 2004 (3)
 SITE TRIALS  Sub-clause 2004 (4)
 Control tests  Early works : every 6 m 3 of each
Compressive strength class.
When compliance is established :
every 20 m3 or part of it.
REINFORCEMENT:  Clause 2014
MISCELLANEOUS STRUCTURES 2400
GABIONS 2401  Gabion wires :  Sub-clause 2401 (4)
Tensile Strength, Mass, Uniformity
MATERIALS and adhesion of Zinc coating
 Specific gravity and water absorption  Sub-clause 2401 (4)
of stones
 Dismantling of gabion boxes for  Every 50 m3 or part of it
workmanship
CRIB WALLS
2402  Gradation of backfill material  Minimum one test for every 250
m3 or part of it and for each
SUB-SURFACE DRAIN
source of material
2404  Gradation Analysis  One set of test for every 50 m 3
and or part of it and for each
change in source of material
BRICKWORKS FOR
STRUCTURES
2502  Quality of Bricks  As required
MATERIALS  Quality of cement and sand
MORTAR 2511  Control tests  Every 10 m3of brick work or part

Compressive strength of mortar of it.
MASONRY FOR STRUCTURES
MATERIALS
2602  Quality of cement and sand  As required
MORTAR 2610  Control tests
Compressive strength of mortar  Every 10m3 of masonry of part of it
 Dismantling of masonry (1m×1m)  Every 30m3of masonry or part of it

12
511 LABORATORY
(1) Location
The Laboratory shall be located on the site as described in the contract or shown on
the Drawing. It may be established specifically for the contract with the approval of the
Engineer.
(2) Setup
All laboratories to be provided under the contract shall be set up and shall be in fully
operating condition not later than sixty days after the Engineer's order to commence
the work.
No construction work shall be permitted until the laboratories have been accepted by
the Engineer.
If the Contractor fails to provide the laboratories within the specified period, the
Engineer shall make alternative arrangements as he considers necessary. These
arrangements may include the use of rented accommodation, purchased caravans,
portacabins and/or the contracting of laboratory services etc. The Contractor shall bear
all the costs of such temporary arrangements made by the Engineer, including that of
additional transport.
(3) Laboratory Equipment
All equipment necessary for testing of materials and workmanship shall be deemed to
form part of the permanent works unless otherwise provided in the contract. It shall be
delivered to the site in accordance with the schedule of requirements of such
equipment described in the contract. However the non-inclusion of any item of such
equipment in the schedule of requirements shall not relieve the Contractor of the
responsibility to supply it if it is required for the proper control of the quality of the
materials and/or workmanship, notably when identified in the list of appropriate
equipment to be supplied in accordance with Clause 504 (1) (c). The equipment shall
be delivered to the site not later than sixty days after the order to commence the works.
(4) Ownership
Unless otherwise stated in the contract the ownership of all laboratories and equipment
shall revert to the Contractor.
(5) Attendance
The Contractor shall keep the Laboratories in a well maintained, clean and habitable
condition.

13
The Contractor shall keep all laboratory equipment in good working condition
throughout the period of the contract at his own expense.
The Contractor shall provide all tools, consumable items for testing and all the
assistance as may be required by the Engineer and his staff for measuring and
checking the works.
(6) Measurement
(a) The laboratory which has been set up and equipped as per requirement of
these Specifications shall be measured for payment in number.
(b) Laboratory Equipment
The laboratory equipment provided as per the required list of these

Specifications shall be measured for payment in one lot for each laboratory.
(c) Laboratory Staff
The laboratory staff assigned as per requirement confirming to the list provided
in the contract shall be measured in man-month for each personnel. The man-
month shall include the holidays and leaves as specified in the contract.
(7) Payment
(a) Laboratory
The laboratory as measured in number shall be paid as per the contract price
on lumpsum basis. The contract price shall be the full and the final
compensation to the Contractor for providing the laboratories premises;
electricity supply; water supply, gas and heating, attendance etc. in
accordance with the requirement of the Specifications.
(b) Laboratory Equipment
The laboratory equipment measured in a lot shall be paid as per contract price
on lump sum basis. The contract price shall be the full and the final
compensation to the Contractor for providing and maintaining all the equipment
needed in accordance with the schedule of requirements as well as other
equipment required for the proper control of the quality of the materials and/or
workmanship in accordance with these Specifications. The price shall also
include the cost for tests to be conducted outside the site laboratories.
(c) Laboratory Staff
The laboratory staff shall be paid at the contract unit rate for each personnel
required and assigned to the laboratory, in accordance with their position and
responsibilities. The duration of the personnel shall be as required by the
quality control and testing activities according to the general programme of
testing. The remuneration rate shall cover salaries, including overtime

14
remuneration if any, allowances, bonuses, social charges and overheads,

travel, accommodation and miscellaneous and incidental expenses etc. and all
costs incurred by the Contractor for the staff who will render their services in
the laboratory on site for the duration as required.

15
SECTION 600 - MATERIALS AND TESTING OF MATERIALS
Page No.
601 SCOPE 6-1

602 QUALITY OF MATERIALS 6-1
603 SOURCES OF MATERIALS 6-1
604 INSPECTION AND ACCEPTANCE OF MATERIALS 6-2
605 MATERIALS AND MANUFACTURED ARTICLES 6-2
606 DEFECTIVE MATERIALS 6-3
607 TRADE NAMES AND ALTERNATIVES 6-3
608 FOREIGN MATERIALS 6-3
609 GENERAL CLASSIFICATION OF MATERIALS 6-4
610 DEFINITION OF GENERAL TYPES OF MATERIALS 6-7
611 SIEVES 6-8
612 SOILS AND GRAVELS 6-8
613 STONE, AGGREGATE, SAND AND FILLERS 6-10
614 CEMENT 6-11
615 LIME 6-12
616 LIME TREATED MATERIALS 6-12
617 CONCRETE 6-13
618 BITUMINOUS BINDERS 6-14
619 BITUMINOUS MIXETURES 6-17
620 REINFORCING STEEL 6-17
621 TESTING OF WELDS 6-18
622 PAINTS FOR STRUCTURAL STEELWORK 6-19
623 BRICKS 6-20
624 MORTAR 6-20
625 REINFORCED CONCRETE PIPES 6-20
626 HIGH DENSITY POLYTHENE PIPES 6-20
627 GEOTEXTILES 6-20
628 TIMBER FOR STRUCTURAL WORKS 6-21
629 PAINT FOR ROAD MARKING 6-21
630 MANHOLE COVERS AND FRAMES 6-21
631 PRECAST CONCRETE CHANNELS 6-21
632 CAST IRON DRAINAGE GRATINGS 6-21
633 GABION 6-21
634 MEASUREMENT AND PAYMENT 6-21
SECTION 600 - MATERIALS AND TESTING OF MATERIALS
601 SCOPE
This section covers the general requirements relating to materials, the specific requirements for
basic materials, the tests and methods of testing which are required for the selection and quality
control of materials.
602 QUALITY OF MATERIALS
The materials supplied and used in the works shall comply with the requirements of these
Specifications. They shall be new, except as provided elsewhere in the contract or permitted by
the Engineer in writing. The materials shall be manufactured, handled and used skillfully to
ensure completed works to comply with the contract.
603 SOURCES OF MATERIALS
The use of any one kind or class of material from more than one source is prohibited, except by
written permission of the Engineer. Such permission, if granted, shall set forth the conditions
under which the change may be made. The sources or kinds of material shall not be changed
without written permission of the Engineer. If the product of any source proves unacceptable,
the Contractor shall make necessary arrangements for the supply of acceptable material. Any
claims for compensation associated with such arrangements or changes shall not be
considered, unless the source of the unacceptable material is designated in the contract as a
source of material.
In the case of borrow pits, gravel, sand, binder, soil deposits and rock quarries, the "source of
material designated in the contract" shall be construed to mean:
(1) any restricted area (within the pit or quarry) which is designated as the source of
material; or
(2) the entire area of the pit or quarry, if no such restricted area is designated.
Movements of equipment within the "source" as above defined shall not be considered as a
"change of source."
Selection and exploitation of material sources as well as use of the materials shall follow the
DOR Environmental Guidelines (latest publication) and comply with other pertinent
environmental specifications including those detailed in Section 100 & 800.
When any manufacture d product, either new or used, is to be furnished by the Employer, the
location at which such material shall be delivered to the Contractor shall be designated in the
contract. In such cases, the Contractor shall haul the materials from the designated delivery
point to the point of use. The compensation for such hauling shall be included in the contract
unit rate for placing the materials in the finished work.
604 INSPECTION AND ACCEPTANCE OF MATERIALS
SECTION 600 MATERIALS AND TESTING OF MATERIALS Page 6 –1

Final inspection and acceptance of materials shall be made only at the site of the work. The
Engineer reserves the right to sample, inspect, and test the materials throughout the duration of
the works and to reject any materials which are found to be unsatisfactory.
A preliminary inspection of materials may be made at the source for the convenience and
accommodation of the Contractor, but the presence of a representative of the Engineer shall
not relieve the Contractor of the responsibility of furnishing materials complying with their
Specifications.
The representative of the Engineer shall have free entry at all times to those parts of any plant
which concern production of the materials ordered.
605 MATERIALS AND MANUFACTURED ARTICLES
(1) Order for Materials and Manufactured Articles
The Contractor shall, before placing any order for materials and manufactured articles
for incorporation in the Works, submit to the Engineer the names of the firms from
whom he proposes to obtain such materials and manufactured articles, giving for each
firm a description of the materials and manufactured articles to be supplied, their origin,
the manufacturer's specification, quality, weight, strength and other relevant details.
The Contractor shall submit the samples of such materials and manufactured articles
when requested by the Engineer and when appropriate, manufacturer's certificates of
recent test carried out on similar materials and manufactured articles shall also be
submitted.
(2) Storage
All materials and manufactured articles shall be stored on site in a manner acceptable
to the Engineer. The Contractor shall carefully protect all work, materials and
manufactured articles from the weather and vermin.
(3) Test Certificates
When instructed by the Engineer, the Contractor shall submit to him all Test Certificates
from the suppliers/manufacturers of the materials and/or manufactured articles to be
used for the contract. Such certificates shall certify that the materials and/or
manufactured articles concerned have been tested in accordance with the
requirements of these Specifications. All Test results shall be enclosed along with such
certificates. The Contractor shall provide adequate means of identifying the materials
and/or manufactured articles delivered on the site with the corresponding certificates.
606 DEFECTIVE MATERIALS
All materials not conforming to the requirements of the contract shall be rejected whether in
place or not. They shall be removed immediately from the site unless otherwise permitted by
the Engineer. Even after rectification of the defects no rejected material shall be used in the
work unless approved by the Engineer in writing. Upon failure of the Contractor to comply
promptly with any order of the Engineer given under this Clause, the Engineer shall have
SECTION 600 MATERIALS AND TESTING OF MATERIALS Page 6 –

2
authority to cause the removal and replacement of rejected material and to deduct the cost
thereof from any monies due to the Contractor.
607 TRADE NAMES AND ALTERNATIVES
For convenience in designation in the contract, certain articles or materials to be incorporated

in the work may be designated under a trade name or the name of a manufacturer and his
catalogue information. The use of an alternative article or material which is of equal or better
quality and of the required characteristics for the purpose intended shall be permitted, subject
to the following requirements:
(1) The proof as to the quality and suitability of alternatives shall be submitted by the
Contractor. He shall also furnish all information necessary as required by the Engineer.
The Engineer shall be the sole judge as to the quality and suitability of alternative
articles or materials and his decision shall be the final and binding upon the Contractor.
(2) Whenever the specifications permit the substitution of a similar or equivalent material
or article, no tests or action relating to the approval of such substitute material shall be
made until the request for substitution is made in writing by the Contractor
accompanied by complete data as to the equality of the material or article proposed.
Such request shall be made well in advance to permit approval without delaying the
work.
608 FOREIGN MATERIALS
Materials which are manufactured, produced or fabricated outside Nepal shall be delivered at a
point in Nepal as specified in the contract where they shall be retained for a sufficient time to
permit inspection, sampling, and testing. The Contractor shall not be entitled to an extension of
time for acts or events occurring outside Nepal and it shall be the Contractor’s responsibility to
deliver materials obtained from outside Nepal to the point of delivery in Nepal. The Contractor
shall supply the facilities and arrange for sting required at his own cost. All testing by the
Contractor shall be subject to witnessing by the Engineer.
The Contractor shall furnish to the Engineer a “Certificate of Compliance” with the
specifications from the manufacturer, producer or fabricator of foreign material where required.
In addition, certified mill test reports clearly identifiable to the lot of material shall be furnished
where required in these Specifications or otherwise requested by the Engineer. Where
structural materials requiring mill test reports are obtained from foreign manufacturers, such
materials shall be furnished only from those foreign manufacturers who have previously
established, to the satisfaction of the Engineer, the sufficiency of their in-plant quality control, as
deemed necessary by the Engineer or his representative, to give satisfactory assurance of
their ability to furnish material uniformly and consistently in conformance with their
Specifications. At the option of the Engineer, such sufficiency shall be established whether by
submission of detailed written proof thereof or through in-plant inspection by the Engineer or
his representative.
If the welding of steel for structural steel members or the casting and pre-stressing of precast
prestressed concrete members is to be performed outside of Nepal, the following requirements
shall apply:

3
(1) Such fabrication shall be performed only within the plants and by fabricators who have
previously established, to the satisfaction of the Engineer, that they have the
experience, knowledge, trained manpower, quality control, equipment and other
facilities required to produce the quality and quantity of the work required. At the option
of the Engineer, prequalification of the plant and fabricator shall be established either
by the submission of detailed written proof thereof or through in-plant inspection by the
Engineer or his representative, or both.
(2) The Contractor shall make written application to the Engineer for approval for such
foreign fabrication at the earliest possible time and in no case later than 60 calendar
days in advance of the planned start of fabrication. The application shall list the
specific units or portion of a work which shall be fabricated outside of Nepal.
(3) The Contractor shall advise the Engineer, in writing, at least 20 calendar days in
advance of the actual start of any such foreign fabrication.
(4) All documents pertaining to the contract, including but not limited to, correspondence,
tender documents, working drawings and data shall be written in the English/Nepali
language and all numerical data shall use the metric system of units of measurement.
609 GENERAL: CLASSIFICATION OF MATERIALS
Classes of soils and classes of materials referred to in the relevant Sections correspond to the
General Classification of Soils and Materials for Road and Bridge Works in Nepal and are
given in the Table 6.1, Table 6.2 and Table 6.3.
Table 6.1 shows the classification of rocks and soils and includes definitions, identification
criteria for stones and soils.
Table 6.2 shows conditions for rock and soil utilisation as subgrade, capping layers and
pavements.
Table 6.3 shows Material Classification into Classes of Quality.
Table 6.3 : Classes of Material Quality
MATERIAL LAA AIV SSS Degradability Flakiness Crushing
CLASSES % ACV Test Test Index Ratio
% % % %
A <25 <20 <12 <5 <20 100
B <30 <20 <12 <5 <25 100
C1 <35 <25 <12 <5 <25 80
C2* <30 <20 <12 <5 <25 -
D1 <40 <30 <12 <5 <30 60

4
D2* <35 <20 <12 <5 <30 -
E1 >35 & <50 <25 <18 <10 - -
E E2 >40 & <50 <30 <18 <10 - -
E3 >50 <30 <18 - - -
(1): Criteria to be applied to crushed materials only.

* Classes for rounded materials only.

5

610 DEFINITION OF GENERALTYPES OF MATERIALS
The following definitions shall apply to materials in this Section and other relevant Sections.
(1) "Topsoil" shall mean the top layer of soil that can support vegetation. It shall include all
turf
acceptable for turfing.
(2) "Suitable Material" shall comprise all that is acceptable in accordance with the
contract for use in the works and which is capable of being compacted in the manner
specified in Clauses 909 and 910 to form a stable fill having side slopes as indicated
in the Drawing. The material used in fill (except rock fill) shall not contain rock
fragments with dimensions of more than 75 mm.
(3) "Unsuitable Material" shall mean other than suitable material and shall include:
(a) Material from swamps, marshes or bogs;

(b) Peat, logs, stumps, perishable material, organic clays;
(c) Material susceptible to spontaneous combustion;
(d) Material in a frozen condition;
(e) Clay of liquid limit exceeding 70 and/or plasticity index exceeding 45.
Materials stated above in d), if otherwise suitable shall be classified suitable when
unfrozen.
(4) “Rock fill” shall consist of hard material of suitable size for deposition and compaction
as given in Clause 909 and also may comprise rock as defined in Clause 903 and
broken stones.
(5) “Well Graded Granular Material” consisting of gravel and/or sand shall conform to
Clause 609.
(6) "Rock fall", coarse alluvial material shall be loose soils such as moraines, debris, or
alluvial material containing large blocks or large boulders. Individual blocks or boulders
of hard materials greater than 0.3m 3 each in volume shall be classified as hard
material.
(7) "Hard Material" shall mean any material which conforms to the requirements
of Sub-clause 903(4).
611 SIEVES
IS sieves shall be used for all tests. Based on IS-460 the standard sieves series shall be as
follows:
125; 90; 75; 63; 50; 45; 40; 37.5; 31.5; 25; 22.4; 20; 19; 16; 12.5; 11.2; 10; 9.5; 8; 6.3 ;
5.6; 4.75; 4.00; 2.8; 2.36; 2; 1.7; 1.4; 1.18; 1; 0.85; 0.71; 0.6; 0.5; 0.425; 0.400;
0.300; 0.250; 0.212; 0.180; 0.150; 0.125; 0.090; 0.075 mm.
612 SOILS AND GRAVELS

(1) Sampling and Samples
Sampling of soils and gravels shall be carried out as specified or as directed by the
Engineer.
Samples shall be prepared for testing as indicated in IS 2720 part I, except that:
(a) The mass (in g) of a sample required for sieve analysis is about 400D, D being
the maximum particle size (mm).
(b) Sample containing particles larger than 19 mm size shall be prepared for
compaction and CBR tests as described hereunder, provided the proportion in
weight of such particles is less than 30%. An adequate quantity of
representative material shall be sieved over the 50 mm and 19 mm sieve. The
material passing the 50 mm sieve and retained on the 19 mm sieve shall be
weighed and replaced with an equal mass of material passing the 19 mm sieve
and retained on the 4.75 mm sieve. The material for replacement shall be
taken from the remaining portion of the main sample.
When preparing gravel samples, the aggregations of particles shall be broken

with a wooden or rubber hammer or pestle. Care shall be taken that no
individual particles are crushed in the operation.
(2) Standard Methods of Testing
Tests on soils and gravels shall be performed in accordance with the standard methods
given in Table 6.4.
Table 6.4: Tests Procedures Applicable to Disturbed/Undistributed Samples of

Soils and Gravels
Tests Test procedure

Determination of :
i) Moisture Content IS 2720 Part 2 (Oven-drying method)
ii) Liquid Limit IS 2720 Part 5 (Cone Penetrometer or by Casagrande
Apparatus) ApparatusaP
iii) Plastic Limit IS 2720 Part 5
iv) Plasticity Index IS 2720 Part 5
v) Linear Shrinkage IS 2720 Part 20
vi) Specific Gravity of Particles IS 2720 Part 3
vii) Particle Size Distribution IS 2720 Part 4
viii) Organic Matter Content IS 2720 Part 22
ix ) Total Sulphate Content IS 2720 Part 27
x) pH Value IS 2720 Part 26 (Electrometric Method)
xi) Mica Content - Manual mineralogical counting
xii) Density-Moisture Content IS 2720 Part 7
relationship (2.5 kg rammer)
xiii) Density-Moisture Content IS 2720 Part 8
relationship (4.9 kg rammer)
xiv) California Bearing Ratio IS 2720 Part 16
xv) Sand Equivalent IS 2720 Part 37 (Mechanical Shaker or Manual Shaker

8
method)
xvi) Field Dry Density IS 2720 Part 28/Part 29
xvii) Unconfined compression test IS2720 Part 10
xviii) Consolidation test IS2720 Part 15
xix) Direct shear test IS2720 Part 13
xx) Triaxial test IS2720 Part 11,12
xxi) Hydrometer analysis IS 2720 Part 4
xxii) Vane shear test IS 2720 Part 30
It is further specified that:
(a) Wherever in the text of these Specifications and the Special Specification the
term "x% of the MDD (IS 2720 Part 27 or IS 2720 Part 28) is used it shall
mean that a standard of compaction shall be achieved such that the dry
density of the compacted material is x% of the maximum dry density
determined from the respective tests mentioned in Table 6.4. Samples for the
compaction tests shall be taken before compaction of the layers begins unless
in the opinion of the Engineer the compactive effort proposed or applied by the
Contractor is such that the material characteristics have changed in which
case the samples for the tests shall be taken after all compaction is complete.
(b) Compaction tests: when the material is susceptible to crushing during

compaction, a separate and new sample shall be used in the determination of
each point on the moisture/density curve.
(c) The dry density of material placed in the works shall be determined by the
Sand Replacement Method unless the Engineer directs to use a nuclear
method or other method. In the case of nuclear method, tests shall be done at
least at the same frequency required when using the Sand Replacement
Method, but at each nuclear densometer test location the average of three
readings taken at positions rotated by 90° shall be used. A check/comparison
test using the Sand Replacement Method shall be carried out at 10 test
interval.
Initial calibration of the nuclear density testing equipment shall be done by

carrying out at least fifty tests in parallel with the Sand Replacement Method
for each different material encountered. The check tests shall be used to
update the initial calibration of the nuclear density testing equipment.
613 STONE, AGGREGATE, SAND AND FILLERS
(1) Sampling and Preparation of Samples
Sampling shall be carried out as per ASTM–D75 and the samples shall be prepared in
accordance with IS 2386 or according to sampling procedures specified for the
Standard Methods of testing given in Table 6.5.
(2) Standards Methods of Testing
Tests on stone, aggregate, sand and filler shall be performed in accordance with the
standard procedures given in the Table 6.5.

9
Table 6.5: Tests Procedures Applicable to Stone Aggregate and Fillers
Tests Test Procedure

Determination of:
i) Particle Size Distribution IS 2386 Part 1
(Gradation)
ii) Clay, Silt, Dust in Aggregates IS 2386 Part 2
iii) Flakiness Index IS 2386 Part 1
iv) Specific Gravity IS 2386 Part 3
v) Moisture Content IS 2386 Part 3
vi) Bulk Density,Voids & Bulking IS 2386 Part 3
vii) Soluble Chloride Content BS 812 Part 117
viii) Mica Content Manual mineralogical counting
ix) Water Absorption 1S 2386 Part 3
x) Crushing Ratio Manual counting & weighing
xi) Los Angeles Abrasion IS 2386 Part 4
xii) AIV - ACV IS 2386 Part 4
xiii) Polished Stone Value IS 2386 Part 4
xiv) Degradability Test NFP 94 - 067
xv) Sodium Sulphate Soundness IS 2386 Part 5
xvi) Alkali Aggregate Reactivity Test IS 2386 Part 7
xvii) Bitumen Adhesiveness (Vialit NFP-98-274-1
Test)
xviii) Deleterious Substances IS 2386 Part 2
xix) Sand Equivalent IS 2720 Part 37
xx) Crushing Strength of stone IS 2386 Part 4
614 CEMENT
Ordinary and High Strength Portland Cement (OPC and HSPC), Portland Slag Cement (PSC),
Portland Pozzolana Cement (PPC) shall be sampled according to IS 3535 and tested
according to IS 4031.
Chemical and physical requirements for Ordinary Portland Cement, High Strength Portland
Cement, Portland Slag Cement and Portland Pozzolana Cement shall be in accordance with IS
269, IS 8112, IS 12269, IS 455, IS 1489 respectively.
The requirements on their physical characteristics shall be as given in Table 6.6.
Table 6.6: Requirements on the Physical Characteristics of Cement
S.N. Physical characteristics OPC / PSC HSPC Test Procedure
i) Fineness, m2/kg: (by Blaine's Air Permeability 225 225 IS-4031

method) Part 2
ii) Setting Time :
(a) Minimum Initial Setting Time (minutes) 45 45
IS 4031 Part 5
(b) Maximum Final Setting Time (minutes) 600 600
iii) Soundness by Lechatelier method, mm, 10 10 IS 4031 Part 3

maximum

10
iv) Compressive Strength :

Minimum Average Compressive Strength of
three mortar cube(N/mm²)
(a) 3 days 16 27
(b) 7 days 22 37 IS 4031 Part 6
(c) 28 days 33 53
615 LIME
Limes shall be sampled and tested in accordance with BS 890 and shall comply with all
requirements specified therein.
Lime for treatment of road materials shall be Hydrated Calcium Lime or Quicklime and, unless
otherwise specified, shall comply with the requirements given in Table 6.7.
Table 6.7: Requirements of Lime for Treatment of Road Materials
S. No. Characteristics Hydrated lime Quicklime

i) Fineness
Residue on 0.212 mm sieve - Maximum 1% 10%
Residue on 0.075 mm sieve - Maximum 10% 50%
ii) Chemical requirements
Free lime content - Minimum 50% 60%
Hydrated lime content - Maximum - 5%
616 LIME TREATED MATERIALS
(1) Sampling
Sampling and preparation of samples of lime treated material shall be carried out as
specified or as instructed by the Engineer except that:
Samples containing particles larger than 19 mm shall be prepared for compaction and
CBR tests as specified in Sub-clause 612 (1)b). (The fraction coarser than 19 mm shall
be replaced by an equal weight of material passing through 19mm sieve and retained
on 4.75 sieves).
(2) Standard Methods of Testing
The tests on lime treated materials shall be performed in accordance with the Standard
methods given in Tables 6.4 and 6.8.
Table 6.8: Additional Tests Procedures Applicable to Lime Treated Materials

Determination of :
(i) Unconfined Compressive Strength (UCS) BS 1924 – Part2
(ii) Effect of immersion on UCS BS 1924 – Part 2
(iii) Lime Content BS 1924 – Part 2

11
617 CONCRETE
Sampling and testing on concrete shall be carried out in accordance with the standard methods
given in the Table 6.9.
Table 6.9: Tests Procedures Applicable to Concrete
Tests Test Procedures

Determination of :
(i) Air contents of fresh concrete BS 1881–106
(ii) Density of hardened concrete BS 1881–114
(iii) Compressive strength of concrete cubes BS 1881–116
(iv) Tensile splitting strength BS 1881–117
(v) Flexural strength BS 1881–118
(vi) Compressive strength of concrete cores BS 1881–120
(vii) Water absorption BS 1881–122
(viii) Mixing and sampling fresh concrete in
laboratory BS 1881–125
(ix) Normal curing of test specimens (20 o C
method) BS 1881–111
(x) Accelerated curing of test specimens BS 1881–112
(xi) Making test cubes from fresh concrete BS 1881–108
Non destructive tests shall be carried out in accordance with the standard method and
recommendations given in Table 6.10 as and when required.
Table 6.10: Non-destructive Tests Applicable to Concrete
S.No. Tests References to Test Procedures

(i) Method of testing hardened concrete for other than
strength BS 1881–5
(ii) Guide to the use of non destructive methods of test
for hardened concrete BS 1881–201
(iii) Recommendation for surface hardened testing by
rebound hammer BS 1881–202
(iv) Recommendation for measurement of velocity of
ultrasonic pulses in concrete BS 1881–203
(v) Recommendation on the use of electromagnetic
cover meters BS 1881–204
(vi) Recommendation for the assessment of concrete
strength by near to surface tests. BS 1881–207
The test specimens shall be cured at a temperature of 27°C  2°C.
Water to be used in concrete shall be tested as specified in BS 3148.
The total chloride content, expressed as chloride ion, arising from all ingredients in a mix
including cement, water and admixtures shall not exceed the following limits, expressed as a
percentage of the weight of cement in the mix :-
For prestressed concrete, steam cured concrete or concrete

12
containing sulphate resisting or supersulphated cement : 0.1 per cent
For any other reinforced concrete : 0.4 per cent
The total sulphate content expressed as SO 3 of all the ingredients in a mix including cement,
water and admixtures shall not exceed 0.4 per cent by weight of the aggregates or 4.0 per cent
of the weight of the cement in the mix, whichever is the lesser.
618 BITUMINOUS BINDERS
Sampling of straight-run and cut-back bitumens shall be carried out in accordance with
ASTM D 140.
Sampling of bitumen emulsion shall be carried out in accordance with BS 434, Part 1,
except that where a delivery is made in drums or barrels, the number of samples shall
be as indicated in AASHTO sampling method, T40 para.11.1.
(a) Straight-run Bitumen
Test on straight-run bitumen shall be carried out in accordance with the

standard methods given in Table 6.11.
Table 6.11: Tests Procedure Applicable to Straight run Bitumen

Determination of :
i) Penetration ASTM D 5
ii) Softening point (Ring and Ball) ASTM D 36
iii) Flash and fire points (Cleveland open cup) ASTM D 92
iv) Loss on heating ASTM D 6/D1754
v) Ductility ASTM D 113
vi) Water Content ASTM D1461/D95
vii) Solubility in Trichloroethylene ASTM D 2042
viii) Specific gravity ASTM D70
ix) Penetration of residue from loss on heating ASTM D5
(b) Cut Back Bitumen
Test on cut-back bitumen shall be carried out in accordance with the standard
methods given in Table 6.12.
Table 6.12: Tests Procedure Applicable to cutback Bitumen

Determination of :
i) Kinematic viscosity ASTM D 2170
ii) (a) Flash point (Tag open cup) (RC-MC) ASTM D 3143

13
(b) Flash point (Cleveland open cup) (SC) ASTM D 92

iii) Penetration ASTM D 5
iv) Specific gravity by hydrometer method ASTM D 3142
v) Asphalt residue of 100 pen (SC) ASTM D 243
vi) Water content ASTM D 95
vii) Distillation ASTM D 402
viii) Penetration of residue from distillation ASTM D 5
ix) Ductility of residue from distillation ASTM D 113
x) Solubility of residue from distillation ASTM D 2042
(c) Bitumen Emulsion
Test on bitumen emulsion shall be carried out in accordance with the standard
Table 6.13: Tests Procedure Applicable to Bitumen Emulsion
Test Test Procedures

Determination of :
(i) Residue on 0.710 mm sieve BS 434 Part I, Appendix C1
(ii) Residue on 0.150 mm sieve " " " C2
(iii) Stability to mixing with coarse aggregate " " " D1
(iv) Stability to mixing with cement " " " D2
(v) Binder content " " " E
(vi) Engler viscosity " " " F1
(vii) Redwood II viscosity " " " F2
(viii) Storage stability (short period) " " " H1
(ix) Storage stability (long period) " " " H2
(x) Particle charge " " " J
(3) Requirements
(a) General
Before any bituminous binder is delivered to the site, the Contractor shall
provide the Engineer with a certificate from the manufacturer that the material
to be supplied complies in all respects with the relevant specifications.
Any bituminous binder delivered in leaking or deteriorated containers shall be

rejected.
(b) Straight-run Bitumens
Straight run bitumens shall comply with all the requirements give in Table 6.14.
Table 6.14: Specification for Straight run Bitumen
S.N. Specifications Penetration Grade

60/70 80/100 180/200
i) Penetration, at 25°C (100g-5s), in 0.1 mm 60-70 80-100 180-200
ii) Softening point (Ring and Ball), °C 44-54 41-51 33-42
iii) Flash point (Cleveland open cup), °C (min) 250 225 200
iv) Ductility at 25°C, cm (min) 100 100 100
v) Loss on heating (5 h at 163°C) % (max) 0.2 0.5 0.5

14
vi) Penetration of residue from loss on heating at 25°C

(100 -5s) % of initial pen (min) 80 80 80
vii) Specific Gravity at 25°C 1.01-1.06 1.00-1.05 1.00-1.05
viii) Water, % by weight (max) 0.2 0.2 0.2
ix) Solubility in tricloroethylene, % by weight (min) 99.0 99.5 99.5
The number of tests and criteria for conformity shall be as per IS 73.
(c) Cut Back Bitumen
Slow curing, medium-curing and rapid curing cut-backs bitumen shall comply
with all the requirements of ASTM Standard Specification D2026, D2027 and
D2028 respectively and the number of tests and criteria for conformity shall be
as per IS 217.
(d) Bitumen Emulsion
Bitumen emulsions shall comply with all the requirements of BS 434, Part 1.
619 BITUMINOUS MIXTURES
Sampling of bituminous mixtures shall be carried out in accordance with ASTM Method
D 979.
Tests on bituminous mixtures shall be carried out in accordance with the standard
Table 6.15: Tests Procedure Applicable to Bituminous Mixtures

Determination of :
i) Moisture and volatile distillates ASTM D 1461
ii) Quantitative extraction of bitumen ASTM D 2172
iii) Specific gravity of compacted mixture ASTM D 1188 & D 2726
iv) Recovery of bitumen from solution ASTM D 1856
v) Coating and stripping ASTM D 1664
vi) Degree of particle coating ASTM D 2489
vii) Maximum specific gravity ASTM D 2041
viii) Degree of pavement compaction AASHTO T230
ix) Marshall stability ASTM D1559
620 REINFORCING STEEL
All reinforcement for use in the Works shall be tested for compliance as specified in Clause
2014 in a Laboratory acceptable to the Engineer and two copies of each test certificate shall be
supplied to the Engineer. The sampling and frequency of testing shall be as set out in the NS
84-2042 and NS 191-2045.

15
In addition to the testing requirements described above, the Contractor shall carry out
additional testing as instructed by the Engineer.
621 TESTING OF WELDS
(1) The tests detailed in Clause 2206 shall be carried out by the methods described in BS
709. The following requirements shall also be met with.
(a) General
In any respect the test results of welded joints shall not be inferior to the British
Standard test requirements for the parent material.
(b) Procedure Trials
(i) Tensile and Bend Test
Should any one of the weld joint pieces selected for transverse tensile
and transverse and longitudinal bend test fail to comply with the
requirements applicable to the parent metal of the joint, 2 additional test
pieces shall be taken from the joint material represented by the test.
Both the test pieces shall comply with the requirements in order to
qualify for the acceptance.
(ii) Charpy V-notch Tests
Should the average impact value obtained from any set of 3 Charpy V-
notch tests on specimens fail to comply with the requirements, 3
additional test pieces from the same sample shall be tested. The
average of the 6 test results shall comply with the test requirements in
order to qualify for acceptance.
(iii) Revised Procedures
In the event of failure to meet the requirements, the Contractor shall

carry out further trials, using revised procedures, and further tests to the
(c) Production Tests
(i) Tensile and Bend Tests
Should any one of the weld joint test pieces selected for transverse
tensile and transverse bend tests fail to comply with the test
requirements applicable to parent metal of the joint represented by the
test, additional specimens shall be taken from the same production test

16
plates and the test shall be repeated. Should any of the additional tests
fail to comply with the requirements, the joint shall be rejected.
(ii) Charpy V-notch Tests
Should the average impact value obtained from any set of 3 Charpy V-
notch specimens selected fail to comply with the test requirements, 3
additional test pieces from the same production test plates shall be
tested. Should the average of the 6 results fail to comply with the test
requirements the joint shall be rejected.
(iii) Re-welding and Re-Testing
In the event of failure to meet the test requirements the welded joint
represented by the tests shall be completely cut out. The joint shall then
be rewelded and the test repeated.
(iv) Non-destructive Testing
A method of non-destructive testing agreed with the Engineer shall be

used for the examination of butt welds in tension members.
622 PAINTS FOR STRUCTURAL STEELWORK
The Contractor shall submit the proposal to the Engineer about the paint system to be used in
the Works.
The system shall comply with Sub-clause 2209 (9) and shall be defined at least by the
following informations, supported by the paint manufacturer's data sheets:
 Type of system, composition of each component,

 Minimum thickness of each coat,
 Drying time at 10°C and 20°C within a range a relevant hygrometric conditions,
including handling conditions, minimum and maximum time of overlap,
 Type of painting method and thinner content, (airless spray, brush, roller etc.)
 Thinner type,
 Blending ratio,
 Maximum time limit of use, by 75% of relative humidity and for a relevant range of
temperature and hygrometric conditions,
 Ripening time for a relevant range of temperatures and at least for 20 0C and 30°C.
 Weather conditions constraint for painting and drying, including minimum and maximum
ambient temperature and temperature of surfaces to be painted.
623 BRICKS
Bricks shall conform to NS-1-2035 with the exceptions specified in Sub-clause 2502(1).
624 MORTAR
Mortar shall comply with Sub-clause 2502(2).

17
625 REINFORCED CONCRETE PIPES
Reinforced concrete pipes shall comply with the requirements of NS 80-2042/IS 458:1988.
626 HIGH DENSITY POLYTHENE PIPES
High density polythene pipes shall comply with the requirements of NS 40-2040.
627 GEOTEXTILES
Geotextile used for sub-surface drains shall be made of polyethylene or polypropylene or

polyster or similar fibres, either woven or nonwoven. Unless otherwise shown on the Drawing,
the geotextile shall:
(a) sustain a load of not less than 10 kN/m at break and have a minimum failure strain of
10 percent when determined in accordance with BS: 6906 or shall have a grab tensile
strength more than 0.4 kN/m and grab elongation corresponding to this limit in
accordance with ASTM D4632.
(b) have apparent opening size as shown on the Drawing. If no size is shown on the
Drawing, then the apparent size shall be 0.1 mm.
(c) allow water to flow through it at right angles to its principal plane, in either direction at
a rate of not less than 50 litres/sq.m./sec. under a constant head of 100 mm,
determined in accordance with BS: 6906 (Part 3) or ASTM D4491, unless otherwise
shown on the Drawing. The flow rate determined in the test shall be corrected to that
applicable to a temperature of 15 0C using data on variation in viscosity of water with
temperature.
(d) have a minimum puncture resistance of 200 N when determined in accordance with
ASTM D 4833.
(e) have a minimum tear resistance of 350 N when determined in accordance with ASTM
D 4533.
Geotextile used for drilled sub-surface drains shall be as specified in Clause 2405.
628 TIMBER FOR STRUCTURAL WORKS
Timber used for structural works shall comply with IS: 883.
629 PAINT FOR ROAD MARKING
Paint for road marking shall comply with NS 408-2054. Paint used for other purposes shall be
as specified in the respective sections of these Specifications.
630 MANHOLE COVERS AND FRAMES
Manhole covers and frames shall be of cast iron and shall comply with IS: 1726-1991.
For manholes constructed in carriageway and shoulders, heavy duty circular covers

18
and frames shall be used. In footpaths, medium duty circular covers shall be used. In
other locations light duty covers and frames shall be used.
631 PRECAST CONCRETE CHANNELS
Precast concrete channels, kerbs, edging, quadrants and gutters shall comply with the
requirements of IS: 5758 - 1984.
632 CAST IRON DRAINAGE GRATINGS
Cast iron gratings for drainage purposes shall comply with the requirements of ARE: 5961 –
1970.
633 GABION
All wire used in the fabrication of gabions and wiring operations during construction shall
comply with the requirements of NS: 169-2045. The wires shall be galvanised with heavy
coating of zinc. The coating of zinc shall comply with NS: 163-2045 (Heavy Coated Wire) as
given in Clause 2401.
634 MEASUREMENT AND PAYMENT
If otherwise not specified in the contract, no separate measurement and payment shall be
made for sampling, samples and testing of materials, trials and construction control/process
control testing. It shall be deemed to have included in the rates of the relevant items for
complying with the requirements of this Section 600.

19
SECTION 700 - PIPE DRAINS, PIPE CULVERTS AND CONCRETE CHANNELS
Page No.
701 PIPE DRAINS AND PIPE CULVERTS 7–1

702 CONCRETE CHANNELLING 7–5
703 COMPLETION OF DRAINAGE WORKS 7–7

SECTION 700 - PIPE DRAINS, PIPE CULVERTS AND CONCRETE CHANNELS
701 PIPE DRAINS AND PIPE CULVERTS
(1) Scope
This Clause covers the works for the construction of pipe drains and culverts with or
without prefabricated reinforced cement concrete pipes and/or high density polythene
pipes (HDP Pipes).
(2) Materials
(a) Reinforced Concrete Pipes
Reinforced concrete pipes shall comply with the requirements of NS 80/2042

or IS 458:1988.
(b) HDP Pipes
HDP pipes shall comply with the requirements of NS 40/2040.
(3) Excavation for Pipes
The foundation bed for the pipe culverts/drains shall be excavated in accordance with
Section 900 true to the lines and levels shown on the Drawing or to such other lines
and depths as the Engineer may direct. The pipes shall be placed in shallow
excavation of the natural ground or in open trenches cut in existing embankments,
taken down to the levels as shown on the Drawing. The additional width of the trench
on either sides of the pipe shall be 150 mm or one-fourth of the diameter of the pipe
whichever is more. Should the Contractor desire to use mechanical plant for
excavating trenches or for laying pipes he shall submit his proposals for approval by
the Engineer, but such approval shall not relieve the Contractor from his
responsibilities in case of damage to pipes.
The pipe shall be placed where the ground for the foundation is reasonable firm.
Where the bottom of the trench as excavated does not provide a suitably firm
foundation for the culvert, due to soft, mucky or other unsuitable material being
encountered, the unsuitable material shall be excavated to such depth, width and
length as directed by the Engineer. The excavation shall then be backfilled with gravel
or other approved granular material which shall be properly shaped and thoroughly
compacted up to the specified level.
(4) Timbering of Pits and Trenches
The sides of trenches shall, where required, be adequately timbered and supported to
the satisfaction of the Engineer. All such excavations shall be of sizes sufficient to
enable the pipes and concrete to be laid accurately and the formwork withdrawn
before refilling and ramming is carried out.
SECTION 700 PIPE DRAINS, PIPE CULVERTS AND CHANNELS Page

7–1
(5) Water in Excavation
Trenches shall be kept free from water until the pipes are installed and the joints have
hardened. The Contractor shall, at his own expense, construct any sumps or
temporary drains that the Engineer may consider necessary. The Contractor shall
make good at his own expense, any damage caused by prolonged and excessive
pumping, and shall take all precautions necessary for the safety of adjoining structures
by shoring or otherwise, during the time the trenches are excavated or open.
(6) Laying and Jointing Pipes
Arrangements for handling including lifting, loading, transporting, unloading, storage

and lowering the pipes in bed shall be such that the pipes do not suffer any damage.
The pipes shall be laid true to line and level, commencing from the outfall. No pipes
shall be laid until the Engineer has approved by the Engineer. Pipes shall be laid such
that each one is in contact with the bed throughout the length of barrel. The pipes shall
be laid closely together against each other so as to obtain tight joints.
Where two or more pipes are to be laid adjacent to each other, they shall be separated
by a distance equal to half the diameter of the pipe subject to a minimum of 450 mm.
Concrete pipe culverts shall be laid on granular bedding or concrete bedding or as

The concrete pipes shall be jointed either by collar joint or flush joint. In case of collar
joint, the collar shall be of reinforced cement concrete 150 to 200 mm wide according
to the diameter of the pipe and having the same structural strength as the pipes to be
jointed. Caulking space shall be between 13 to 19 mm according to the diameter of the
pipe as specified by NS 80/2042 or IS: 458:1988. Caulking material shall be slightly
wet mix of cement and sand in the ratio of 1:2 rammed with caulking irons. Before
caulking, the collar shall be placed such that its centre coincides with the joint and an
even annular space is left between the collar and the pipe. In case of flush joint, the
ends of the pipes shall be spaced to form a self centering joint with a jointing space of
13 mm side. The jointing space shall be filled with cement sand mortar in the ration of
1:2. Care shall be taken to fill all voids and to see that any excess of cement mortar is
neatly cleaned off while each joint is being made and any earth, cement or other
material thoroughly cleaned out of the pipes. All joints shall be made with care so that
the interior surface is smooth and consistent with the interior surface of the pipes. After
finishing, the joint shall be kept covered and damped for at least four days. A properly
fitted plug shall be well secured at the end of each pipes already laid and shall be
removed only when next pipe is being laid or on completion of the culvert or drain. The
trench shall be kept free from water until the joints are thoroughly set.
Jointing of HDP pipes shall be done by heating as prescribed by the manufacturer.

(7) Cement Mortar for Jointing

7–2
Cement mortar for jointing pipes shall consist of one part by weight of portland cement
to two parts by weight of sand. Sand shall comply with Sub-clause 2502 (2). The
materials shall be accurately gauged and mixed in an approved manner. Cement
mortar shall be made in suitable small quantities only as and when required, and any
mortar which has begun to set or which has been mixed for a period of more than the
initial setting time shall be rejected.
(8) Pipe to be left Clean on Completion
On completion, all pipe lines, drains etc., shall be flushed from end to end with water
and left clean and free from obstructions.
(9) Pipes Bedding and Encasing
Pipes shall be laid on granular or concrete bedding or as shown on the Drawing.
(a) Granular Bedding
The pipes shall be laid on a layer of fine granular material, 100 mm thick, after
the bottom of excavation has been shaped to conform to the lower part of the
pipe as shown on the Drawing. The bedding material shall be well graded and
suitably compacted granular material passing 5.6 mm sieve.
(b) Concrete Bedding
Where indicated on the Drawing, the pipes shall be laid on grade M10/40
concrete confirming to Section 2000 so that the bottom of the pipe rests on
concrete of the specified thickness. The thickness of the concrete below the
pipe and the height to which it extends upwards shall be as indicated on the
Drawing.
(c) Concrete Encasing
Where shown on the Drawing, pipes shall be fully encased in concrete as

shown on the Drawing. The grade of the concrete shall be as shown on the
Drawing. In carrying out this work the Contractor shall take care to pack the
concrete under and around the pipes to ensure even bedding and solidity in
the concrete; in no instance shall the concrete be thrown directly on the pipes.
The concrete shall be placed in such a way that all spaces around the pipe are
completely filled with concrete. Concrete casing shall be cast in one
continuous operation until completed. The upper surface of the concrete shall
be struck off with a wooden screed and neatly finished off.
(10) Joining New Work to Old Work
Where partial demolition is required for extension to the existing structures, the contact
face shall be cut to predetermined lines and levels. The loose and fragmented material
shall be removed and projecting steel cleaned and bent as directed by the Engineer.
Where no partial demolition but only extension is required, the contact area shall be
roughened and cleaned of all dirt and loose particles.

7–3
(11) Refilling Trenches
Backfill for pipes and minor drainage structure shall be obtained from the material
excavated in forming the excavation. In the event of there being insufficient excavated
material or the culvert is laid close to or above existing ground level then selected
backfill shall be obtained from borrow pits. All backfill whether from excavated material
or borrow pits shall be suitable material as defined in Clause 902 and shall have a
CBR of at least 5% measured after 4 days soak on laboratory mix compacted to 93%
MDD (Heavy Compaction), plasticity Index of less than 35%, maximum particle size of
40 mm and shall be compacted to a dry density of 93% MDD (Heavy Compaction).
For pipe culverts which have been placed and where no concrete haunch or surround
is called for, selected fill of suitable material available from the excavation shall be
placed in layers not exceeding 150 mm of loose thickness. The material shall be
uniformly mixed with water or dried out such that the moisture content at the time of
compaction is between 95% and 100% of the Optimum Moisture Content. Then it shall
be compacted thoroughly. Similar selected material shall then be laid in layers, not
exceeding 150 mm of loose thickness, mixed, dried or watered as necessary and
carefully compacted, and brought up uniformly on both sides of the pipe up to a height
of not less than 300 mm over the crown. The remainder of the trench shall then be
backfilled with suitable materials, placed in layers not exceeding 150 mm of loose
thickness, mixed, watered or dried as necessary and carefully compacted. All
backfilling material except the top 300 mm below formation level shall be compacted to
a minimum dry density of 93% of MDD (Heavy Compaction). The top 300 mm below
formation level shall be placed in layers not exceeding 150 mm of loose thickness,
mixed, watered or dried as necessary and carefully compacted to at least 95% of MDD
(Heavy Compaction).
For pipe culverts which have been constructed close to, above or where the culverts
protrudes above the existing ground the backfilling under the flanks and alongside and
over the culverts shall be placed and compacted in layers not exceeding 150 mm to a
density of at least the density required for the material in adjoining layers of fill. All
existing ground under this backfill shall be compacted to 93% MDD (Heavy
Compaction) to a depth of 150 mm.
Backfilling shall be carried out simultaneously and equally on both sides of the culvert
to avoid unequal lateral forces. In all cases there shall be cover of at least 600 mm
over the crown of the culvert before construction equipment is driven over it unless
protective measures approved by the Engineer have been provided.
(12) Inlet and Outlet Structures and Catchpits
Catch pits, headwalls, wing walls, aprons and other ancillary works shall be
constructed in accordance with the details shown on the Drawing. Masonry for these
works shall conform to Section 2500 or 2600 as applicable. Concrete shall conform to
Section 2000 and aprons shall conform to Section 2400.
(13) Opening to Traffic
No traffic shall be allowed to cross the pipeline unless the height of the filling is not less
than 600 mm above the top of the pipe line or is as shown on the Drawing.

7–4
(14) Tests and Standard of Acceptance
The Contractor shall submit manufacturer’s test certificates for each lot of pipes
supplied. The test results shall meet the requirements of the relevant Specifications.
Backfilling/Refilling shall be tested in accordance with Section 900 and all the test
results shall meet the criteria specified. Compaction shall be tested in each layer of
backfill/refill. Gradation of granular bedding shall be tested at least once a day and the
test results shall meet the specified criteria.
The pipe drains/culverts shall be constructed to the true lines and levels indicated on
the Drawing or instructed by the Engineer.
(15) Measurement
Pipes shall be measured along their centre between the inlet and outlet ends in linear
meters of individual pipe element of each sizes, completed and accepted in place.
Collar shall not be measured for payment. Excavation, bedding, concrete for encasing
and backfilling works shall be measured separately in cubic meters. Ancillary works
such as head walls, wing walls, etc., shall be measured as provided for in the
respective Sections of these Specifications.
(16) Payment
Pipes, measured as provided above, shall be paid for at the contract unit rates per
linear meter of each particular size which shall be the full and the final compensation to
the Contractor as per Clause 112.
Cost for cement jointing shall deemed to be included in the contract unit rate of pipe.
Ancillary works such as excavation, backfilling, granular bedding and/or concrete for
bedding/encasing and masonry shall be paid for separately, as provided under
respective Clauses of these Specifications.
702 CONCRETE CHANNELING
(1) Scope
This Clause covers the works for the construction of concrete channelling for drainage.
(2) Materials
Concrete channels may be pre-cast units or may be cast in-situ. All concrete work and
reinforcement shall be carried out in accordance with the requirements of Section
2000.

7–5
The material on which concrete is to be bedded shall be granular bedding as provided

in Clause 701.
(3) Construction
(a) Excavation and Bedding
Trenches for channels shall be excavated to the required depth as shown on

the Drawing. The bottom and side of the trench shall be neatly trimmed. All
loose materials shall be thoroughly compacted. The bedding material shall
then be laid on the bottom of the trench and it shall be thoroughly compacted
and accurately shaped to the required line and level. No concrete shall be
placed on uncompacted or disturbed material.
(b) Precast Concrete Channeling
Precast concrete channelling shall be laid with close joints with 1:2 cement
sand mortar at the ends. The joints shall not exceed 10 mm in thickness and
shall be neatly pointed with a pointing trowel. Guide lines and straight edges
shall be used to ensure that the exposed faces and edgings are set to true
lines and levels.
Care shall be taken to protect all precast units against chipping or breakage
during handling and lying. Broken or chipped Sections shall not be used and
shall be replaced with undamaged units.
(c) Cast in-situ Channels
Channels shall be cast in alternative Sections. The length of Sections shall be

uniform throughout and shall be equal to 2 m, except where shorter Sections
are necessary for closures or where otherwise shown on the Drawing.
Forms shall be accurately set to line, levels and elevation and shall be firmly
held in position during the placing of the concrete. Stops at the ends of
Sections shall be placed accurately so as to ensure that the joints are truly
perpendicular to the surface of the concrete and right angles to the edge of the
road. After concrete has been placed in the forms, it shall be tamped and
spaded until the exposed surfaces are entirely covered with mortar. Exposed
faces shall then be finished to smooth and even surfaces.
The forms of exposed concrete surfaces shall be removed after 24 hours after
the concrete has been placed. Minor defects shall be repaired with a 1:2
cement sand mortar. Plastering shall not be permitted on exposed faces and
all rejected portions shall be removed and replaced at the Contractor’s
expense. Exposed surfaces shall be finished while the concrete is still green,
by wetting a soft brick or wooden block and rubbing the surfaces until they are
smooth. When the concrete has smoothed by using water, it shall be rubbed
with a thin paste of 1:1 cement sand mortar until a uniform colour is obtained.

7–6
When completed the Sections shall be cured in accordance with the

requirements of Section 2000.
After the concrete in alternate Sections has been set, the intermediate
Sections shall be cast and finished in accordance with all the requirements
specified above. The exposed end surfaces of the alternate Sections cast first
shall be painted with a coat of approved bituminous emulsion containing 60%
of net bitumen by mass, and the emulsion shall be allowed to set and dry
before the intermediate Sections are cast.
Guide lines and straight edges shall be used to ensure that the exposed faces
are formed to the true line, level and elevation.
All concrete works shall be tested in accordance with Section 2000 and the test results
shall meet the specified criteria. The concrete channelling works shall be constructed
to the true lines and levels shown on the Drawing or instructed by the Engineer.
(5) Measurement
Concrete channelling shall be measured in linear meter. Formworks and reinforcement

shall not be measured separately. Excavation and bedding shall be measured as
provided under respective Sections of these Specifications.
(6) Payment
Concrete channelling shall be paid as per the contract unit rate which shall be the full
and the final compensation to the Contractor as per Clause 112. Excavation and
bedding shall be paid as provided under respective Sections of these Specifications.
703 COMPLETION OF DRAINAGE WORKS
All culverts and/or other drainage works shall be completed well in advance of the construction
of the base course, hard shoulders and/or surfacing of the carriageway.

7–7
SECTION 800 - QUARRIES, BORROW PITS, STOCKPILE AND SPOIL AREAS
Page No.
801 GENERAL 8–1

803 LOCATING MATERIAL SOURCES 8–2
2 804 SAFETY AND
PUBLIC HEALTH REQUIREMENTS 8–4
805 ACCESS ROADS AND TRAFFIC CONTROL 8–4
806 SITE CLEARANCE AND REMOVAL OF TOPSOIL AND OVERBURDEN 8–4
807 SELECTION, MIXING AND STOCKPILING OF MATERIALS 8–5
808 PRE-SELECTION OF MATERIALS 8–5
809 PROCESSING 8–6
810 MATERIAL UTILISATION 8–8
SECTION 800 - QUARRIES, BORROW PITS, STOCKPILE AND SPOIL AREAS
801 GENERAL
Unless otherwise stated in the contract, it is the responsibility of the Contractor to select the
sources of aggregates for concrete, stone for base, subbase, bituminous mix base, binder
course and wearing course, chippings for surface dressing, rockfill for swamps etc. and the
sources of natural/suitable materials, such as fill material, for the construction of embankments,
gravel for subbase, base, surfacing and shoulder. Such sources shall be designated as rock
quarries, quarries, alluvial deposits and borrow pits and are defined in Clause 802. Certain
rock quarries, quarries, alluvial deposits, borrow pits may have or have been identified prior to
the commencement of the contract and the Engineer shall instruct the Contractor as to which of
these shall be utilised for the extraction as natural or suitable materials to be used in the works.
Provisions are included in subsequent clauses of this section of the Specification for additional
rock quarries, quarries, alluvial deposits, borrow pits to be identified and located by the
Contractor during the contract. Stockpile and spoil areas shall be located by the Contractor
subject to the approval of the Engineer.
802 DEFINITIONS
(1) Rock Quarry
A rock quarry is an open surface working in massive rock from which stone is removed
by drilling and blasting for use in the works.
(2) Quarry
A quarry is an open surface working from which stone or aggregates for subbase, base
and surfacing are extracted for use in the works.
(3) Alluvial Deposit
An alluvial deposit is a site where gravel and aggregates of alluvial origin are extracted
for use in the works.
(4) Borrow Pit
A borrow pit is a site from which loose material, other than stone, is removed for use in
the works.
(5) Stockpile Area
A stockpile area is an area where material such as topsoil, fill material, gravel or
aggregate is stockpiled prior to use in the works
(6) Spoil Area
SECTION 800 QUARRIES, BORROW PITS, STOCKPILE AND SPOIL AREAS

Page 8 1
A spoil area is a site upon which surplus or unsuitable materials arising out of the
works are dumped within or beyond the road reserve as indicated on the Drawing or
directed by the Engineer.
803 LOCATING MATERIAL SOURCES
(1) The Contractor shall be responsible for locating all material sources and for the
acquisition or renting of all land required for rock quarries, quarries, alluvial deposits,
borrow pits, spoil and stockpile areas and for access thereto in accordance with the
Conditions of Contract.
The location and size of rock quarries, quarries, alluvial deposit, borrow pits, spoil and
stockpile areas proposed by the Contractor shall be subject to the approval of the
Engineer.
The Engineer shall withhold his approval, if in his opinion the rock quarry, quarry,
alluvial deposit, borrow pit, spoil and stockpile area, or access into them
(a) will have a detrimental effect on the environment;
(b) would be very difficult to acquire;
(c) is in or near an urban centre;
(d) will require an access road which is excessively long;
(e) has excessively thick layers of overburden;
(f) covers too large an area;
(g) would constitute a danger to the public;
(h) is an excessive distance from the location where the material is to be used or
removed from; or
(i) a source of suitable material is closer.
(2) The Contractor shall submit for the Engineer's approval full information regarding the
proposed location of the material source not later than 30 days after issue the order to
commence the works of all rock quarries, quarries, alluvial deposits, borrow pits, spoil
and stockpile areas that the Contractor will require for the whole of the works.
The Contractor's written notice shall include the following for each rock quarry, quarry,
alluvial deposit, borrow pit, spoil and stockpile areas :
(a) A plan at 1:500 scale in ink on a stable transparent material giving details of :
(i) plot boundaries

(ii) owners names and addresses, and if appropriate identification
numbers;
(iii) the District, Location, Registration Section and Number for each plot;

Page 8 2
(iv) local details such as buildings, fences, types and areas of cultivation
and services, all agreed with the Land Owners; and
(v) areas to be used for working areas, stockpile areas, safety blasting
zones etc.
(b) Cadastral maps covering the areas to be acquired when availble.
(c) Details of the proposed access road route.
(d) Technical supporting information relevant to rock quarries, quarries,

alluvial deposits, borrow pits, including:
(i) Summary of geophysical surveys (electric, and /or seismic,),

geotechnical surveys, indicating for alluvial deposits the thickness of
layers, thickness of overburden, lenticular beds, depth and
configuration of the bedrock, etc., and in addition for rock quarries, the
discontinuity families, the intervals between discontinuities, thickness
and nature of the infilling, the Weathering Index,
(ii) Laboratory results including petrographic identification, and for alluvial

deposit material, grading, tests on the fine fraction (PI, SE, Methylene
Blue test, Mica content, Organic matters), tests on the coarse fraction
(LAA, AIV, ACV, Micro Deval, FI, Adhesivity test), CBR test, or for
quarry material, LAA, AIV, ACV, Micro Deval, Adhesivity test, Specific
Gravity, Water Absorption
(iii) Conclusions on qualities and quantities.
(3) Where the Contractor uses a rock quarry, quarry, alluvial deposit, or a borrow pit
identified or instructed by the Engineer he shall obtain the Engineer's approval of the
areas required for the rock quarry, quarry, alluvial deposit, or borrow pit and of the
siting of the access roads into the rock quarry, quarry, alluvial deposit, or borrow pit.
The Engineer may require the Contractor to modify his requirements for any of the
reasons outlined in Sub-clause 803(1) (a), (b), (c), (d),
or (f).
Where rock quarries, quarries, alluvial deposits, or borrow pits, available for inspection
at the time of the Tender, are instructed by the Engineer the Contractor shall satisfy
himself as to the quality and quantity of materials available before providing the
information required in this Clause. Should such investigations reveal that there is
insufficient suitable material for the use for which such material sources were intended,
the Contractor shall immediately inform the Engineer in writing and the Engineer shall
either direct that such sources are extended or that new sources shall be used.
(4) When a rock quarry, quarry, alluvial deposit, borrow pit spoil or stockpile area has
insufficient suitable material or area for the use for which it was intended the Contractor
shall propose in writing that either any existing rock quarry, quarry, alluvial deposit,
borrow pit, spoil or stockpile area be extended or that a new rock quarry, quarry,
alluvial deposit, borrow pit spoil or stockpile area shall be used. The approval and
acquisition of such new or extended rock quarries, quarries, alluvial deposits, borrow
pits, spoil or stockpile areas shall be in accordance with all the above provisions of this

Page 8 3
Clause for the acquisition of the original rock quarries, quarries, alluvial deposits,
borrow pits, spoil or stockpile areas.
804 SAFETY AND PUBLIC HEALTH REQUIREMENTS
The Contractor shall comply with the prevalent laws and Regulations including those of the
Local Authority regarding public health and safety in respect of the operation of rock quarries,
quarries, alluvial deposits, borrow pits, spoil or stockpile areas, and in the absence of, or in
addition to such Regulations, shall comply with the following conditions : -
(1) All areas of work, if they are not naturally under water, shall be drained and kept
drained. Where a quarry or borrow pit has been excavated such that it will not drain
naturally, it shall be kept pumped dry while being used.
(2) The Contractor shall confine his operations solely to the areas provided and shall
demarcate the boundary of the area and erect temporary or permanent fencing as
(3) Where the height of any face exceeds 1 metre, the Contractor shall provide, erect and
maintain at his own expense stockproof fencing and gates to prevent unauthorised
access to the top of the working face.
(4) On completion of the work all faces shall be neatly trimmed to a slope flatter than 1:4.
Where this is impracticable or where the working face is to be left exposed, the edge
shall be permanently fenced, as instructed by the Engineer and measurement and
payment for such fencing shall be in accordance with Section 400.
(5) On completion of work temporary fences and all temporary structures shall be
demolished and removed. All latrine pits shall be filled in and drained. The site shall be
topsoiled and left neat and tidy.
805 ACCESS ROADS AND TRAFFIC CONTROL
The Contractor shall comply with the provisions of Clause 103 and with the Conditions of
Contract with regard to the construction and maintenance of access roads to rock quarries,
quarries, alluvial deposits, borrow pits spoil and stockpile areas and with regard to traffic
operations thereon.
806 SITE CLEARANCE AND REMOVAL OF TOPSOIL AND OVERBURDEN
Unless otherwise specified in the contract or instructed by the Engineer, the Contractor shall
clear the sites of all rock quarries, quarries, alluvial deposits, borrow pits, spoil and stockpile
areas in accordance with Section 200 but measurement and payment shall be made in
accordance with this Section.
All existing fences, trees, hedges and other features which the Engineer shall instruct shall not
be removed or otherwise dealt. They shall be protected in accordance with Section 200.
Unless otherwise directed by the Engineer, the Contractor shall remove topsoil and/or
overburden from rock quarries, quarries, alluvial deposits, borrow pits and spoil and stockpile

Page 8 4
areas. The Engineer shall direct whether topsoil shall be stripped and stockpiled separately or
shall be excavated and spoiled together with the overburden. If suitable, the Engineer may
direct for the use of overburden in the works.
On completion of the work in any rock quarry, quarry, alluvial deposit, borrow pit, spoil or
stockpile area the overburden and/or topsoil which has not been used in the works shall be
pushed back, spread and landscaped over the area of the rock quarry, quarry, alluvial deposit,
borrow pit, spoil or stockpile area. Where topsoil has been stockpiled separately, it shall be
pushed back and spread over the rock quarry, quarry, alluvial deposit, borrow pit, spoil or
stockpile area after landscaping unless the Engineer has instructed that it shall be used for
topsoiling in accordance with Section 600.
807 SELECTION, MIXING AND STOCKPILING OF MATERIALS
Before a quarry, alluvial deposit or borrow pit is opened, the Engineer shall instruct the
Contractor as to the type of material to be excavated and the areas and depth to be worked.
The Engineer may require specific operations of equipment according to the characteristics of
the raw material and the characteristics of the final product to be obtained in accordance with
Clauses 808 and 809 or other relevant Sections of those Specifications.
The Contractor may be required to mix the selected materials by bulldozing into stockpiles
and/or face loading by shovel. The stockpiles shall be formed at least six weeks before
intended use of the materials which are to be treated and at least three weeks before intended
use for materials which are not to be treated.
The Contractor shall ensure that oversize material, clay humus or unsuitable material
encountered in the working operations is separated from the materials proposed for use in the
works and such inferior material shall be removed to spoil.
A separate stockpile shall be used for each type and grading of material.
When removing material from stockpiles, none of the underlying material shall be mixed with it,
and generally at least the bottom 100 mm layer shall be left behind.
Should any stockpile prove surplus to requirements, the Contractor shall spread the material
over the area of the quarry or borrow pit unless directed otherwise by the Engineer.
808 PRE-SELECTION OF MATERIALS
When necessary to meet requirements of the Specifications for materials extracted from
quarries or alluvial deposits the Contractor shall carry out a preliminary size selection or
screening of the raw materials as follows:
(1) Size Selection
The size selection shall be carried out by unloading the materials through appropriate
grids to select the size fraction which contains the required fraction of the required type
of stone specified in the Specifications, based on the identification of the petrographic
composition of the various size classes of the raw material through laboratory trials in
accordance with Clause 506.

Page 8 5
The size selection shall be carried out provided the conditions given in Table 8.1 are
fulfilled, where:
RP (%) = the minimal ratio between the quantity of required material obtained
after processing (including selection, crushing, screening etc.) and the
initial quantity of raw material treated.
Q min (m3) = the minimal quantity of processed materials of such type required for
the works
A, B, = Classes of material to be produced designated in accordance with the

General Classification of materials specified in Section 600.
Table 8.1: Conditions for Pre-selection of Size
Quality classes Construction works Maintenance works

to be produced RP Q min RP Q min
(%) (m3) (%) (m3)
A 40 7,500 35 4,000
B 70 85,000 60 20,000
(2) Quality Control of the Size Selection
Materials of quality classes A or B shall be tested according to their use in

conformance with the relevant Sections of these Specifications.
When the requirements of the final products are not met, the Engineer may require the
Contractor to control the quality of the size selection.
The quality of the size selection shall be assessed by sampling 1000 boulders or
stones in every 500 m3 of pre-selected materials and counting the boulders or stones
of the required petrographic types. If the percentage of such boulders or stones in the
sample is less than 0.8 of the expected percentage, the corresponding pre-selected
materials shall be pre-selected again.
809 PROCESSING
The Contractor shall use adequate processing equipment and methods to achieve the
characteristics and performances of the aggregates to be produced.
The processing methods may include successive steps such as primary crushing, screening
for elimination of fine and soft materials, secondary crushing and recycling, washing.
The Contractor shall carry out site trials in accordance with Clause 507 using the
Constructional Plant and methods proposed for selecting and processing the materials to
demonstrate their suitability to achieve the materials requirements specified in the
Specifications.
(1) Crushing
The crushing process shall include all crushing stages, such as primary crushing,
secondary crushing or grinding (after primary screening) tertiary grinding (after

Page 8 6
secondary screening), as necessary to meet the requirement of the final product

specified in the Specifications.
The feeding hoppers shall be equipped with appropriate devices, such as drawer or
vibrating metallic desk, to allow for a regular and full charge supply of the materials to
the crushers.
Depending on the type, size and characteristics of the raw material, equipment
required to meet aggregate characteristic and performances requirements may include
the use of equipment given in Table 8-2 according to the classes of quality of the
materials to be produced.
Table 8.2: Crushing Equipment According to Quality Classes of Final Material Product
Quality classes Type of equipment

of the final Primary crushing Secondary crushing or grinding Tertiary grinding
product
A or B
 Jaw Crusher or Gyratory Crusher  Cone Grinder or Gyratory
In general (for more than 1000T/h only) Grinder
(for more than 1000T/h only)
Quartzite & Sand  Gyratory Crusher  Cone Grinder or Gyratory  Cone Grinder
Production (for more than 1000T/h only) Grinder (Gyradisc)
Limestone  Jaw Crusher or Large Opening  Impact crusher

Percussion Crusher (& recycling)
 Cone Grinder
C1  Jaw Crusher (& Recycling)
D1  Jaw Crusher  (& Recycling)
(2) Screening
The Contractor shall eliminate polluted or soft materials after the primary crushing by
screening the crushed materials through a 50 mm mesh screen.
The Engineer may instruct the Contractor to modify the above mentioned size for the
elimination of soft materials according to the results of the laboratory trials.
In case of materials sensitive to crushing, the Engineer may instruct the Contractor to
carry out a secondary screening after the secondary crushing.
(3) Recycling and Sand Production
According to the type and quality of materials to be produced, and notably the sand
materials, the Contractor shall include in the crushing process the recycling of the
coarse fraction resulting from the primary crushing through the secondary crusher or
through the secondary or tertiary grinder.
(4) Washing

Page 8 7
Where the washing of aggregates is required to meet the cleanliness requirements,

and notably for the chippings for surface dressing, the Contractor shall incorporate to
the processing plant an appropriate washing station including adequate equipment
such as vibratory washing machine, a washing screw, washing tube etc. and of
adequate capacity.
Sands with too high mica content shall be washed using appropriate equipment such
as screw classifiers, paddle wheel etc.
(5) Testing
Each type of final products shall be tested in accordance with the tests and frequencies
of testing as specified in the relevant Sections of these Specifications.
(6) Records
The Contractor shall maintain records in respect of the following data throughout the
production period:
(a) daily production
(b) testing results, in accordance with the test schedules specified in the relevant
Sections of these Specifications.
(c) Incident occurred during the production, if any.
810 MATERIAL UTILISATION
All materials from rock quarries, quarries, alluvial deposits, borrow pits as instructed by the Engineer
shall only be used for permanent works shown on the Drawing or instructed by the Engineer and any
other use shall be subject to the Engineer's approval.
No separate measurement and payment shall be made in respect of all items in this Section, if
otherwise not specified in the contract. The Contractor shall be deemed to have allowed the
cost of complying all requirements of this Section elsewhere in his rates including all site
clearance, overburden and topsoil removal, access roads to rock quarries, quarries, alluvial
deposits, borrow pits, spoil or stockpile areas and reinstatement including landscaping and
spreading topsoil.
Where the Engineer has instructed that overburden or topsoil will be used in the works,
measurement and payment shall be in accordance with the relevant Sections of these
Specifications.

Page 8 8
SECTION 900 - EARTHWORKS
Page No.
901 SCOPE 9–1

902 DEFINITIONS AND GENERAL REQUIREMENTS 9–1
903 CLASSIFICATION OF EXCAVATED MATERIALS 9–3
904 EXPLOSIVES AND BLASTING 9–4
905 EXCAVATION IN CUTTING 9–7
906 EXCAVATION BELOW EMBANKMENTS AND BELOW
FORMATION LEVEL IN CUTTINGS 9–7
907 EXCAVATION FOR FOUNDATION 9–8
908 REFILING OF FOUNDATION PITS AND TRENCHES, REMOVAL
OF SUPPORTS AND FILLINGS TO STRUCTURES 9–11
909 FORMING OF EMBANKMENT AND OTHERS AREAS OF FILL 9–12
910 COMPACTION OF EMBANKMENTS AND OTHER AREAS
OF FILL/BACKFILL 9–13
911 COMPACTION TRIALS 9–14
912 BENCHING 9–15
913 EARTHWORKS TO BE KEPT FREE OF WATER 9–15

914 WATERCOURSES 9–15
915 FILLING EXISTING WATERCOURSES 9–16
916 PROCESS CONTROL 9–16
918 PAYMENT 9–17
SECTION 900 – EARTHWORKS
901 SCOPE
This Section covers the works related to the roadway excavation, roadway filling, excavation
for foundation, backfilling, excavation for drains, channels, intercepting drains etc.
902 DEFINITIONS AND GENERAL REQUIREMENTS
(1) Earthwork includes two types of operations i.e. (i) earth excavation and disposal of the
excavated materials (ii) earth excavation and use of excavated materials. The use of
excavated materials may be in the form of filling embankment, backfilling, filling other
areas as required.
Earth excavation and disposal implies excavation of all types of materials including
part of the structures below ground level within and outside of the limit of the right of
way except for otherwise specified, shaping the exposed surface of excavation as
specified or directed by the Engineer, removal, hauling and disposal of the excavated
material at the locations and in the manner as specified or directed by the Engineer.
Excavation and filling implies excavation of materials and shaping the exposed surface
of excavation as stated above, removal, hauling and use of the excavated material at
the location and in the manner as specified or directed by the Engineer.
Excavation and disposal shall include:
(i) Excavation and disposal of any type of material indicated on the Drawing.
(ii) The excavation and disposal of existing surfacing,
(iii) Excavation and disposal of slides, breakages and caving-ins.
(iv) Excavation and disposal for stream channel, trenches and drains etc.
(v) Excavation required in cuts or under embankments below the lowest normal
limit of excavation as indicated on the Drawing or below ground line.
(vi) Excavation and disposal of unsuitable materials.
(vii) Removal or partial removal of existing embankments and disposal of the
materials as shown on the Drawing or as directed by the Engineer.
(viii) Excavation for foundation and disposal of materials.
Excavation and filling shall include:
(i) Filling for embankment
(ii) Filling for guide bunds, coffer dams, etc.
(iii) Backfilling in trenches, foundation pits etc.
(iv) Any type of other filling or backfilling whereby the ground level is raised or a
hole is filled up.
(2) The following definitions of earthwork materials shall apply to this and other Clauses of
these specifications, if otherwise not specified.
(i) "Topsoil" shall mean the top layer of soil that can support vegetation. It shall
include all turf acceptable for turfing.
SECTION 900 EARTHWORKS Page 9 –1

(ii) "Suitable Material" shall comprise all that is acceptable in accordance with the
Contract for use in the Works and which is capable of being compacted in the
manner specified in Clauses 909 and 910 to form a stable fill having side
slopes as indicated in the Drawing. The material used in fill (except for rock fill)
shall not contain rock fragments with dimensions of more than 75 mm.
(iii) "Unsuitable Material" shall mean other than suitable material and shall include:
(a) Material from swamps, marshes or bogs;
(b) Peat, logs, stumps, perishable material, organic clays;
(c) Material susceptible to spontaneous combustion;
(d) Material in a frozen condition;
(e) Clay of liquid limit exceeding 70 and/or plasticity index exceeding 45;
Materials stated above in (d) if otherwise suitable shall be classified suitable when
unfrozen.
(iv) “Rock Fill” shall consist of hard material of suitable size for deposition and
compaction as given in Clause 909 and also may comprise rock as defined in
Clause 903 and broken stones.
(v) “Well Graded Granular Material” consisting of gravel and/or sand shall
conform to Clause 609.
(3) No excavated suitable material other than surplus to requirements of the contract shall
be removed from the site except on the direction of the Engineer. Should the
Contractor be permitted to remove suitable material from Site to suit his operational
procedure, then he shall make good at this own expense any consequent deficit of
filling arising therefrom.
(4) Material in surplus to the total requirements of works, and all unsuitable materials shall,
unless the Engineer permits otherwise, be run to spoil dumps.
(5) Where the excavation reveals a combination of suitable and unsuitable materials the
Contractor shall carry out the excavation in such a manner that the suitable materials
are excavated separately for use in the works without contamination by the unsuitable
materials.
(6) The Contractor shall make his own arrangements for the stockpiling of top-soil and/or
suitable material.
(7) At all times the Contractor shall ensure that earthworks are not damaged by weather
or traffic. In the event of such damage occurred, the Engineer may withdraw approval
from the affected works until the Contractor has carried out repairs to restore the works
to their original condition.
The cost of all such repairs and any additional testing shall be borne by the Contractor.
(8) Prior to commencement of any earthwork, the work shall be set out where required as
specified in Clause 104 following the clearing and grubbing as per Section 200 and a
survey of the existing ground shall be conducted jointly by the Contractor and the

Engineer. The survey records shall serve as initial measurements for the determination
of the final quantities of earthwork performed under the contract.
(9) Work on embankments and/or cuttings in areas required for the construction of bridges
and other structures shall not be carried out until the Engineer agrees that construction
of such structures is sufficiently advanced that there is no interference or damage to
them.
(10) The Contractor shall get approval of the Engineer in respect of method of earthwork,
type of equipment to be used, disposal and other details before commencement of the
earthwork.
903 CLASSIFICATION OF EXCAVATED MATERIALS
The excavated materials shall be classified under the following categories. The decision of the
Engineer in respect of the classification of excavated materials shall be the final and binding
upon the Contractor.
(1) Soft Soil
It shall mean soft soil comprising any of the following:
(a) Vegetable or organic soil, turf, sand, loam clay, mud, peat, black cotton soil,
stiff heavy clay, shale, moorum and any mixture of these soil.
(b) Mud concrete below ground level.
(c) Generally any material which yields to the ordinary application of pick and
shovel or other digging implements.
(2) Hard Soil
It shall mean hard soil comprising any of the following:
(a) Gravel, shingle and river or stream bed boulders having maximum dimensions
up to 300mm in one direction.
(b) Soling of roads, paths, etc. and hard core, macadam surfaces of any
description (water bound, grouted, bituminous surface etc.)
(c) Lime concrete, stone masonry in lime mortar and brick work in lime cement
mortar below ground level.
(d) Generally any material which requires the close application of picks, scarifiers
or other digging implement.
(3) Soft Rock
It shall mean rock comprising any of the following:
(a) Lime stone, sand stone, laterite, soft conglomerate or other soft or
disintegrated rock which can be quarried or split with crowbars or wedges.
(b) Unreinforced portland cement concrete which can be broken up with crowbars
or picks; stone or brick masonry in cement mortar below ground level.
(4) Hard Rock

It shall mean rock comprising any of the following:
(a) Any rock or portland cement concrete for the excavation of which the use of
pneumatic/mechanical equipment or blasting is required.
(b) Reinforced cement concrete (reinforcement cut through, but not separated
from the concrete) below ground level.
(5) Hard Rock (Blasting Prohibited)
It shall mean rock comprising any of the above mentioned hard rock where blasting is
prohibited.
904 EXPLOSIVES AND BLASTING
(1) General
The procurement, transportation, storage, use, account and disposal of balance and
defective explosive materials shall be strictly as per prevalent laws and ordinances
applicable to the work site. Should there be any discrepancy found between
procedures described hereunder and the prevalent laws and ordinance, the later shall
superceed.
Blasting shall be carried out in a manner that completes the excavation to the lines
indicated on the Drawing or as directed by the Engineer, with the least disturbance to
adjacent material. It shall be done only with the written permission of the Engineer.
The Contractor shall adopt such method that is consistent with the safety and job
requirements. Prior to starting any phase of the operation, the Contractor shall provide
information describing pertinent blasting procedures, dimensions and notes.
(2) Materials, Tools and Equipment
All the materials, tools and equipment used for blasting operations shall be of
approved type. The Engineer may specify the type of explosives to be allowed in
special cases. The fuse to be used in wet locations shall be water-resistant and shall
remain unaffected when immersed in water for 30 minutes. The rate of burning of the
fuse shall be uniform and definitely known to permit such a length being cut as shall
permit sufficient time to the firer to reach to a safe place before explosion takes place.
Detonators shall be capable of giving effective blasting of the explosives. The blasting
powder, explosives, detonators, fuses, etc., shall be fresh and not damaged due to
dampness, moisture or any other cause. They shall be inspected before use. The
damaged articles, if any, shall be discarded totally and removed from the site
immediately.
(3) Personnel
The blasting operation shall remain in the charge of competent and experienced
blaster with legal license and thorough knowledge of handling explosives and blasting
operations.
(4) Blasting Operations

Explosives shall be used in the quantities and manner recommended by the

manufacturers. The written permission of the Engineer shall be obtained for each
location or series of locations where the Contractor wishes to use more than 5 kg of
explosives in one series of blast. Such permission shall not in any way relieve the
Contractor of his liabilities under the Conditions of Contract.
The blasting shall be carried out during fixed hours of the day preferably during the
mid-day luncheon hour or at the close of the work as ordered in writing by the
Engineer. The hours shall be made known to the people in the vicinity. All the charges
shall be prepared by the blaster only.
The Engineer must be notified at least 24 hours in advance of any blasting operation.
When blasting is to be carried out, the Contractor shall determine the danger zone
likely to be created, and shall ensure that all personnel, vehicles and livestock are
clear of the zone before and during the blast. In settled areas, the Contractor shall
take steps to avoid damage to property from flying rock by using blasting mats or other
suitable blanketing materials.
The Contractor shall notify each public utility organisation/company having structures
in proximity to the site of the work of his intention to use explosives. Such notice shall
be given sufficiently in advance to enable the companies to take such steps as they
may deem necessary to protect their property from injury.
Danger red flags shall be displayed prominently in all directions during the blasting
operations. The flags shall be planted 200 m from the blasting site in all directions.
People, except those who actually light the fuse, shall be prohibited from entering this
area, and all persons including workmen shall be excluded from the flagged area at
least 10 minutes before the firing, a warning siren being sounded for the purpose.
The charge holes shall be drilled to required depths and at suitable places. Blasting
shall be as light as possible consistent with thorough breakage of the material
necessary for economic loading and hauling. Any method of blasting which leads to
overshooting shall be discontinued.
Not more than 10 charges shall be prepared and fired at a time. The man in charge
shall blow a siren in a recognized manner for cautioning the people. The charges shall
be lighted by the blasters only. The blaster shall count the number of explosions. He
shall satisfy himself that all the charges have been exploded before allowing the
workmen to go back to the work site.
After blasting operations, the Contractor shall compact the loose residual material
removed below sub-grade and replace the material removed below sub-grade with
suitable material.
When forming final cut faces, pre-split blasting techniques as recommended in the
Specification for Road and Bridge (IRC) shall be carried out to ensure that blasting
damage to the cut face is minimised. Details of the pre-splitting technique to be used
shall be notified to and approved by the Engineer at least 24 hours in advance of the
blasting operation.
(5) Misfire

In case of misfire, the following procedure shall be observed:
(a) Sufficient time shall be allowed to account for the delayed blast. The blaster
shall inspect all the charges and determine the missed charge.
(b) If it is blasting powder charge, it shall be completely flooded with water. A new
hole shall be drilled at about 450 mm from the old hole and fired. This should
blast the old charge. Should it not blast the old charge, the procedure shall be
repeated till the old charge is blasted.
(c) In case of charges of gelignite, the blaster shall gently remove the tamping
and the primer with the detonator. A fresh detonator and primer shall then be
used to blast the charge. Alternatively, the hole may be cleared of 300 mm of
tamping and the direction then ascertained by placing a stick in the hole.
Another hole may then be drilled 150 mm away and parallel to it. This hole
shall then be charged and fired when the misfired hole should explode at the
same time. The blaster shall at once report to the Contractor’s office and the
Engineer all cases of misfire, the cause of the same and what steps were
taken in connection therewith.
If a misfire had been found to be due to defective detonator or

gelignite/dynamite, the whole quantity in the box from which defective article
was taken must be sent to the authority as directed by the Engineer for
inspection to ascertain whether all or part of the remaining materials in the box
are also defective.
(6) Account
A careful and day to day account of the explosive shall be maintained by the
Contractor in an approved register and manner which shall be open to inspection by
the Engineer at all times. Records must be kept by the Contractor of all drilling and
blasting operations showing hole diameters and depths, drilling pattern, explosive
charge and type per hole, detonator delay times and total charge per blast. These
records must be submitted to the Engineer on completion of charging.
905 EXCAVATION IN CUTTING
(1) Clearing and grubbing shall be performed as specified in Section 200.

(2) While executing excavations, the Contractor shall take adequate precautions against
soil erosion and water pollution
(3) All suitable excavated materials shall be used in construction of the roadway to the
extent as required.
(4) Hauling of material from cuttings or borrow pits to embankments or other areas of fill
shall proceed only when sufficient plant or labour is operating at the place of deposition
to ensure that adequate spreading and compaction of material can take place.
(5) Over-excavation shall not be permitted. Any excess depth excavated below the
formation levels as specified shall be made good by the Contractor at his own expense
by backfilling with suitable material of similar characteristics to those of moved
materials with compaction as specified in Clauses 909 and 910.

(6) The slopes of cutting shall be cleared of all rock fragments which move when prised by
a crow-bar, unless otherwise directed by the Engineer. Where the Engineer considers
that the slope, immediately after dressing, shall not be permanently stable, he shall
direct the Contractor as to the stabilization measures required. The Contractor shall
carry out these measures soon after Engineer's instruction.
When completed, the excavation slopes shall be true to the lines and levels as shown
on the Drawing or directed by the Engineer. When completed, no point on slopes shall
vary from the designated slopes by more than 150 mm measured at right angles to the
slope, except where excavation is in rock, no point shall vary more than 300 mm from
the designated slope.
(7) If slips, slides, overbreaks or subsidence occur in cutting, they shall be removed.
Adequate precautions shall be taken to ensure that during construction, the slopes are
not rendered unstable or give rise to recurrent slides after construction.
(8) If water is encountered in excavations due to seepage, springs, or other causes, it
shall be removed by suitable diversions or bailing out and the excavation shall be kept
dry. The drained water shall be discharged into suitable outlets as not to damage to the
works, crops or any other property. If any such damage is caused due to any
negligence of the Contractor, it shall be the sole responsibility of the Contractor to
repair/restore to the original condition at his own cost or compensate for the damage.
906 EXCAVATION BELOW EMBANKMENTS AND BELOW FORMATION LEVEL IN

CUTTINGS
(1) Where any unsuitable material below the natural ground level under proposed
embankments or below formation level in cuttings is required to be excavated, it shall
be removed to such depth and over such areas as shown on the Drawing or as
directed by the Engineer. The excavated materials shall be disposed off as indicated
on the Drawing or directed by the Engineer. The resultant excavation shall be
backfilled with suitable material and shall be levelled and compacted to the density as
specified for forming of the embankments. Nevertheless, if such backfill has to be
carried out in standing water, the Contractor shall use only an approved non-plastic
well-graded granular material having maximum size of not greater than 75mm. Such
materials may be deposited in water without use of compaction equipment.
(2) Where shown on the Drawing, approved, graded stones having size from 380 mm to
150 mm and containing not more than 10 percent, below 150 mm in size shall be
placed directly on the natural occurring unsuitable material. This type of rock fill
material shall be deposited in accordance with the requirements of Clause 909 and
compacted as per Clause 910.
(3) If after the removal of material as specified in Sub-clause 906 (1), the Contractor allows
the materials so exposed to reach a condition where compaction of back filling is
impracticable, he shall make good at his own expense either by additional excavation
and filling in the manner specified in this Clause, or by waiting until the condition of the
exposed material is fit to receive the approved backfill.
907 EXCAVATION FOR FOUNDATION
(1) Scope

Excavation shall consist of the removal of material for the construction of foundations
for drainage structures, retaining walls, head walls, cut off walls, culvert, bridges and
other similar structures to the lines and dimensions shown on the Drawing or as
instructed by the Engineer in accordance with the requirements of these Specifications.
The work shall include construction of the necessary cofferdams and cribs and
subsequent removal of all necessary sheeting, shoring, bracing, diversion of
water/flow, draining and pumping, the removal of all logs, stumps, grubs and other
deleterious matters and obstructions necessary for placing the foundations; trimming
bottoms of excavations; and clearing up the site and the disposal of all surplus
material.
(2) Excavation
Excavation shall be taken to the length and width of the lowest step of the footing and
the sides shall be left to plumb where the nature of soil allows it. Where the nature of
soil or the depth of the trench does not permit vertical sides, the Contractor at his own
expense shall put up necessary shoring, strutting and planking or cut slopes to a safer
angle or both with due regard to the safety of personnel and works and to the
The depth to which the excavation is to be carried out shall be as shown on the
Drawing or as directed by the Engineer.
Where blasting is to be resorted to, the same shall be carried out in accordance with
Clause 904.
(3) Dewatering, Diversion of Flow and Protection
Normally, open foundations shall be laid dry. Where water is encountered in excavation
due to stream flow, seepage, springs, rain or other reasons, the Contractor shall take
adequate measures such as bailing, pumping, constructing diversion channels,
drainage channels, bunds, cofferdams and other necessary works to keep the
foundation pit or trenches dry, when so required and to protect the green
concrete/masonry against damage by erosion, failure of cut slopes or sudden rising of
water level. The methods to be adopted in this regard and other details thereof shall
be left to the choice of the Contractor, but subject to approval of the Engineer.
Approval of the Engineer shall, however, not relieve the Contractor of the responsibility
for the adequacy of dewatering and protection arrangements and for the quality and
safety of the works.
Where cofferdams are required, these shall be carried to adequate depths and heights,
be safely designed and constructed and be made as watertight as is necessary for
facilitating construction to be carried out inside them. The interior dimensions of the
cofferdams shall be such as to give sufficient clearance for the construction and
inspection and to permit installation of pumping equipment, etc., inside the enclosed
area.
Cofferdam sheet-piling shall be carried down well below the bottom of the pile caps or
footings, but without interference with any bearing piles. Cofferdams shall be rigidly
constructed and efficiently braced to withstand external pressures when water is
pumped out. Sheeting shall be reasonably watertight and all appreciable leaks

encountered during the operations shall be stopped so that construction of pile caps
can be carried out in the dry. The Contractor shall rectify any cofferdam which, for any
reason, has moved, tilted, or changed its shape and/or size.
Pumping from the interior of any foundation enclosure shall be done in such a manner
as to preclude the possibility of the movement of water through any fresh concrete. No
pumping shall be permitted during the placing of concrete or for a period of at least 24
hours thereafter, unless it is done from a suitable sump and is separated from the
concrete work by a watertight wall or other similar means.
At the discretion of the Contractor, cement grouting or other approved methods may be
used to prevent or reduce seepage and to protect the area of excavation.
The Contractor shall take all precautions in diverting flow and in discharging the
drained water as not to cause damage to the works, crops or any other property. If any
such damage is caused due to any negligence of the Contractor, it shall be the sole
responsibility of the Contractor to repair/restore to the original condition at his own cost
or compensate for the damage.
(4) Preparation of Foundation Base
The bottom of the foundation pit shall be levelled both longitudinally and transversely
or stepped as directed by the Engineer. Before footing is laid, the surface shall be
slightly watered and rammed, if surface is not wet. In the event of excavation having
been made deeper than that shown on the Drawing or as otherwise ordered by the
Engineer, the extra depth shall be made up with concrete or masonry of the foundation
grade at the cost of the Contractor. Ordinary filling shall not be allowed for the purpose
to bring the foundation to level.
When rock or other hard strata is encountered, it shall be freed of all soft and loose
materials, cleaned and cut to firm surface either leveled or stepped as directed by the
Engineer. All seams shall be cleaned out and filled with cement mortar or grout to the
satisfaction of the Engineer. In the case of rock excavation, annular space around
footing shall be filled with concrete of grade M10 up to top level of rock.
After the excavation is completed, the Contractor shall inform the Engineer to that
effect and no footing, bedding materials or structures shall be placed until the Engineer
has approved the depth and the suitability of foundation material.
If, at any point, in any foundation excavation, material unsuitable for foundations is
encountered, the Contractor shall, if so instructed by the Engineer, shall remove all
such materials and refill with suitable materials thoroughly compacted by tamping or
rolling in layers of not more than 150 mm thick each.
(5) Slips and Blows
If there are any slips or blows in the excavation, these shall be removed by the
Contractor at his own cost.
(6) Public Safety

Where required, trenches and foundation pits shall be securely fenced, provided with
proper caution signs and marked with red lights at night to avoid accident as per Sub-
clause 102 (5).
The Contractor shall take adequate protective measures to see that the excavation
operations do not affect or damage adjoining structures.
(7) Removal of Cofferdams

All cofferdams with all temporary sheeting and bracing shall be removed by the
Contractor after the completion of the substructure unit. The removal shall be carried
out in such a manner as not to disturb or damage the finished concrete. However,
sheet piling below the top of the pile caps may be left in place at the Contractor's
option and expenses.
No bracing nor other material shall be left in cofferdam in such a way as to extend into
the concrete of the structure.
Cofferdam located in embankments under the roadway shall be removed to an
elevation at least 1.2m below the subgrade. Those located in a stream or lake and
within the limits of low water shall be removed to the elevation of the stream or lake
bed, except that in established navigation channels, they shall be removed to an
elevation at least 600mm below the established bottom of the channel. Those located
outside the above defined limits shall be removed to an elevation at least 600mm
below subgrade.
908 REFILLING OF FOUNDATION PITS AND TRENCHES, REMOVAL OF

SUPPORTS AND FILLING TO STRUCTURES
Refilling of foundation pits and trenches shall consist of pervious backfill and/or common
backfill as shown on the Drawing or as directed by the Engineer.
(1) Materials
(a) Pervious Backfill
Unless otherwise specified in the contract, it shall consist of gravel, crushed

gravel, crushed rock, natural sands, manufactured sands or combinations
thereof. It shall conform to the grading limits set out in Table. 9.1
SECTION 900 EARTHWORKS Page 9 –

10
Table 9.1: Grading Limits of Pervious Backfill
Sieve Size (mm) Percentage Passing by Weight

40 100
10 45-100
2.36 25-80
0.60 8-48
0.075 0-6
(b) Common Backfill
Common backfill materials other than pervious backfill shall be suitable

material as defined in Sub-clause 902 (2).
(2) Method of Filling
Backfilling material shall not be permitted under water unless specifically described in
the contract or approved by the Engineer. It shall be placed and compacted in layers in
compliance with the requirements of Clause 910. Any support structures for the
excavation shall be withdrawn as the filling proceeds unless described in the contract
or ordered by the Engineer to be left in. The backfill shall be placed in by such methods
which shall avoid loading the structure in any manner which may affect its stability or
overload its underlying foundation material or substructure. The backfill in front of
abutments and wing walls shall be placed first to avoid the possibility of forward
movement. Precautions shall be taken to prevent any wedge action against upright
surfaces, and the slopes bounding the excavation shall be stepped as directed by the
Engineer before backfill is placed. The backfill material around box culverts, piers and
curtain walls shall be placed simultaneously on both sides of the structure. When the
structure is so designed that its strength is dependent on the restraining effect of the
superstructure (such as in portal frames and propped abutments), the backfill shall not
be placed until the superstructure has been completed to the extent and strength
necessary to provide the required restraint. When the Contract requires wedges
between steel superstructure and the parapet of wing type abutments, the wedges
shall be placed in advance of placing any fill above the lower 1/3 of the abutment and
shall be removed when directed by the Engineer.
909 FORMING OF EMBANKMENT AND OTHER AREAS OF FILL
(1) The work shall consist of the construction of embankment, filling on other areas and
backfill not specified elsewhere by providing materials as specified or approved by the
Engineer, placing, compacting and shaping to lines, levels, grades and cross sections
as shown on the Drawing or as directed by the Engineer. The maximum size of the
coarse material in the mixture shall not exceed 75mm for general earthfill.
(2) The limits of embankment shall be built sufficiently wider than the design dimension to
facilitate in achieving required compaction near by outerfaces of the embankment. The
surplus material shall be trimmed to conform the specified side slopes and width of the
embankment.

11
(3) Where necessary, the original ground shall be scarified, mixed with water, levelled and
then compacted so as to achieve the density mentioned in Clause 910. Where the
height of embankment, as measured from formation level to the original ground level,
is less than 200 mm, the embankment foundation shall be compacted in accordance
with the requirements of Clause 910 such that the required compaction is achieved
within the upper 300 mm below formation level. Where necessary, embankment
foundations shall be excavated/forrowed and brought under OMC and recompacted in
layers 0f 150mm each in order to achieve the required level of compaction.
(4) Embankments shall be built up evenly over the entire width and shall be maintained at
all times with a sufficient camber to enable surface water to drain rapidly from them.
Damage to compacted layers by constructional or other traffic shall be made good by
the Contractor.
(5) The natural moisture content and the optimum moisture content of the material to be
placed in the embankment shall be checked before start of the placing material. If
found to be out of the specified limits, the same shall be made good. Where water is
required to be added in such constructions, water shall be sprinkled uniformly and
thoroughly mixed in soil by blading or harrowing until uniform moisture content as
specified is obtained.
Moisture content, checked in accordance with IS 2720 (Part 2), at the time of
compaction shall be between 90% and 105% of the Optimum Moisture Content as
determined in accordance with IS 2720 (Part 8).
If the material delivered for fill/backfill is too wet, it shall be dried by aeration and
exposure to sun, till the moisture content is acceptable for compaction. Should
circumstances arise, where owing to wet weather, the moisture content cannot be
reduced by the above procedure, compaction work shall be suspended.
If the material deposited as fill subsequently reaches a condition such that it cannot be
compacted in accordance with the requirements of the specifications the Contractor
shall
(i) Make good by removing the material off the embankment and placing suitable
material; or
(ii) Make good by tipping it elsewhere until it is in a suitable physical condition for
re-use; or
(iii) Make good the material by mechanical or chemical means to improve it's
properties acceptable to the Engineer.
(6) Where fill is required to be constructed across water logged or soft clayey ground that
displays excessive movement under normal constructional equipment, it may be
necessary to construct a capping layer in accordance with Clause 1004.
(7) Rock used in rockfill embankments shall be deposited in horizontal layers not
exceeding 450 mm each extending upto the full width of the embankment.
Material shall be spread, levelled and compacted in accordance with Clause 910. Each
layer shall consist of reasonably graded rock and all surface voids shall be filled with

12
broken fragments before the next layer is placed. The top surface and side slopes of
embankments so formed shall be thoroughly blinded with approved well graded
material to seal the surface.
(8) Isolated boulders each within the range of 0.05 cubic meters in size may be
incorporated in embankments, not of rock fill, at the discretion of the Engineer provided
that the specified compaction requirements are met and it shall not be placed less than
1 m below formation level of carriageways or shoulders.
(9) While filling embankments up to or over culverts or pipe drains, and where required in
the contract, up to bridges, the Contractor shall bring the embankments up equally on
both sides. In rock fill embankments the rock shall be carefully packed for such
distance from the structure as is described in the contract.
Where provision of filter membrane is specified behind structures, the same shall be
laid in layers simultaneously with the laying of fill material.
(10) If the Contractor wishes to continue to use the surface of embankments including
shallow filling for constructional traffic before trimming to formation level, he shall bring
up and maintain the area between the extremities of the carriageways including (if any)
central reserve and hard shoulders to a level not less than 150 mm above formation
level whereupon constructional traffic shall be allowed to use the surface and shall be
made good by the Contractor at his own expense. When it is necessary to complete the
formation level and this has been done, the movement and use of construction
equipment thereon shall be in accordance with Clause 1103.
910 COMPACTION OF EMBANKMENTS AND OTHER AREAS OF FILL/BACKFILL
(1) The Contractor shall obtain the Engineer's approval of all fill layers before covering
with subsequent layers.
(2) All fill shall be compacted to the depth and degree of compaction as specified in Table
9.2 or as shown on the Drawing. This requirement applies whether the specified zone
is in fill or in existing ground, except for any part which may fall within rock or rockfill.
Formation level in this context shall mean top of subgrade.
Table 9.2: Compaction Requirements

3 Location Depth below Formation Minimum Compaction
Level (mm) (% MDD Heavy
Compaction)
4 Roadway 0-300 95
5 Embankment
6 Roadway Cut 0-300 95
All other roadway fill and backfill - 93
not separately specified
(3) Each layer of rock used to fill in embankments shall be spread and levelled in
accordance with Sub-clause 909(7) and systematically compacted.

13
(4) Layers of material other than rockfill shall not exceed 150 mm compacted depth unless
and until the Contractor can demonstrate to the satisfaction of the Engineer that he can
successfully compact layers of a greater thickness.
(5) Each layer shall be constructed in lengths suitable to the compaction and working
methods used. Materials of each layer shall be thoroughly mixed with water as
necessary to facilitate its compaction to the specified density.
(6) In cut areas, the subgrade shall be processed as necessary and compacted to the
depth and compaction requirements as given in Table 9.2. In the event that the
Contractor is unable to achieve the minimum compaction requirements below
formation level he shall excavate and recompact in layers as necessary.
(7) Where it may be impracticable to use conventional rollers, the compaction shall be
carried out by appropriate mechanical means such as small vibratory rollers, power
rammers or plate compactor. Care shall be taken to ensure that the compaction
equipment does not hit or come too close to any structural member so as to cause any
damage to it.
911 COMPACTION TRIALS
(1) Before commencing filling embankment and from time to time as may be considered
necessary by the Engineer, the Contractor shall carry out compaction trials in the
presence of the Engineer on each of the main types of soil and rockfill to be used and
compacted in the Works. He shall carry out all necessary laboratory and field testing
as required by the Engineer and shall submit to the Engineer the results of all tests.
The trial procedure shall include the compaction of trial areas selected by the
Engineer. The surface of each area shall first be well compacted to the satisfaction of
the Engineer. Each type of material being used shall be compacted in equal layers at
uniform but differing moisture contents to a predetermined number of passes using the
Contractor's proposed compaction equipment.
(2) Following completion of the compaction trials, the Contractor shall submit to the
Engineer, for his approval, his proposals for the compaction of each type of material to
be encountered in the Works and its degree of compaction specified. The Contractor's
proposals shall include reference to the types of equipment, the operating weights and
tyre pressure, the methods of adjusting the moisture content, the number of passes
and the loose depth of each layer.
(3) If, in the opinion of the Engineer, the results of the compaction trials indicate that the
Contractor's proposed plant and methods shall achieve the densities as specified, the
Engineer shall approve the same. Otherwise the Contractor shall submit, in writing,
proposals for modifying the plant and/or methods and shall, if the Engineer so requires,
compact further trial areas in accordance with these modified proposals until the
Engineer approves of Contractor's proposals.
(4) When compaction of earthworks is in progress, the Contractor shall adhere to the
compaction procedures approved by the Engineer.
(5) Notwithstanding the Engineer's approval of any of the Contractor's plant or methods,
the Contractor shall at all times be solely responsible for executing the earthworks in
accordance with the Specifications and the Drawing.

14
912 BENCHING
(1) Where embankments are to be constructed on hillslopes or slopes with more than or
equal to 1 vertical to 4 horizontal slopes, benches with vertical and horizontal faces
shall be cut into the existing slope (including rock) and the embankment shall be built
up in successive layers. Where the cross slope is less than 1 vertical to 4 horizontal
slope (other than rock) shall be loosened by scarifying to a depth of not less than 100
mm measured perpendicular to the slope, to ensure a good bond between the
embankment and the embankment foundation. Material which has been loosened
shall be covered with he first layer and compacted to the specified density
simultaneously with the first layer of embankment material placed.
(2) Where existing embankments are to be widened or included in a new embankment

and slopes are not more than 1 vertical to 4 horizontal, the slope of the existing
embankment shall be scarified to a depth of not less than 100 mm to ensure bond.
Where the slope is less than 1 vertical to 4 horizontal, continuous horizontal benches,
each at least 300 mm wide, shall be cut in existing slopes and the widened
embankment shall be built up in successive layers of thickness of 150 mm to the level
of old road.
Where the width of the widened portions is insufficient to permit the use of heavy
rollers, compaction to the specified density shall be carried out with the help of small
vibratory roller/plate compactor/rammer or other approved methods.
913 EARTHWORKS TO BE KEPT FREE OF WATER
By providing temporary water course, ditches, drains, pumping or other means the Contractor
shall arrange for the rapid dispersal of water from the areas of earthworks. Where practicable
the water shall be discharged into the permanent outfall for the drainage system. Adequate
means for trapping silt shall be provided on temporary systems while discharging into
permanent drainage systems.
914 WATERCOURSES
Excavations carried out in the diversion, enlargement, deepening or straightening of

watercourses shall include the operations of any necessary trimming of slopes, grading of
beds, disposal of excavated materials and pumping, tampering works and materials necessary
for dealing with the flow of water.
915 FILLING EXISTING WATERCOURSES
Where watercourses have to be diverted from the sites of embankments or other works, the
original channels shall be cleared of all vegetable growths and soft deposits and filled in with
suitable materials deposited and compacted as specified in Clauses 909 and 910.
916 PROCESS CONTROL
(1) Through out the works the Contractor shall perform tests to determine the suitability
and compaction characteristics of soils to be used in roadway. The compaction test
shall be conducted in accordance with IS 2720 Part 8 in every 1500 cubic metre of fill

15
material and every change in material type. The moisture content test shall be
conducted in accordance with IS 2720 Part 2 in every 250 cubic metre of material.
(2) In addition to the foregoing tests, the Contractor shall carry out field density tests on
the compacted fill materials in accordance with IS 2720 Part 28/29. At least one set of
density determination consisting of three tests per 500 square metres (or any lesser
area) shall be carried out in each layer, including original ground surface on which
embankment is to be constructed. If the result of any test shows that the minimum
specified density has not been achieved, further compaction shall be executed to the
area concerned and the layer re-tested. Unless the test results are satisfactory, the
addition of another layer shall not be allowed.
(3) The Contractor shall carry out tests for determination of moisture content at frequent
intervals on all materials during the course of compaction as per Sub-clause 909(5) to
ensure that the requirements of Clause 910 are met with.
917 MEASUREMENT
(1) The quantities of the various classes of earthwork to be measured for payment under
the contract shall be limited to the lines, grades, slopes and dimensions shown on the
Drawing or as determined by the Engineer.
(2) Except for foundations, all roadway excavation including side drains, filling and
backfilling compacted in place shall be measured in cubic metres by the average end
area method as computed from the original and final cross-sections of the completed
work. The distance between two end areas shall be the distance measured along
central line of the road. Where due to changed conditions, or the nature of a particular
operation, or for any other reason, it is impossible or impractical to measure the
quantities by means of average end areas, the Engineer shall compute the quantities
by a volumetric method, if in his opinion, it is the best suited method to obtain an
accurate determination.
No separate measurement for payment shall be made for excavation made on

borrows, quarries, temporary works or in places outside the scope of permanent works
specified in the contract.
Foundation excavation for structures shall be measured in cubic metres irrespective of

all classes of materials except rock encountered. The quantities to be measured shall
be the net cubic content of the voids formed by the removal of the materials enclosed
between the bottom of the footing and existing ground level by a surface generated by
vertical lines passing through the periphery of the bottom of the footing. No payment
shall be made for any excavation other than the limited excavation described above.
Excavation over increased width or length, cutting of slopes, removal of slides,
shoring, shuttering and planking shall be deemed as convenience for the Contractor in
executing the work and shall not be measured and paid for. Backfill to be measured
shall be limited to this void only with due consideration of the nature of the structure.
Foundation excavation in rock shall be deemed to be covered by the rate for rock
excavation.
(3) Consumption of explosive materials, levelling, watering and compaction of original

ground, construction of coffer dams, pumping out water and other ancillary and
incidental works necessary to complete the item as per this specification shall not be

16
measured for payment. They are deemed included in the measurement of the
concerned item.
(4) If the excavated materials are disposed beyond 10m length and more than 1.5m height
from the place of excavation and if filling materials are brought from beyond 10m
and/or 1.5m below the place of filling, additional leads and lift shall be measured
separately for payment. However initial lead of 10m and lift of 1.5m shall not be
measured separately. They are deemed included in the measurement of the item itself.
However, the measurement of foundation excavation shall be inclusive of all leads and
lifts (i.e. no separate leads and lifts shall be measured in foundation excavation).
The measurement of leads and lifts shall be based on mass diagram of the haulage
wherever applicable. All leads and lifts shall be measured as per the contract. If the
material obtained from roadway excavation is used fully or partially in roadway filling,
the quantities for roadway excavation and roadway filling shall be computed as below.
The quantities of roadway excavation and roadway filling of the distances under
reference shall be calculated separately adopting the method described as above in
this Section. The computed quantity of roadway filing shall be measured in roadway
filling while difference between quantities of roadway excavation and filling shall be
measured in roadway excavation. The same excavated material shall not be measured
both in roadway excavation and roadway filling.
918 PAYMENT
(1) Various classes of earthworks i.e. roadway excavation, roadway filling, backfilling,
additional leads and lifts measured as described above shall be paid at contract unit
rate of the respective item.
The contract unit rates shall be the full and the final compensation to the Contractor as
per Clause 112 and for the cost of:
(i) Arrangement of land as a source of supply of materials as much as needed.

(ii) Process Control tests.
(iii) Execution of all relevant operations described above in this Section and
necessary to complete the item as per this specification.
(2) Foundation excavation for structures, measured as described above, shall be paid for
at the contract unit rate for all classes of excavation. The contract unit rate for
foundation excavation shall be the full and the final compensation to the Contractor as
per Clause 112 and for the cost of carrying out the required operations to excavate to
the lines and levels as required by the Drawing or as directed by the Engineer. No
payment shall be made for the disposal of the excavated materials irrespective of all
leads and lifts, preparation of foundation base, cofferdams, cribs, sheeting, shoring
and bracing, foundation sealing, dewatering including pumping, removal of logs and
stumps, cleaning and grubbing, diversion of flow/channel, if required and all incidentals
works necessary to complete the item in accordance with this Specification.

17
SECTION 1000 - SUBGRADES
Page No.
1001 SCOPE 10–1

1003 PREPARATION AND SURFACE TREATMENT OF FORMATION 10–2
1004 CAPPING LAYERS 10–4
1005 MECHANICAL STABILISATION 10–4
1006 LIME STABILISATION 10–8
1008 PAYMENT 10–14
SECTION 1000 - SUBGRADES
1001 SCOPE
This section deals with the treatment of the upper layers of earthworks including preparation
and surface treatment of the formation, the addition of layers of selected materials, the
improvement of in-situ materials by addition and mixing of selected materials or by addition and
mixing of lime.
1002 DEFINITIONS
The following definitions shall apply to this section and other relevant sections of these
Specifications:
(1) Formation Level
The level of the top surface of the subgrade upon which pavement structure is built up.
(2) Subgrade
Upto 300 mm below formation level is designated as "subgrade".
(3) Capping Layers
Capping layers are layers of specified materials to be laid and compacted in the
subgrade and below, as required, in replacement of in-situ materials to achieve CBR
conforming to Clause 609, Table 6.2.
(4) Stabiliser
The selected natural or crushed material, lime, cement and other similar materials to
be mixed into the in-situ material of the subgrade is defined as the "stabiliser".
(5) Mechanical Stabilisation
The addition and mixing of natural or crushed material to improve the in-situ material of
the subgrade.
(6) Lime Stabilisation
The addition and mixing of lime to improve in-situ material of the subgrade such as in-
situ material with a CBR is less than 5% or saturated soils.
(7) Treated Materials
Following the addition of stabiliser to the in-situ materials, the material is referred to as
"treated material." Treated materials may be either mechanically stabilised, lime
stabilised, cement stabilised, or so on.
SECTION 1000 SUBGRADES Page 10 –

1
1003 PREPARATION AND SURFACE TREATMENT OF FORMATION
Preparation and surface treatment of formation shall be carried out only after completion of all
drainage works unless otherwise agreed by the Engineer and prior to laying the subbase or the
base where no subbase is required. The sequence of operations shall be as follows:
(1) Formation of Loose Untreated Materials
Materials for use in the subgrade shall not contain particles larger then 60 mm. In
addition the material shall have a CBR of not less than 5% measured after a 4-day
soak on a laboratory mix compacted to 95% MDD (heavy compaction), a swell of less
than 1%, a plasticity index of less than 40% and an organic matter content less than
3%. In-situ material in the subgrade in cutting that does not meet these requirements
shall either be spoiled or, if suitable, placed in the embankment. The spoiled material
shall be replaced with material meeting the requirements for loose material in the
subgrade.
In fill areas, and in cuttings except otherwise instructed by the Engineer, according to
the material encountered, loose materials of the embankments and cuttings shall be
deposited in the layers of 150 mm compacted depth. Each layer shall extend
reasonably more than the full width of the embankments or cuttings and shall be
compacted in accordance with the requirements as specified hereunder:-
(a) The material shall be broken down to the above specified grading and any
oversize material which cannot be broken down to the required size shall be
removed and disposed off. The material shall be scarified and the moisture
content shall be adjusted by either uniformly mixing in water or drying out the
material such that the moisture content during compaction is between 95%
and 100% of the Optimum Moisture Content. The moisture content shall be
kept within these limits until compaction is complete except where otherwise
(b) Each layer shall be compacted to a dry density equal to at least 95% MDD
(heavy compaction).
(c) In accordance with Section 500, the Contractor shall submit to the Engineer
his proposals for the compaction of the material to be used in the subgrade.
The proposal shall be based on the type of plant, the range of passes and the
loose depth of the layer.
The Contractor shall carry out site compaction trials, supplemented by

necessary laboratory investigations, and shall satisfy the Engineer that all the
specified requirements regarding compaction shall be achieved. Site
compaction trials shall be completed and approved by the Engineer before the
permanent Works commences .
(d) Testing to be carried out during the construction of subgrade shall include the
following:
The MDD (heavy compaction) and OMC shall be determined for each new
material encountered and in every 3000m² or part of it of each layer of
compacted subgrade.

2
The field dry density shall be determined at least once per 250m² or part
of it of each layer of compacted subgrade. The test of field density shall be
conducted in staggered manner i.e. at left, at crown and at right in the
carriageway.
The soaked CBR of material in the subgrade shall be determined at least

in every 3000m² or part of it of each layer.
The Contractor shall request in writing for the Engineer's approval for each
layer in accordance with Sub-clause 509 (1) and such request shall be
accompanied by the tests results of the above described testing and all
additional relevant information required. If the results are as specified, he
will approve for addition of another layer or will ask for further tests or
rework to meet the requirements.
(2) Formation of Loose Treated Materials
The sequence of operation shall be as described in Clauses 1005 to 1006 of this

Specification.
(3) Formations in Rock Cuttings
The subgrade in rock cuttings shall be regulated after trimming the rock excavation by
a regulating course of minimum 150 mm compacted depth of natural materials
complying with the requirements of natural material for subbase as specified in Sub-
clause 1201 (3).
The regulating course shall be laid, compacted and tested in accordance with Clause
1201 and the surface regularity shall meet the requirements of Clause 1101.
(4) Preparation of Formation for Rehabilitation Works
After reinstatement of any soft areas, all surface below carriageways, lay-bys, cycle
tracks, footways and hard shoulders shall be well cleaned and freed from mud an
slurry
(5) Proofrolling
All subgrade shall be proofrolled with a loaded scraper or truck with a minimum axle
load of 8 tonnes. Proofrolling shall be satisfactorily completed before the layer is
submitted to the Engineer for approval and shall be carried out in the presence of the
Engineer. All proofrolling shall be at the Contractor's expense.
(6) Surface Regularity and Tolerances
The surface regularity and tolerances of the subgrade shall meet the requirements of
Clause 1101. When each layer is completed the Contractor shall comply with the

3
requirements of Clause 510 for requesting the Engineer's approval and protecting the
layer.
1004 CAPPING LAYER
Where shown on the Drawing or where in-situ material in the subgrade in cuttings does not
meet the requirements, in-situ materials shall be replaced with selected material from cuttings
or borrow pits.
Where materials of differing quality are available for placing in the embankments, the Engineer
may also instruct that certain materials should be excluded from the subgrade and that certain
materials should be set apart, or obtained from borrow pits for use in the upper layers.
When materials for subgrade are extracted from borrows to form the capping layers they shall
be natural material complying with the following requirements:-
(1) Material Classification
Materials used in capping layers shall be selected among soils classified as GW, GP,
GC, and SW in the General Classification of Soils, described in Clause 609.
(2) Material Requirements
Materials for use in the capping layers shall not contain particles larger than 60 mm
and their percentage passing by weight the 0.075 mm sieve shall be less than 15%.
The material shall have a CBR of not less than 15% measured after a 4-day soak on a
laboratory mix compacted to 95% MDD (heavy compaction), a swell of less than 1%, a
plasticity index of less than 12%.
(3) Laying and Compaction
The material shall be deposited in the layer of 150 mm compacted depth. Each layer
shall extend over the full width of the embankments or cuttings and shall be compacted
in accordance with the requirements specified in Sub-clause 1003 (1) (a) to (d)).
(4) Proofrolling and Tolerances
Proofrolling and tolerances of capping layers shall be in accordance with Sub-clause

1003 (5) and (6).
When each layer is completed the Contractor shall comply with Clause 510 for
requesting the Engineer's approval and protecting the layer.
1005 MECHANICAL STABILISATION
(1) General
The extent of the mechanical stabilisation shall be detailed in the Special Specification
or shown on the Drawing.

4
In-situ subgrade materials subject to mechanical stabilisation shall be generally soils

classified as SM, ML, CL, MH, CH in the General Classification of Soils described in
Clause 609 with a CBR less than 5% or a moisture content close to saturation or too
high moisture content to meet the compaction requirements as set out in Sub-clause
1003 (1).
(2) Material Requirement
(a) Stabiliser (Additive Material)
Additive material shall be gravel, crushed stone/gravel or sand, according to

the type and characteristics of the in-situ soil as shown in the Table 10.1.
It may be crushed stone/crushed gravel, ( CS) discarded material from primary

crushing, or screened stone ( SS) from debris and screes.
Sand may be soils classified as SP, SW in the General Classification of Soils

described in Clause 610 or Sand ( SSFF) obtained by screening the discarded
fine fraction of primary crushing.
Gravel 12/40 shall have a percentage in weight passing the 12 mm sieve less
than 20% and a percentage in weight passing the 40 mm sieve more than
85%.
Sand shall have a Sand Equivalent more than 60.
TABLE 10.1: TYPES OF ADDITIVE MATERIAL
STABILISER
IN-SITU SOIL (Additive material)
Gravel Sand
SM CS, SS, 12/40 -
ML CS, SS, 12/40 -
CL CS, SS, 12/40 -
MH SP, SW, SSFF
CH SP,SW, SSFF
(b) Stabilised Material Requirements
The amount of stabiliser shall be determined by the Engineer after laboratory

test.
The mechanically stabilised materials after mixing and compacting shall

conform to the following requirements:
 maximum size of particles : 60 mm

 Uniformity Coefficient min 5
 CBR at 95 % MDD (heavy compaction)
measured after 4 days soak : min 25%
 Swell : max. 1%

5
(3) Amount of Stabiliser to be added
The amount of stabiliser to be added shall be generally between 15% and 25% in
weight of the in-situ materials and shall be determined by the Engineer following
laboratory trials, and site trials to be carried out by the Contractor in accordance with
Section 500.
During the site trials, the control testing requirements shall be in accordance with
Clause 507 and in addition, each set of test shall include the following:
 The MDD (heavy compaction) and OMC determined on the mixed material before
compaction,
 The CBR at 95% MDD (heavy compaction) after 4 days soak.
(4) Mixing
(a) Mixing Equipment
The equipment for scarifying the in-situ material and mixing it with the
stabiliser, such as scarifiers and graders, shall be capable of scarifying the
materials and mixing it with the stabiliser to the full depth of the loose layer
necessary to give the specified thickness of compacted material mixed and
compacted in accordance with this Clause.
The equipment shall be only acceptable, if during the site trials carried out in
accordance with Section 500, it produces the material to the specified
requirements.
(b) Preparation of the Layer
Before the stabiliser is applied, the material to be treated shall be scarified. If

required or instructed by the Engineer, oversize material shall be removed or
broken down so that the maximum size of the particles is not more than
specified.
(c) Spreading the Stabiliser
After the layer to be treated has been prepared, the stabiliser shall be
uniformly spread over the width to be worked at the specified rate.
(d) Mixing and Watering
After the stabiliser has been spread, it shall be thoroughly and intimately mixed
into the material for the full depth of the layer. Mixing shall continue until the
resulting mixture forms a homogeneous tilth.
Care shall be taken both during mixing and subsequent watering operations so
that the underlaying layer is not disturbed. No material from the underlaying
layer is mixed with that being processed.

6
If watering is necessary to bring the mixture to the required moisture content,

this shall be done after spreading and mixing with the stabiliser. Water shall be
added in an uniform and controllable manner and, where necessary, in
successive increments. Each increment shall be mixed in as a separate mixing
operation. Concentration of water at any point or a flow of water over the
surface shall be avoided.
Any part of the mixture which becomes too wet for compaction shall be allowed
to dry out until its moisture content is satisfactory for compaction.
Throughout the process of mixing the stabiliser and watering, a uniform
thickness of the mixture shall be maintained and, if necessary, the mixture shall
be graded to maintain the correct uncompacted thickness and shape. Any part
of the mixture that becomes segregated shall be removed and replaced .
(5) Compaction and Finishing
(a) Thickness of Layers
The subgrade shall be constructed in the layer of 150 mm compacted depth.
(b) Compaction Requirements
The minimum density for mechanically stabilised materials shall be 95% MDD
(Heavy compaction). The moisture content at the time of compaction shall be
between 97% and 103% of Optimum Moisture Content.
(c) Finishing
The surface finish after compaction of any treated layer shall be free from
ridges, compaction planes, laminations, loose and segregated material and
other surface irregularities and shall be to the line and the level within the
tolerances as specified in Clause 1101. If the surface fails to meet the
requirements of this Specification, the Contractor shall take the action set out
in the appropriate part of Section 1100 or such other action as the Engineer
may instruct or agree.
(6) Construction Control Testing
(a) In-situ Material
For each new material encountered and in every 3000 m² or part thereof of the
subgrade the following properties shall be determined:
 Grading,
 Moisture Content,
 Atterberg limits,
 The MDD (heavy compaction) and OMC,
(b) Stabiliser

7
The following properties of the additive material shall be determined on

opening up of a new source, in every 500 m 3 or part thereof and when in
opinion of the Engineer the nature of the material is changed.
 Grading,
 SE
(c) Control of Mixing
Prior to compaction in every 400 m2 or part thereof the following properties shall be
determined on each new treated material used after mixing for subgrade of
each layer:
 The MDD (heavy compaction) and OMC,
(d) Control after Completion of Each Layer
The field dry density shall be determined in every 250 m² or part of it of each
layer of compacted subgrade in staggered manner i.e. at left, at crown and at
right in the carriageway.
(7) Tolerances
(a) Geometric Tolerances
As specified in Clause 1101.
(b) Amount of Stabiliser
The average amount of stabiliser, measured before mixing, over a length of

100m, shall not be less than the amount specified.
The average amount of stabiliser, in the treated material, measured at five

points over a length of 100m, shall not be less than the amount specified.
1006 LIME STABILISATION
(1) General
The extent of lime stabilisation shall be as detailed in the Special Specification or as

In-situ subgrade materials subject to lime stabilisation shall be generally soils classified
as ML, CL, MH, CH in the General Classification of Soils described in Clause 609, with
a CBR less than 5% or moisture content close to saturation.
(a) Lime
Lime shall comply with the requirements of Clause 615.

8
Quick lime shall be used on in-situ materials which have a CBR less than 2%
and which moisture content is close to saturation.
Hydrated lime shall be used on in-situ materials which have a CBR between
2% and 5%.
(b) Storage and Handling
All lime shall be kept under cover and protected from moisture. Consignments
shall be used in the same sequence as they received at the site. Damaged
stocks or stored on the site for more than 3 months shall not be used. The
Contractor shall replace them at his own cost. Operators and labour shall be
provided with protective shoes, clothing, masks, gloves, and goggles when
they work with lime
(c) Requirement of Lime Treated Materials
The lime treated materials after mixing and compacting shall conform to the
following requirements:
 maximum size of particles : 20 mm

 CBR at 95 % MDD (heavy compaction)
measured after 4 days soak : min 15%
 Swell : max. 1%
(3) Amount of Lime to be added
The amount of lime to be added shall be determined by the Engineer following

laboratory and site trials to be carried out by the Contractor in accordance with Section
500.
For the laboratory trials, the requirements of lime treated materials shall be as specified
in Sub-clause 1006 (2) (c) except for that the CBR at 95 % MDD (heavy compaction)
measured on a laboratory mix after 3 days curing at ambient temperature and 4 days
soak which shall not be less than 30%.
During the site trials, the control testing requirements shall be in accordance with
Clause 507 and in addition, each set of test shall include the following:
 The MDD (heavy compaction) and OMC determined on the mixed material before
compaction,
 The CBR at 95% MDD (heavy compaction) after 3 days curing at ambient
temperature and 4 days soak shall not be less than 15%
(4) Mixing
(a) Mixing Equipment
The equipment for pulverising the in-situ material and mixing in the stabiliser
shall be purpose-built equipment capable of pulverising the materials and

9
mixing in the stabiliser to the full depth of the loose layer necessary to give the
specified thickness of compacted material mixed and compacted in
accordance with this Clause.
The equipment shall be only acceptable, if during the site trials carried out in
accordance with Section 500, it can produce the material of the specified
requirements.
The mixers shall be equipped with a device for controlling the depth of
processing and mixing blades shall be maintained or reset periodically so that
the correct depth of mixing is obtained at all times.
Mixing by grader shall not be permitted.
(b) Preparation of the Layer
Before the stabiliser is applied, the material to be treated shall be scarified

and/or spread and broken down and oversize material shall be removed or
broken down so that the maximum size of the particles is not more than the
specified. The material shall first be pulverised to the required tilth by
successive passes. Then it shall be shaped true to line, grade and cross
Section and , if required, lightly compacted. The loose thickness shall be such
as to give specified thickness after full compaction has been carried out.
The moisture content of the layer before addition of the stabiliser shall be
adjusted to within the range of 80% to 90% of the OMC.
(c) Spreading the Stabiliser
After the layer to be treated has been prepared to the satisfaction of the
Engineer, the stabiliser shall be uniformly spread at specified rate over the
width to be worked at a time. If a spreader is used to spread the stabiliser
ahead of the mixer, it shall be fitted with a device to ensure a uniform and
controllable rate of spread both transversely and longitudinally.
Only sufficient stabiliser for immediate use shall be spread ahead of the mixing
operation. If, in the opinion of the Engineer, any part becomes defective, the
contractor shall replace the material of that part at his own cost and shall
rework to meet the requirements.
Only equipment actually used in the spreading or mixing operation shall be

allowed to pass over the stabiliser, when so spread, before it had been mixed
into the material to be treated.
(d) Mixing and Watering
Immediately after the stabiliser has been spread, it shall be thoroughly and
intimately mixed into the material for the full depth of the layer. Mixing shall
continue until the resulting mixture forms a fine and homogeneous tilth. The
mixing machine shall be set so that it cuts at least 100 mm into the edge of any

10
adjoining lane processed previously so as to ensure that all the material

forming the layer has been properly processed.
Care shall be taken during mixing and subsequent watering operations that the
underlaying layer is not disturbed and that no material from the underlaying
layer is mixed with that being processed.
If watering is necessary to bring the mixture to the required moisture content,

then this shall be done after spreading and mixing in the stabiliser. Water shall
be added in a uniform and controllable manner and, where necessary, in
successive increments. Each increment shall be mixed in as a separate mixing
operation. Concentration of water at any point or flow of water over the surface
shall be avoided.
Any part of the mixture which becomes too wet after the stabiliser has been
added and/or before the mixture is compacted shall be allowed to dry out until
its moisture content is satisfactory. This part shall be retreated with fresh
stabiliser and finished off in accordance with this Clause.
Throughout the process of mixing in the stabiliser and water, a uniform

thickness of the mixture shall be maintained and, if necessary, the mixture shall
be graded to maintain the correct uncompacted thickness and shape. Any part
of the mixture that becomes segregated shall be replaced by new one.
(5) Compaction and Finishing
For lime treated materials, final compaction and finishing shall be completed within 4
hours after the lime comes into contact with the material to be treated.
(a) Thickness of Layers
The subgrade shall be constructed in the layers of 150 mm compacted depth

each.
(b) Compaction Requirements
The minimum density for lime treated materials shall be 97% MDD (Heavy
compaction). The moisture content at the time of compaction shall be between
95% and 100% of Optimum Moisture Content.
(c) Finishing
The surface finish after compaction of any treated layer shall be free from
ridges, compaction planes, laminations, loose and segregated material and
other surface irregularities and shall be to the line and the level within the
tolerances as specified in Clause 1101. If the surface fails to meet the
requirements of this Specification, the Contractor shall take appropriate action
to set out to comply with the requirements of the Section 1100 or agree with
other action as the Engineer may instruct.
(6) Joints between New and Existing Work

11
The forming of construction joints and the protection of previously treated or other work
shall be carried out so as to produce a uniformly compacted and homogeneous layer
free from ridges or other irregularities.
Full working width, without longitudinal joints, will generally be required. Half working
width may be instructed by the Engineer to pass traffic. When forming longitudinal
joints at least 100 mm of the first laid half-width layer shall be retreated and mixed in
with the layer of second half-width.
When forming transverse joints, at least 1.0m length of the previously laid work shall be
incorporated into the new treated layer and the Engineer may instruct that the
percentage of stabiliser be increased at these places.
(7) Protection and Curing
Treated layers shall be kept continuously damp by lightly spraying with water or
adhering to one of the curing systems specified below.
Treated layers shall be protected, within 8 hours of completion by one of the following
methods:-
(a) Completely covering the layer with clear or light coloured approved polythene
sheeting of minimum thickness 0.1 mm. The sheeting shall be laid to cover the
whole of the surface of the layer. At joints the sheeting shall be lapped by at
least 500 mm and any damaged sheeting shall be replaced at the Contractor's
expense.
The sheeting shall be securely held in contact with the layer by an approved
method.
(b) Completely covering the treated material with a layer of damp uncompacted
gravel or soil material of minimum thickness 100 mm. The material which may
form part of the next layer shall be kept continuously damp.
Plant used for dumping and spreading material, and spraying water shall be
approved by the Engineer and shall have individual axle loads not exceeding
6 tonnes.
Immediately prior to application of a curing system the surface of the treated

layer shall be made thoroughly damp by lightly spraying water.
The curing system shall be kept in place and intact for a minimum of 7 days
after completion of compaction. Small areas may be temporarily removed for
the purposes of carrying out control testing but only for the minimum amount of
time required for the testing.
(8) Construction Control Testing/Process Control Testing
(a) In-situ Material

12
The following properties shall be determined for each new material

encountered and in every 3000 m² of the subgrade or part thereof:
 Grading, Moisture Content,

 Atterberg limits,
 The MDD (heavy compaction) and OMC.
(b) Lime
Lime shall be tested in accordance with Clause 615 for each consignment
delivered at the site.
(c) Control of Mixing
The following properties shall be determined after mixing on every new treated
material used for subgrade and in every 400m² and part thereof of each layer
of mixed material prior to compaction :
 The MDD (heavy compaction) and OMC
 The CBR at 95% MDD (heavy compaction) after 3 days curing at ambient
temperature and 4 days soak which shall be not less than 15%.
(d) Control of Compaction
The field dry density shall be determined in every 250 m² or part of it of each
layer of compacted subgrade in a staggered manner i.e. left, at crown and at
right in the carriageway.
(9) Traffic
Traffic or equipment other than that actually engaged in the various treatment or
protection processes, shall not run over the layer being processed or compacted.
On completion of curing, no traffic or equipment shall be allowed on the treated layer

with the exception of that required for proofrolling , priming or construction of the
subsequent layer.
(10) Tolerances
(a) Geometric Tolerances
The work shall be completed within tolerances as specified in Sub-clause 1003

(6).
(b) Amount of Stabiliser
The average amount of stabiliser, measured before mixing, over a length of

100m, shall not be less than the amount ordered.
The average amount of stabiliser, in the treated material, measured at five

points over a length of 100m, shall not be less than the amount ordered.

13
The amount of stabiliser, measured at any point after mixing may vary within
30% of the amount ordered.
(c) Determination of Stabiliser Content
The lime content in mixed materials shall be determined according to test 15 of
BS 1924.
1007 MEASUREMENT
(1) Subgrade construction with loose untreated/treated materials, formation in rock cutting
shall be measured in cubic metre by taking cross Sections at intervals of 10 metres or
as directed by the Engineer in the original position before the work starts and after its
completion and computing the volumes of the respective work in cubic metres by
average end area method.
(2) Preparation of formation for rehabilitation works shall be measured in square metre.
(3) Capping layer shall be measured in cubic metre by end area method as described in
Sub- clause 1007 (1).
(4) Mechanically stabilised subgrade shall be measured in cubic metre as described in
Sub-clause 1007 (1) and shall be exclusive of the measurement of the stabilisers.
Stabilisers (additive material) such as gravel, crushed stone/gravel or sand shall be
measured in cubic metre as per procedure described below.
(a) Before mixing the stabiliser (i.e. gravel, crushed stone/gravel sand)
quantity to be used shall be measured in stacks or in the body of
transporting trucks/trippers, if it can be measured.
(b) In a length of 100m five standard holes at the equal distances shall be
dig up and materials shall be collected separately from the each hole.
The average percentage of stabiliser obtained from each hole shall be
worked out. Based on average percentage of stabiliser and volume
treated total quantity of stabiliser used shall be computed.
Least of the quantities computed in (a) and (b) above shall be
accepted for payment.
(5) The volume of lime stabilised material shall be measured in cubic metre as per end
area method inclusive of lime used. The lime used shall be measured in tonne.
(6) Quick lime/Hydrated
Lime (stabiliser) shall be measured in tonne as per actual consumption.

1008 PAYMENT
The subgrade construction with loose untreated/treated materials, formation in rock cutting,
additive materials and stabilisers, preparation of formation, capping layer, mechanically
stabilised subgrade, and lime stabilised material shall be paid at their respective contract unit
rate which shall be the full and the final compensation to the Contractor as per Clause 112 and
also for the cost of:

14
(1) Arrangement of land as a source of supply of material required.

(2) Compacting the ground supporting subgrade where removal and replacement of
unsuitable material or loosening and recompacting is involved.
(3) Watering or drying of material in the subgrade as required.
(4) Mixing, spreading in layers brining in appropriate moisture content and compacting to
the requirement of Clause 1003.
(5) Profrolling and testings.

(6) All other operations including incidental costs necessary to complete the item as per
this Specification.

15
SECTION 1100 - ROADWORKS OVERALL REQUIREMENTS
Page No.
1101 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND

SURFACE REGULARITY OF PAVEMENT COURSES 11–1
1102 ADVERSE WEATHER WORKING 11–4
1103 USE OF SURFACES BY CONSTRUCTIONAL TRAFFIC 11–5
1104 CARE OF WORKS 11–5
SECTION 1100 - ROADWORKS OVERALL REQUIREMENTS
1101 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY OF

PAVEMENT COURSES
(1) Construction Control Testing/Process Control Testing
Unless otherwise directed, values given in these Specifications are minimum values for
the properties of materials and the workmanship. They shall be considered satisfactory,
if all results of the tests, taken at the frequencies specified, are at least equal to the
values given in the relevant Section of these Specifications.
(2) Tolerances
(a) Horizontal Alignments
Horizontal alignments shall be determined from the centreline of the pavement

surface as shown or calculated from the Drawing. The centreline of the
pavement surface as constructed, and all other parallel alignments, shall be
correct within a tolerance of  13 mm therefrom.
(b) Thickness of Pavement Layers
The average thickness of any pavement layer measured at five conjugative

points at every 20m in any Section shall not be less than the thickness
specified nor more than 120% of the thickness specified or ordered by the
Engineer. The thickness of the pavement layer measured at any point shall
have tolerance of + 25 % and - 2 % of the thickness specified.
(c) Surface Levels of Pavement Layers and Formation
The level measured at any point on the surface of a pavement layer to the
formation level shall not deviate from the corresponding level calculated from
the Drawing by more than the tolerances shown in Table 11.1.
For checking compliance with Table 11.1 measurements of surface levels shall
be taken at points to be selected by the Engineer at 12.5m centres
longitudinally and at 2m centres transversely. At junctions, the grid point
spacings shall be determined by the Engineer.
(d) Surface Regularity
The surface regularity of pavement layers and the formation shall be tested at
points decided by the Engineer with a rigid, steel straight-edge of 3 m length
placed parallel to or at right angles to the centreline of the road. The maximum
allowable deviation of the surface below the straight-edge shall not deviate
from that shown on the Drawing by more than the tolerances shown in Table
11.1.
SECTION 1100 ROADWORKS OVERALL REQUIREMENTS

In addition the longitudinal slope or transverse crossfall shall not deviate from
that shown on the Drawing by more than the tolerances shown on Table 11.1.
If tolerances given in Table 11.1 for level and straight edge are not in
agreement, in that case the tolerances given for straight edge shall prevail.
TABLE 11 .1: TOLERANCES FOR LEVEL AND SURFACE
REGULARITY
Level Straight edge Slope or Crossfall
Layer mm mm %
Bituminous Wearing Course  10 6*  0.25
Bituminous Binder Course  10 6  0.25
Base  10 6  0.25
Subbase  15 10  0.50
Gravel Wearing Course  15 15  0.50
Formation (subgrade) +0 20  0.50
-25
* In case of asphalt concrete surface it shall be 4mm.

(e) Shoulders
Shoulders shall be constructed to the same requirements of thickness, level

and surface regularity as for the adjacent pavement layers.
(f) Cuttings and Embankment Slopes
In the final trimmed slope of cuttings or embankment a tolerance of +0.25 shall

be permitted, i.e. if a slope of 1 in 2 is specified, the acceptable slope shall be
not steeper than 1 in 2 or slacker than 1 in 2.25.
(g) Width of Cuttings and Embankments
The tolerance permitted in the width of the bottom of cuttings shall be 200 mm
between the centreline of the road and the toe of the cutting slope.
The width of embankments measured horizontally and perpendicular to the

centreline of the road at the top of the embankment shall not be less than
shown on the Drawing or more than that shown on the Drawing plus 50 mm.
(h) Depth of Side Drains
The difference between road level measured at the centre line of the road and
that of the bottom of the side drain measured perpendicular to the centre line of
the road shall not deviate from the specified in the drawing by  25 mm.
(3) Rectification of Earthworks and Pavement Layers Exceeding Tolerances
Where any tolerances in Sub-clause 1101 (2) are exceeded, the Contractor shall
assess the full extent of the area which is out of tolerances and shall make good the
surface of the pavement course, earthworks or formation in the manner described
below.

(a) Earthworks
Where a cutting slope is steeper, and an embankment slope is slacker than the
specified slope, then the slope shall be trimmed to the specified slope. When
the cutting slope is slacker, the natural ground slope above top of the cutting
and the adjacent cut slopes in the both sides of the slacker slope shall be so
trimmed that the entire cut slopes match together and they are environmentally
stable. Where an embankment slope is steeper than the specified slope, then
the slope shall be benched and fill material shall be placed and compacted.
Subsequently the slope shall be trimmed all in accordance with the
Where the width of a cutting is less than, and the width of an embankment is
more than the specified width, then the cutting or embankment shall be
trimmed to the specified width. Where the width of the cutting is more than the
specified width but cut slope is slacker than the specified slope, the slope shall
be trimmed as described in the preceeding paragraph. If the cut slope is
steeper, it shall be trimmed to specified slope. The adjacent slopes shall be
also trimmed to make them in harmony. Where the width, of an embankment is
less than the specified width, the embankment shall be benched and filled with
suitable material and compacted. The slopes shall be trimmed all in
accordance with the requirements of Section 900.
Where the depth of a side drain is less than that specified, the side drain shall
be excavated to the specified depth and grade. Where the depth of a side
drain is more than the specified depth, the side drain shall be backfilled with
suitable material, compacted to a dry density of at least 95% of MDD (Heavy
compaction) up to the specified depth or the extra excavated depth shall be
made good by the same material of lining of the drain as directed by the
Engineer.
(b) Subgrades
Where the levels and or widths are out of tolerance, the full depth of the layer
shall be reworked to the Specification. The area to be treated shall be as
determined by the Engineer necessary for compliance with the Specification.
Where the results of the construction control tests are less than specified the
full depth of the layer in the area representing the test shall be reworked to the
Specification. However, if needed, more tests shall be conducted to ascertain
the extent of the area required to be reworked.
(c) Base and Subbase
Where these consist of unbound (i.e. natural or graded stone) material the full
depth of the material shall be replaced by the material complying to the
specification. The area treated shall be at least 30m long and 3m wide or such
area determined by the Engineer necessary for compliance with this
Specification.

For bituminous bases the material of the full depth of the layer shall be
replaced with fresh approved material laid and compacted to specification. Any
area so treated shall be at least 5m long and the full width of the paving laid in
one operation.
(d) Wearing Course
The method of rectification shall be adopted depending upon the nature of the
failure. Rectification shall be effected either by removing base and replacing
with approved material and doing wearing course or redoing wearing course
alone. The Engineer shall instruct appropriate method of rectification. The area
rectified shall be the full width of the paving laid in one operation and at least
15m long.
The Contractor shall be deemed to have allowed in his general rates and prices for the
cost of complying with the requirements of Clause 1101.
Not withstanding the provisions of Sub-clauses 1101 (2) and 1101 (3) measurement
and payment for earthworks and pavement works shall be made on the basis of the
net-cross-Section ordered by the Engineer or as shown on the Drawing. No additional
payment shall be made for any variation. If the executed work is within the limit of
tolerance, but is less than the specified on drawing or ordered by the Engineer, the
payment shall be made for actual quantity executed, if the executed work is more, the
payment shall be made for as shown on the drawing or ordered by the Engineer.
1102 ADVERSE WEATHER WORKING
(1) No material in frozen condition shall be incorporated in the works, but it shall remain on
site for use, if suitable when unfrozen.
(2) Laying of materials containing bitumen, or mixture thereof, shall cease under the
following adverse conditions:
(a) during foggy and rainy weather;
(b) when rain is imminent.
(3) While the air temperature is rising, work may be performed at the temperatures of:
 6 degree Celsius with a wind velocity of 25 km/hr

 10 degree Celsius with a wind velocity of 55 km/hr
(4) When the air temperature is falling, works must be stopped as soon as the
temperature reaches 6 degree Celsius, regardless of wind velocity. It shall not be
resumed until the temperature is definitely rising.
(5) When strong wind is blowing and this is likely to interfere with the proper execution of
the work, no surfacing, especially spraying of binder shall be done.

(6) Concrete shall not be placed during falling temperatures when the ambient
temperature falls below 7 degree Celsius or during rising temperatures when the
ambient temperature is below 3 degree Celsius. The temperature of the placed
concrete shall not be allowed to fall below 5 degree Celsius until the concrete has
thoroughly hardened. When necessary, concrete ingredients shall be heated before
mixing but cement shall not be heated.
When the ambient air temperature exceeds 40 degree Celsius during the concreting
operation, the Contractor shall take measures to control the temperature of the
ingredients. Such measures shall include spraying the aggregates stockpile with water
to promote cooling down by evaporation and, where feasible, shading of stockpiles
and the area where concreting is carried out, reducing time between mixing and
placing, and restricting concreting as far as possible to early mornings and late
evenings. Curing shall commence after placing of the concrete in order to prevent
excessive loss of moisture.
1103 USE OF SURFACES BY CONSTRUCTION TRAFFIC
(1) The loads and intensity of construction traffic used on pavements under construction
shall be regulated so that no damage is caused to sub-grade and pavement layers
already constructed.
(2) The wheels and track of plant moving over various pavement courses shall be kept
free of deleterious materials.
(3) Bituminous base course shall be kept clean and uncontaminated as long as it remains
uncovered by a wearing course and surface treatment. Should the base course or
tack/prime coat becomes contaminated, the Contractor shall make good by cleaning it
to the satisfaction of the Engineer, including removal of the contaminated layer and
replacing it as per the requirements of these Specifications which shall be done by the
Contractor at his own risk and cost.
1104 CARE OF WORKS
The general obligations for “Care of the Works” shall inter-alia include the following:
(1) Materials shall not be spread on a layer that is wet and may damage it during
compaction of subsequent layer or when opened to traffic.
When material is spread out on the road, it shall, be given a good cross-fall and a light
compaction on the surface with a steel-tyre roller, in order to facilitate run-off during
rainy weather.
(2) All completed works in a layer shall be protected and maintained until the subsequent
layer is placed. Maintenance shall include immediate repairs to any damage or
defects, which may occur and shall be repeated as often as is necessary to keep the
layer continuously intact and in a good condition.
(3) Before priming any completed layer or placing a subsequent layer thereon, any
damage to the existing layer shall be repaired so that after repair or reconstruction if
necessary, it shall conform in all respects to the requirements specified for that layer.

All repair work other than repairs of minor surface damages shall be inspected and
tested before covering up.
The previously constructed layer shall also be thoroughly cleaned of all foreign material
before construction of a succeeding layer. In the case of bituminous work, the existing
layer shall be thoroughly broomed and all dung, clay, mud and other deleterious and
loose material shall be removed. Where necessary, the surface shall be sprayed with
water before, during and after brooming to remove all foreign material.
Roads shall not be made dirty as a result of construction of works, transportation of

equipments, plants, labour and/or materials. In the case of becoming dirty, they shall be
cleaned immediately.
No measurement and payment shall be made for the works required under this Clause. All
costs in connection with the requirements specified herein shall be deemed included in the
rates and prices of the related items of works in the Bill of Quantities.

SECTION 1200 - SUBBASE, BASE, HARD SHOULDER AND GRAVEL WEARING
COURSE
Page No.
1201 MECHANICALLY STABLE SUBBASE 12–1

1202 GRADED CRUSHED STONE BASE AND SUBBASE 12–4
1203 WATER BOUND MACADAM BASE AND SUBBASE 12–9
1204 SHOULDERS 12–14
1205 GRAVEL WEARING COURSE 12–15
1206 TELFORD BASE (BLOCK PITCHING) 12–20
SECTION 1200 - SUBBASE, BASE, HARD SHOULDER AND GRAVEL WEARING

COURSE
1201 MECHANICALLY STABLE SUBBASE
(1) Scope
This clause covers the construction of subbase with naturally occurring mechanically
stable quartzitic gravels, river gravels and transported gravels, or granular materials
resulting from the weathering of rocks, or clayey/silty sand.
(2) Sources of Materials
Subbase materials shall be obtained from approved sources in borrow or cut or from such
other sources of supply as may be specified or approved from time to time for use.
The Contractor shall comply with all requirements of Section 800 in respect of borrow pits.
The subbase material after placing and compaction shall conform to the following
requirements:
(a) Gravel
The grading of the material after placing and compaction shall be a smooth curve
within and approximately parallel to the envelope given in Table 12.1.
The Plasticity Index shall not exceed 6.
Table 12.1: Grading Envelope for Gravel
Sieve size (mm) Percentage passing by

weight
63.0 100
40.0 70 - 100
20.0 50 -85
10.0 40 - 75
4.75 30 - 60
2.36 20 - 45
1.18 15 - 37
0.075 4 - 15
(b) Sands, Silty and Clayey Sands
SECTION 1200 SUBBASE, BASE, HARD SHOULDER AND GRAVEL WEARING COURSE Page 12
1
 % passing 2mm sieve : max 95%

 % passing 0.075 mm sieve : min 10 - max 30%
 Plasticity Index : min 5 - max 12%
 Plasticity Modules : max 300%
(PI × % passing 0.425 mm sieve)
(c) All Materials
The CBR of the material, after 4 days soaking, shall not be less than 30% at 95%
MDD (Heavy Compaction).
(4) Compaction Trials
Before commencing construction and from time to time as may be considered necessary
by the Engineer, the Contractor shall carry out compaction trials in the presence of
Engineer on each main type of materials to be compacted in the Works. He shall carry out
all necessary laboratory and field testings and supply the Engineer with the copies of the
results of all tests.
Following completion of the compaction trials, the Contractor shall submit to the Engineer,
for his approval, proposals for the compaction of each main type of material. The
Contractor's proposals shall include reference to the type of equipment, the operating
weights and tyre pressures and the method of adjusting moisture content.
If, in the opinion of the Engineer, the results of the compaction trials indicate that the
Contractor's proposed plant and methods shall achieve the densities specified, the
Engineer shall approve the same. Otherwise the Contractor shall submit in writing
proposals for modifying the plant and/or methods and shall compact further trials in
accordance with these modified proposals until the Engineer approves the Contractor's
proposals.
(5) Laying and Compacting
The material shall be deposited in such quantity and spread in a uniform layer across
the full width required, so that the final compacted thickness is nowhere less than
shown on the Drawings or instructed by the Engineer. Every reasonable effort shall be
made to prevent segregation during mixing, dumping, spreading, trimming and
compacting operations.
The compacted thickness of any layer laid, processed and compacted at one time shall
not exceed 150 mm and when a greater compacted thickness is required, the material
shall be laid and processed in two or more layers. The minimum layer thickness shall be
100 mm.
The material shall be broken down to the grading specified in Sub-clause 1201(3). Any
oversize material which cannot be broken down to the required size shall be removed and
disposed off.
The material shall be scarified and the moisture content adjusted by either uniformly
mixing with water or drying out the material such that the moisture content during
compaction is between 95% and 100% of the Optimum Moisture Content (IS 2720 Part
8). It shall be graded and trimmed to final line and level. Light compaction may be applied
2
before the final trim is carried out, but once 25% of the compactive effort has been applied
no further trimming or correction of surface irregularities shall be allowed.
The final trim shall be in cut and the Contractor shall ensure that material from the trim is
neither deposited in low areas nor spread across the section but graded clear of the
works. Following the final trim the material shall be compacted to a dry density of at least
95% of MDD (IS 2720 Part 8). During the grading, trimming and compaction of the
material the Contractor shall ensure that the surface and/or the material does not dry out.
If so, the Contractor need to apply fog sprays of water or other approved means sufficient
to maintain the surface and/or material within the specified limits of moisture content.
On completion of compaction, the surface shall be well closed, free from movement under
compaction plant and free from compaction planes, ridges, cracks, loose or segregated
material. If the surface fails to meet the specified requirements, the Contractor shall take
the action set out in the appropriate part of Section 1100 or such other action as directed
by Engineer.
(6) Proofrolling
Unless otherwise directed by the Engineer, the Contractor shall proofroll the completed
layer with a steel three wheeled roller applying a load of not less than 5 tonnes per metre
width of roll and the layer shall be free from visible movement under the proofroller.
Approval of the layer shall only be given after the satisfactory completion of the
proofrolling and any remedial measures shall be at the Contractor’s expense.
(7) Setting out and Tolerances
The layer shall be set out and constructed to the appropriate tolerances specified in
Section 1100.
(8) Drainage of Subgrade and Subbase
The subgrade and subbase shall be kept continuously drained and any damage caused
by water accumulating on or running off the surface shall be made good at the
Contractor’s expense.
Water accumulated on any part of the subgrade or subbase, shall be removed and
disposed off. Any material which becomes saturated, or cannot then be compacted to the
required density, shall be replaced as specified at Contractor's own expense.
(9) Testing
(a) Process Control
The minimum testing frequency for the purpose of process control shall be as
given in Table 12.2.
Table 12.2: Minimum Testing Frequency
Tests One test in every Min. no of tests per

section
Materials:
3
Gradation 200 m3 or part of it and change in source 2

Plasticity Index " " " " 2
Maximum Dry Density and 1000 m3 " " " 2
Optimum Moisture Content
Field Density and Moisture 500 m2 2
Content
Construction Tolerances:
Surface Levels 10 m -
Thickness 25 m -
Width 200 m -
(b) Routine Inspection and Testing
Routine inspection and testing shall be carried out by the Engineer to test the
quality of materials and workmanship for compliance with the requirements of this
section.
Any materials or workmanship that do not comply with the specified requirements
shall be replaced with materials and/or workmanship complying with the specified
requirements or be repaired to comply with the specified requirements.
(10) Measurement
Mechanically stable subbase shall be measured in cubic metre by taking cross Sections
at intervals of 10 metres or as directed by the Engineer in the original position before the
work starts and after its completion and computing the volumes in cubic metres by
(11) Payment
The subbase construction shall be paid at their respective contract unit rate. In addition to
stated in Clause 112, the contract unit rate shall be also the full and the final compensation
for cost of making arrangement for traffic control and other costs required to complete the
work complying with the requirement of Sections 500, 800 and Clause 1201.
1202 GRADED CRUSHED STONE BASE AND SUBBASE
(1) Scope and Definition
This clause covers procuring, furnishing and placing of approved crushed stone on top
of the completed subgrade or subbase and constructing a crushed stone subbase or
base, as the case may be, in accordance with the requirements of this Specification.
"Graded crushed stone" shall mean crushed stone with a smooth grading curve within a
specified envelope.
The class of the stone of the graded crushed stone to be provided shall be specified in the
Special Specification or in the Bill of Quantities.
4
The Contractor shall be responsible for locating and developing suitable sources of
material for graded crushed stone. Such sources shall be termed quarries. The opening
up of quarries, and the construction and maintenance of access roads shall be carried out
in accordance with Section 800.
The material shall comply with the following requirements:
(a) It shall consist of crushed stone, free from clay, organic or other
deleterious matter.
(b) It shall comply with the physical requirements defined in Table 12.3.
Table 12.3: Physical Requirements of Graded Crushed Stone
Tests Base Subbase
B* C1* D1*
LAA Max. % 30 35 40
AIV Max. % 20 25 30
SSS Max. % 12 12 12
FI % 25 25 30
CBR Min. % 80 80 60
CR Min. % 100 80 30
PI Max. NP NP 6
* B, C1 and D1 are classes of materials
(c) It shall comply with the Following Gradings
After processing, placing and compaction in the pavement the grading of

the material shall be a smooth curve within and approximately parallel to
one of the envelopes defined in Table 12.4.
Table 12.4: Grading Envelope for Graded Crushed Stone
Percentage passing by weight

Sieve Size Base Subbase
(mm) SB1* SB2*
63.0 - 100 100
5
40.0 100 75 - 100 85 - 100

31.5 85 - 100 42 - 75 75 - 95
20.0 62 - 92 25 - 60 60 - 87
10.0 40 - 70 15 - 45 50 - 80
4.75 26 - 55 12 - 37 12 - 32
2.36 21 - 53 6 - 25 7 - 21
0.60 12 - 28 5 - 21 6 - 17
0.075 2 - 10 3 - 12 3 - 10
* SB1 and SB2 are classes of subbase.
(4) Crushing, Screening and Mixing
Unless otherwise instructed, crushing shall be carried out at least in two stages.
The crushing, screening and proportioning of materials and their subsequent mixing shall
be carried out using methods and machines acceptable to the Engineer. To avoid
segregation, graded crushed stone shall be moistened when being handled and shall not
be stockpiled in heaps higher than 5 m.
If the Contractor wishes to add material from another source in order to achieve the
specified grading, the following conditions shall apply:
(a) The Contractor shall be responsible for all costs associated with the provision
and mixing in of the material, including land acquisition.
(b) The material shall be non-plastic, hard, sharp and durable as specified. Particles
shall be free from organic materials, clays and other deleterious substances.
(c) Only material passing the 6.3mm sieve may be added, the percentage to be
added shall be agreed with the Engineer and in any case shall not exceed 15%
by weight of the mixture.
(d) The minimum crushing ratios as well as other physical requirements as specified
in Sub-clause 1202 (3) shall be maintained.
(5) Transporting Graded Crushed Stone
Graded crushed stone shall be transported and dumped in such a way that no
segregation occurs.
The Contractor shall carry out compaction trials in accordance with Sub-clause 1201 (4).
The Contractor shall take appropriate measures to prevent segregation during dumping
and spreading operations.
6
The graded crushed stone shall be laid by plant capable of distributing the graded
crushed stone in a layer of uniform thickness and without segregation.
not exceed 150 mm, and where a greater thickness is required, the graded crushed stone
shall be laid in two or more equal layers.
The compacted thickness of any base layer shall not be less than 3 times the maximum
size of the graded crushed stone and the compacted thickness of any subbase layer shall
not be less than 2 times the maximum size of the graded crushed stone.
As soon as possible after laying, compaction shall be carried out. The moisture content
shall be adjusted as necessary and, during compaction; care shall be taken to maintain
the moisture content evenly at the specified value. Unless otherwise instructed by the
Engineer, the moisture content at the time of compaction shall be between 95 and 100%
of the Optimum Moisture Content determined as per IS 2720 Part 8. The appropriate
Sections of Sub-clause 1201(5) shall also be applicable for this Clause 1202.
All rolling shall be longitudinal and shall commence at the outer edges of the pavement
and progress towards the centre, except that on superelevated curves, rolling shall
progress from the lower to the higher edge. Where laying is carried out in lanes care must
be taken to prevent water entrapment.
The minimum dry densities to be achieved as a percentage of the Maximum Dry Density
(MDD) determined in accordance with IS 2720 Part 8 shall be:
Base : 98% of MDD

Subbase : 95% of MDD
On completion of the compaction the surface shall be well closed, mechanically stable,
free from visible movement under compaction plant and free from compaction planes,
ridges, and cracks, loose or segregated material. If the surface fails to meet the
requirements of these Specifications, the Contractor shall take the action set out in the
appropriate part of Section 1100 or such other action as directed by the Engineer.
(8) Proofrolling
The Contractor shall proofroll completed layers in accordance with Sub-clause 1201 (6).
Graded crushed stone subbase and base shall be set out and constructed to the
tolerances given in Section 1100.
(10) Testing
(a) Process Control
The minimum testing frequency for process control shall be as specified in Table
12.5.
7
Table 12.5: Minimum Test Frequency
Min. no of tests
Tests One test in every per section
Materials:
Plasticity Index " " " " 2
Flakiness Index " " " " 2
Maximum Dry Density and 1000 m3 " " " 2
Optimum Moisture Content
Los Angeles Abrasion 200 m3 " " " -
Aggregate Impact Value " " " " -
Sodium Sulphate Soundness 500 m3 " " " -
Crushing Ratio 200 m3 " " " -
CBR 500 m3 " " " -
Field Density and Moisture 500 m2 2
Content
Thickness 25 m -
Width 200 m -
Smoothness 40 m2 -
section.
shall be replaced by materials and/or workmanship complying with the specified
requirements, or be repaired so that after being repaired it shall comply with the
specified requirements.
(11) Measurement
Graded crushed stone base and subbase shall be measured in cubic metre by taking
cross Sections at intervals of 10 metres or as directed by the Engineer in the original
position before the work starts and after its completion and computing the volumes in
cubic metres by average end area method.
(12) Payment
The graded crushed stone construction shall be paid at their respective contract unit rate.
In addition to stated in Clause 112, the contract unit rate shall be also the full and the final
compensation for cost of making arrangement for traffic control and other costs required
to complete the work complying with the requirement of Sections 500, 800 and Clause
1201.
1203 WATER BOUND MACADAM BASE AND SUB-BASE
8
(1) Scope
This work shall consist of clean, crushed aggregates mechanically interlocked by rolling
and bonded together with screening binding material and water laid on a properly
prepared subgrade/subbase/base or existing pavement, as the case may be and finished
in accordance with the requirements of this specification and in close conformity with the
lines, grades, cross Sections and thickness as per approved plans or as directed by the
Engineer.
The Contractor shall be responsible for locating and developing suitable sources of
material for water bound macadam. Such sources shall be termed quarries or borrows.
The opening up of quarries/borrows and the construction and maintenance of access
roads shall be carried out in accordance with Section 800.
(3) Materials Requirements
(a) Coarse Aggregates
Coarse aggregates shall be either crushed or broken stone, crushed slag. The
aggregates shall conform to the physical requirements set forth in Table 12.6.
Table 12.6: Physical Requirements of Coarse Aggregates
Base Subbase
Tests D1* E1*
LAA Max. % 40 45
ACV Max. % 30 30
FI Max. % 30 30
* D1 and E1 are classes of materials
The crushed or broken stone shall be hard, durable and free from excess flat,
elongated, soft and disintegrated particles, dirt and other deleterious material.
After processing, placing and compaction in the place the grading of the material
shall be a smooth curve within and approximately parallel to one of the
envelopes defined in Table 12.7.
Table 12.7: Grading Envelope of Course Aggregates
Sieve Size Percent passing by weight

(mm) Grading 1 Grading 2
75.0 100 -
63.0 90 - 100 100
50.0 35 - 70 90 - 100
40.0 0 - 15 35 - 70
25.0 - 0 - 15
20.0 0-5 -
12.5 - 0-5
9
(b) Screenings
Screenings to fill voids in the coarse aggregate shall generally consist of the
same material as of the coarse aggregate. However, where permitted
predominantly non-plastic material like crushed rock fines or natural angular pit
sand may be used for this purpose.
Screenings shall conform to the gradings set forth in Table 12.8.
Table 12.8: Grading Requirements for Screenings
Sieve Size Per cent Passing

(mm) by Weight
9.50 100
4.75 85 - 100
0.10 10 - 30
The Contractor shall carry out trials in accordance with Sub-clause 1201(4).
(5) Construction Operations
(a) Preparation of Base
The surface of the sub-grade/sub-base/base to receive the water bound

macadam course shall be prepared to the specified lines and crossfall and made
free of dust and other extraneous material. Any ruts or soft yielding places shall
be corrected in an approved manner and rolled if necessary by sprinkling water
until firm surface is obtained.
As far as possible, laying water bound macadam course over an existing thick,
bituminous layer may be avoided since it shall cause problems of internal
drainage of the pavement at the interface of two courses. It is desirable to
completely pick out the existing thin bituminous wearing course where water
bound macadam is proposed to be laid over it. However, in exceptional cases,
where the intensity of rain is low and the interface drainage facility is efficient,
water bound macadam can be laid over the existing thin bituminous surface by
cutting 50 mm x 50 mm furrows at an angle of 45 degrees to the centre line of the
pavement at one metre intervals in the existing road. The directions and depth of
furrows shall be such that they provide adequate bondage and also serve to
drain water to the existing granular base coarse beneath the existing thin
bituminous surface.
(b) Inverted Choke
If water bound macadam is to be laid directly over the sub-grade, without any
other intervening pavement course, a 25 mm thick screenings or coarse sand
10
shall be spread on the prepared subgrade before application of the coarse

aggregates is taken up.
(c) Spreading Coarse Aggregates
The coarse aggregates shall be spread uniformly and evenly upon the prepared
subgrade/subbase/base to proper profile by using templates placed across the
road about 6 m apart, in such quantities that the thickness of each compacted
layer is not more than twice the maximum size of the aggregate. Wherever
possible, approved mechanical devices shall be used to spread the aggregates
uniformly so as to minimise the need for manual rectification afterwards.
Aggregates placed at locations which are inaccessible to the spreading
equipment, may be spread in one or more layers by any approved means so as
to achieve the specified results.
The spreading shall be done from stockpiles along the side of the roadway or
directly from vehicles. In no case the aggregates shall be dumped in heaps
directly on the surface prepared to receive the aggregates nor shall hauling over
uncompacted or partially compacted base be permitted. No segregation of
coarse or fine aggregates shall be allowed and the coarse aggregate as spread
shall be of uniform gradation with no pockets of fine material.
The surface of the aggregates spread shall be carefully checked with templates
and all high or low spots shall be remedied by removing or adding aggregates as
required. The surface shall be checked frequently with a straight edge while
spreading and rolling so as to ensure a finished surface as per approved plan.
(d) Rolling
Immediately following the spreading of the coarse aggregate, rolling shall be

started with three wheeled power rollers of 8 to 10 tonne capacity or tandem or
vibratory rollers of approved type. The type of roller to be used shall be approved
by the Engineer based on trial run.
Except on superelevated portions where the rolling shall proceed from inner
edge to the outer, rolling shall begin from the edges gradually progressing
towards the centre. First the edge/edges shall be compacted with roller running
forward and backward. The roller shall then move inwards parallel to the
centreline of the road, in successive passes uniformly lapping preceding tracks
by at least one half width of wheel of the roller.
Rolling shall be discontinued when the aggregates are partially compacted with
sufficient void space in them to permit application of screenings. During rolling,
slight sprinkling of water may be done, if necessary. Rolling shall not be done
when the subgrade is soft or yielding or when it causes a wave-like motion in the
subgrade or subbase course.
The rolled surface shall be checked transversely and longitudinally, with

templates and any irregularities corrected by loosening the surface, adding or
removing necessary amount of aggregates and re-rolling until the entire surface
11
conforms to desired crossfall and grade. In no case shall the use of screenings
be permitted to make up depressions.
Material which have been crushed excessively during compaction or have

become segregated shall be replaced with aggregates of the same or better
quality.
(e) Application of Screenings
After the coarse aggregate has been rolled as above screenings shall be applied
gradually over the surface to completely fill the interstices. These shall not be
damp or wet at the time of application. Dry rolling shall be done while the
screenings are being spread so that vibrations of the roller cause them to settle
into the voids of the coarse aggregate. The screenings shall not be dumped in
piles but be spread uniformly in successive thin layers either by the spreading
motions of hand shovels or by mechanical spreaders, or directly from tipper with
suitable grit spreading arrangement. Tipper operating for spreading the
screenings shall be so driven as not to disturb the coarse aggregate.
The screenings shall be applied at a slow and uniform rate (in three or more
applications) so as to ensure filling of all voids. This shall be accompanied by dry
rolling and brooming with mechanical brooms, hand-brooms or both. In no case
shall the screenings be applied as fast and thick as to form cakes of ridges on the
surface in such a manner as would prevent filling of voids or prevent the direct
bearing of the roller on the coarse aggregate. These operations shall continue
until no more screenings can be forced into the voids of the coarse aggregate.
The spreading, rolling, and brooming of screenings shall be carried out in only
such lengths of the road which could be completed within one day’s operation.
(f) Sprinkling of Water and Grouting
After the screenings have been applied, the surface shall be copiously sprinkled
with water, swept and rolled. Hand brooms shall be used to sweep the wet
screenings into voids and to distribute them evenly. The sprinkling, sweeping and
rolling operation shall be continued, with additional screenings applied as
necessary until the coarse aggregate has been thoroughly keyed, well-bonded
and firmly set in its full depth and a grout has been formed of screenings. Care
shall be taken to see that the base or subgrade does not get damaged due to the
addition of excessive quantities of water during construction.
The minimum dry densities to be achieved as a percentage of the specific gravity
shall be:
Base : 82% of the specific gravity
Subbase : 80% of the specific gravity
(g) Setting and Drying

After the final compaction of water bound macadam course the pavement shall
be allowed to dry overnight. Next morning hungry spots shall be filled with
screenings or binding material as directed, lightly sprinkled with water if
necessary and rolled. No traffic shall be allowed on the road until the macadam
12
has set. The Engineer shall have the discretion to stop hauling traffic from using
the completed water bound macadam course, if in his opinion it would cause
excessive damage to the surface.
The compacted water bound macadam course shall be allowed to completely dry
and set before the next pavement course is laid over it.
(5) Proofrolling
The Contractor shall proofroll compacted layers in accordance with Sub-clause 1201(6).
Water bound macadam base and subbase shall be set out and constructed within the
tolerances given in Section 1100.
(7) Testing
(a) Process Control
The minimum testing frequency for process control shall be as given in Table
13.8.
Tests One test in every Min. no of tests

per section
Materials:
Flakiness Index " " " " 2
Los Angeles Abrasion " " " " -
Aggregate Impact Value " " " " -
Field Density 500 m2 2
Thickness 25 m -
Width 200 m -
Smoothness 40 m2 -
section.
shall be replaced by materials and workmanship complying with the specified
requirements, or be repaired so that after being repaired it shall comply with the
specified requirements.
(8) Measurement
13
Water bound macadam subbase/base shall be measured in cubic metre by taking

cross Sections at intervals of 10 metres or as directed by the Engineer in the original
position before the work starts and after its completion and computing the volumes in
cubic metres by average end area method.
(9) Payment
Water bound macadam construction shall be paid at their respective contract unit rate. In
addition to stated in clause 112, the contract unit rate shall be also the full and the final
1201.
1204 SHOULDERS
(1) Definition
The term "shoulder" means the part of the road falling between the edge of the pavement
and the side ditch or embankment slopes above the formation level.
(2) Material for Construction of Shoulders
Material for construction of shoulders shall be as shown on the Drawing or instructed by

the Engineer. It may consist of and include:-
(a) Gravel wearing course or natural material in accordance with Clauses 1205 and
1201.
(b) Graded crushed stones in accordance with Clause 1202.
(c) A single bituminous surface treatment (SBST) in accordance with Clause 1303.
(d) A sand seal surfacing in accordance with Clause 1305.
(3) Construction of Shoulders
Shoulders shall be constructed concurrently with construction of the adjacent pavement

layers and with the same materials, except in case the base course is a bituminous mix,
the "upper shoulder" shall be constructed subsequent to the base course. Shoulders shall
not be constructed ahead of adjacent pavement layers and the Contractor shall ensure
that the method of construction is such that at no time water gets prevented from draining
off the pavement layers. The method of laying and compacting shoulder material and the
compaction requirements shall be in accordance with the relevant Sub-clauses of 1201,
1202 and 1205.
Shoulders shall be set out and constructed to the tolerances given in Section 1100.
(5) Surface Treatment of Shoulders
14
Surface treatment of shoulders shall be as shown on the Drawing or instructed by the

Engineer. Materials for bituminous surface treatment shall be in accordance with Sub-
clause 1204 (2) and the method of construction shall be in accordance with the relevant
Clauses of Section 1300.
Where topsoil and grassing is shown on the Drawing or instructed by the Engineer, 50
mm of humus or topsoil shall be spread on the completed shoulder and lightly rolled.
Grass seeds shall be planted in accordance with the relevant Clauses of Section 2800
and kept watered until growth is established. Top soiling and grassing shall be in
accordance with relevant Clauses of Section 2800.
Where shoulders are constructed with the same material as the adjacent pavement layers
no separate items shall be included in the Bill of Quantities for shoulder construction and
the measurement and payment shall be in accordance with the relevant Clauses of
Section 1200.
Where shoulder construction differs from that of adjacent pavement layers the method of
measurement and payment shall be in accordance with the relevant Clauses relating to
the type of material shown on the Drawing or instructed by the Engineer for shoulder
construction.
Bituminous surfacing shall be measured and paid in accordance with relevant Clauses of
Section 1300. Top soiling and grassing shall be measured and paid in accordance with
relevant Clauses of Section 200 and 2800.
1205 GRAVEL WEARING COURSE
(1) General
(a) Definitions
The term "gravel" used throughout in this Clause means any material used as a
wearing course, and shall include crushed rock, natural or crushed gravel,
decomposed rock and clayey sands.
A "gravel wearing course" means a top surfacing course constructed from one or
a combination of the materials stated above and may be a course placed on the
formation of a new road where final pavement surface is not included in the
Contract, or placed on the formation of a service, diversion or access road.
(b) Sources of Material
Material for gravel wearing course may be obtained from any of the sources
described hereunder.-
(i) Borrow pits, alluvial deposits, etc.
(ii) Spoil areas
15
(iii) Excavation in cuttings, widened if necessary.
In all cases the Engineer shall instruct the Contractor about the source of material
to be used and the location where the material will be placed.
(c) Inspection of Site
Where a source of material is available for inspection during the Tender Period
the Contractor shall satisfy himself as to the nature and amount of work involved
particularly in respect of the volume of overburden, the suitability of material in
work, the degree of selection necessary, the method of extraction, and access to
the source.
(d) Borrow pits, Alluvial Deposits, etc. and Spoil Areas

The Contractor shall comply with all the requirements of Section 800 in respect of
borrow pits, alluvial deposits, etc. and spoil areas.
(2) Classification of Material
Materials for gravel wearing course shall be classified as RF2, SC, GC for natural
materials as per the definition given in Clause 609 or crushed stones.
The material may require the use of either a grid or sheepsfoot roller with more than 8 ton
mass per metre width of roll to break it down and/or screening to achieve the specified
grading.
The grading of the gravel after placing and compaction shall be a smooth curve within
and approximately parallel to the grading envelope given in the Table 13.9.
Table 13.9: Grading Envelope of Wearing Course Material
Sieve size Percentage passing by weight

(mm) Class 1 Class 2
37.5 - 100
25.0 100 85-100
20.0 95-100 85-100
14.0 80-100 65-100
10.0 65-100 55-100
4.75 45-85 35-92
2.00 30-68 23-77
1.00 25-56 18-62
0.425 18-44 14-50
0.075 12-32 10-40
The material shall have a minimum CBR of 30% after 4 days soaking at 95% MDD
(heavy compaction) and plasticity index between 15 and 35..
16
Materials of the respective class namely D1, C2, E1, or E2 whichever may be
applicable shall conform to its requirements specified in Table 6.3 of Section 600.
(4) Sequence of Works
Unless otherwise instructed by the Engineer, the Contractor shall commence laying
wearing course starting as close as possible to the source and shall work away from it so
that the maximum amount of compaction is given to the wearing course by the
Contractor's vehicles. The Contractor shall route/regulate his vehicles to give even wear
and compaction over the whole width of the wearing course.
(5) Preparation of Formation

For new road construction, the formation shall be prepared in accordance with Section
1000.
For existing roads the minimum requirements for preparation of the formation are as
follows:
The formation shall be cleaned of all foreign matter and loose materials. Any potholes,
ruts, corrugations, depressions and other defects which have appeared due to improper
drainage, traffic or any other cause shall be corrected. If considered necessary by the
Engineer, the Contractor shall scarify water, grade and recompact the subgrade to line
and level all at his own expense. The Engineer may require the formation to be proofrolled
by a loaded truck, scraper or other approved means prior to dumping of the wearing
course material. The cost of all such proofrolling shall be at the Contractor's expense.
(6) Setting Out
The gravel wearing course shall be set out to the tolerances given in Section 1100.
The gravel wearing course material shall be deposited in such quantity and spread in a
uniform layer across the full width required, so that the final compacted thickness is
nowhere less than shown in the Drawing or instructed by the Engineer. Every reasonable
effort shall be made to prevent segregation during the loading, hauling, dumping,
spreading, mixing, trimming and compacting operations.
not exceed 150 mm and where a greater compacted thickness is required, the material
shall be laid and processed in two or more equal layers.
The material shall be broken down in the pavement to the grading specified in Sub-clause
1205 (3). Any oversize material which cannot be broken down to the required size shall
be removed and disposed off by the Contractor.
The material shall be scarified and the moisture content adjusted by either uniformly
mixing with water or drying out the material such that the moisture content during
compaction is between 95% and 102% of the Optimum Moisture Content determined as
17
per IS 2720 Part 8. It shall be graded and trimmed to final line and level. Light compaction
may be applied before the final trim is carried out but once 25% of the compactive effort
has been applied no further trimming or correction of surface irregularities shall be
allowed.
The final trim shall be in cut and the Contractor shall ensure that material from the trim is
neither deposited in low areas nor spread across the section but graded clear of the
works.
Following the final trim the material shall be compacted to a dry density of at least 95%
MDD (Heavy compaction). During the grading, trimming and compaction of the material
the Contractor shall ensure that the surface and/or the material does not dry out by
applying fog sprays of water or other approved means sufficient to maintain the surface
and/or material within the specified limits of moisture content.
Vibratory rollers for the final compaction shall not be allowed.
(8) Proofrolling
The Contractor shall proofroll the completed layers in accordance with Sub-clause
1201(6).
(9) Tolerances
The gravel wearing course shall be constructed to the tolerances specified in Section
1100.
(10) Testing
(a) Process control
The minimum testing frequency for process control shall be as given in 13.10.
Tests One test in every Min no. of test

per section.
Materials :
Gradation 300m3 or part of it and change in source -
Plasticity index " " " -
CBR " " " -
LAA " " " -
AIV " " " -
3
Maximum Dry Density and 400m " " -
Optimum moisture content 200m2
Field Density & moisture content 3
10m
Construction Tolerance: 25m
Surface Levels 200m
Thickness 40m2
Width
Smoothness
18
Routine inspection and testing will be carried out by the Engineer to test the
quality of materials and workmanship for compliance with he requirements of this
Section.
Any materials or workmanship that do not comply with the specified

requirements shall be replaced with materials and /or workmanship complying
with the specified requirements or be repaired so that after being repaired it
shall comply with the specified requirements.
(11) Maintenance
The wearing surface shall be maintained by the Contractor in its finished condition and
shall be watered, graded, dragged, reshaped, or recompacted as necessary, until the
Certificate of Completion is issued, or until the Engineer instructs that the road shall be
opened to public traffic, whichever is the sooner.
(12) Measurement
Gravel wearing course shall be measured in cubic metre by taking cross Sections at
intervals of 10 metres or as directed by the Engineer in the original position before the
work starts and after its completion and computing the volumes in cubic metres by
13) Payment
Gravel wearing course shall be paid at their respective contract unit rate. In addition to
stated in clause 112, the contract unit rate shall be also the full and the final compensation
for cost of making arrangement for traffic control and other costs required to complete the
work complying with the requirement of Sections 500, 800 and Clause 1201.
1206 TELFORD BASE (BLOCK PITCHING)
(1) Block pitching shall consist of clean hard durable single size stones of size equivalent to
the thickness of the base course, but not less than 150 mm or more than 300 mm in their
longest dimension.
(2) A layer of sand or quarry dust shall first be laid over the base to a thickness of 75 mm.
The block pitching shall then be laid with the longest dimension of each stone in the
vertical direction and breaking joint with adjoining stones. The highest points of protruding
stones shall then be broken off with a knapping hammer and the interstices filled with
spalls. The whole shall then be rolled with a smooth wheeled roller of not less than 8
tonnes capacity. Spalls shall be continuously added to the interstices during rolling until
the whole remains immovable under the roller and has a uniform surface without high or
low spots.
(3) Measurement
19
Telford base shall be measured in cubic metre by taking cross Sections at intervals of 10
metres or as directed by the Engineer in the original position before the work starts and
after its completion and computing the volumes in cubic metres by average end area
method.
(4) Payment
The Telford base construction shall be paid at their respective contract unit rates. In
addition to stated in Clause 112, the contract unit rate shall be also the full and the final
1201.
20
SECTION 1300 - BITUMINOUS SURFACE AND BASE COURSE
Page No.
1301 GENERAL REQUIREMENTS FOR PRIME COAT, TACK COAT,

SURFACE DRESSING, PENETRATION MACADAM, SAND
SEAL AND SLURRY SEAL 13–1
1302 PRIME COAT AND TACK COAT 13–5
1303 SURFACE DRESSING 13–9
1304 PENETRATION MACADAM. SEMI- GROUT 13–17
1305 SAND SEAL 13–23
1306 SLURRY SEAL 13–25
1307 GENERAL REQUIREMENTS FOR ASPHALT CONCRETE, SAND
ASPHALT, EMULSION AGGREGATE MIX AND COLD ASPHALT 13–29
1308 ASPHALT CONCRETE 13–35
1309 SAND ASPHALT 13–39
1310 EMULSION AGGREGATE MIX 13–42
1311 COLD ASPHALT 13–48
SECTION 1300 - BITUMINOUS SURFACE AND BASE COURSE
1301 GENERAL REQUIREMENTS FOR PRIME COAT AND TACK COAT, SURFACE
DRESSING, PENETRATION MACADAM, SAND SEAL AND SLURRY SEAL
(1) Scope
This Clause comprises general requirements for bituminous binder, aggregate and trial
sections common to Clauses from 1302 to 1306.
(2) Bituminous Binder
All bituminous binders shall comply with the relevant requirements set out in Section 600.
(3) Storage and Handling of Bituminous Binder
When carried in bulk containers, records of binder temperature during and at the time of
storage shall be kept in a manner acceptable to the Engineer. During storage the
temperature of the bituminous binder shall be kept as low as possible, consistent with
reasonable pumpability. Any bituminous binder not conforming to the requirements of
Sub-clause 1301 (4) shall be rejected by the Engineer as unsuitable for use.
Where bitumen emulsions are stored on site in drums, the drums shall be regularly
"rolled" to ensure mixing of the contents. Prior to using, all bituminous emulsion drums
shall be "rolled" just before opening and use. Emulsions shall be protected against frost
and temperatures below 30 C.
The bitumen storage area and heating station shall be cleared of vegetation, kept neat
and tidy. The drums shall be stacked on their sides in small quantities with gaps between
each stack to reduce fire risk.
Bitumen distributors and boilers shall be kept clean at all times. When changing the
grade of bitumen and at the end of each day’s work, all boilers and distributors shall be
thoroughly cleaned out with a solvent. The flushings from boilers and distributors shall
not be poured any where indiscriminately, but shall be led by drainage channels to
disposal pits. Care shall be taken that flushings do not find their way into storm water
ditches or streams. All boilers, pre-heating pits, tools, and plant shall be kept
scrupulously clean.
When filling the bitumen distributor from the boilers or bulk containers, the bitumen shall
be passed through a filter of fine wire mesh having opening of not more than 0.6 mm.
On completion of the works, the disposal pits and drainage channels shall be filled in and
topsoiled. The site shall be left clean and tidy.
(4) Heating of Bituminous Binder
SECTION 1300 BITUMINOUS SURFACE AND BASE COURSE Page 13 1

The bituminous binder shall be heated in boilers or bulk storage containers, equipped
with adequate pumps and accurate thermometers. No bitumen shall be heated in a
boiler when the thermometer is broken, inaccurate or not equipped with it.
The minimum pumping temperatures, the range of spraying temperatures and the
maximum heating temperatures of cut-backs, penetration grade bitumens and emulsions
are given in Table 13.1 below.
Table 13.1: Temperatures Ranges for Heating and Spraying Binders
Temperatures (oC)
Binder Minimum Spraying * Maximum
Pumping Slot-jets Atomising jets Heating
Cut-back RC 800 60 110 - 115 - 120
RC 3000 80 125 - 135 - 135
Cut-back MC 30 10 35 - 45 50 - 60 65
“ MC 70 25 55 - 65 70 - 85 85
“ MC 800 60 100 - 115 120 - 135 135
“ MC 3000 80 125 - 135 135 - 150 150
Bitumen 180/200 105 155 - 165 160 - 170 170
“ 80/100 115 160 - 170 160 - 170 170
Emulsion**K1-60 - - - 95
“ **A1-60 - - - 95
* These spraying temperatures are for guidance only, since the optimum spraying
temperature depends on the temperature/viscosity relationship of the bitumen.
** The minimum pumping and spraying temperatures for K1-60/A1-60 shall be in
accordance with the manufacturer’s recommendations.
For slot-jets the viscosity for spraying shall be 70 to 100 centistokes and for atomising
jets 35 to 60 centistokes.
No penetration grade bitumen, cut-back bitumen, or emulsion shall be heated above the
maximum temperature given above in the Table. Any overheated bitumen, cutback
bitumen or emulsion shall be removed from the site and disposed off by the Contractor.
The rates of application of binder specified or instructed by the Engineer refer to volumes
of binder corrected to 15.6oC using the Standard Petroleum Measurement Table (ASTM
D 1250).
(5) Weather Limitations
The minimum surface temperatures for spraying of the different types and grades of
binder shall be:
80/100 penetration grade bitumen: 500 C

MC-3000 cutback bitumen: 220 C
Emulsions: 50 C

Temperature of road surface shall be generally in the range of 50-60oC when prime coat
is applied with MC70.
When a cold wind is blowing the above temperatures shall be increased by 50 C.
No bituminous work shall be done during foggy or rainy weather. Strong wind may
interfere with the proper execution of the work. Therefore, no surfacing, especially
spraying of binder, shall be done when strong wind is blowing.
Bituminous material, except for bitumen emulsions and certain types of prime coat if
instructed by the Engineer shall not be applied on a damp surface.
(6) Cutting Back of Bitumen
The maximum amounts of paraffin as given in Table 13.2 may be added with the
permission of the Engineer to the basic 80/100 penetration grade bitumen depending
upon the road surface temperature at the time of spraying. Lesser amounts than those
indicated may be used, if the site conditions allow the development of sufficient adhesion
between binder, aggregate and existing surface. Diesel or kerosene shall be used for
cutting back of bitumen as per the direction of the Engineer.
Table 13.2: Maximum Addition of Paraffin
Range of Road Surface Maximum Addition of Range (approximate) of

Temperature Paraffin by Volume % Corresponding Ambient Air
0
C Temperature 0 C
22 - 29 7 10 - 16
29 - 36 5 16 - 21
36 - 43 3 21 - 26
43 - 50 1 26 - 31
above 50 NIL above 31
The temperature of bitumen, when paraffin is introduced, shall not be higher than 120 0 C.
The paraffin shall be sucked from 200 litre drums in measured quantities through the
bitumen pump and circulated with the bitumen for a minimum of 45 minutes. During this
process all burners shall be shut off and no open flames allowed near the distributor.
(7) Adhesion Agent
Where required the adhesion agent shall be of an approved type and shall be used in
accordance with the manufacturer’s instructions and as instructed by the Engineer.
(8) Safety Precautions
The Contractor shall take every precaution to avoid fire or health hazards. He shall
always ensure that:
(a) bitumen is heated only to the temperature required for the particular
application;
(b) hot bitumen never comes in contact with water;

(c) suitable protective clothings, foot wears and gloves are used when
handling bitumen; and
(d) dust is reduced to the minimum.
Care is required when using rapid-curing cut-back, because of the highly flammable
nature of the solvent.
(9) Trial Sections
The Contractor shall carry out trial sections at location instructed by the Engineer to
demonstrate to the Engineer that his surfacing operation is capable of executing the
works in accordance with the Specification.
Prior to the commencement of trials the Contractor shall submit in writing to the Engineer
his proposals for applying binders and aggregate. On receipt of the Engineer's approval,
the Contractor shall proceed with the trials, but in absence of such approvals the
Contractor shall submit fresh proposals to the Engineer.
In the course of such trials the Engineer may call upon the Contractor to modify his
method of working, to employ other items of equipment and to amend the rates of spread
at which various materials are applied.
When the Engineer is satisfied that the Contractor is capable of constructing surfacing
that complies with the Specification after trial Section or Sections, the Contractor shall
receive permission to commence the works. No variation in the approved procedures
shall be made without the Engineer's prior consent in writing.
None of the foregoing provisions prevent the Engineer from requiring the Contractor to
vary his materials, equipment or methods of working at any time during the execution of
Works, if he considers this to be essential for execution of the works in accordance with
this Specification.
No separate measurement and payment shall be made for complying with the
requirements of Sub-clauses from 1301 (1) to 1301 (9). The Contractor shall include
related costs of complying with the requirements of Clause 1301 in his rates of the items
covered in Clauses from 1302 to 1306.
1302 PRIME COAT AND TACK COAT
(1) Scope and Definitions
This Clause covers the application of a bitumen prime and tack coat to be applied on a
prepared pavement layer.
A prime coat means a thin layer of low viscosity bituminous binder applied to an
absorbent non-bituminous surface. If the prime coat is to be trafficked, it shall be covered
with blinding material.
A tack coat means a thin layer of bituminous binder applied to a bituminous surface.

(2) Materials
The prime coat shall consist of cut back bitumen MC30/MC70 or emulsion K-2-60
complying with Section 600 from a source approved by the Engineer. The grade and the
rate of application of cutback to be used shall be instructed by the Engineer on site after
field trails.
However, the nominal rate of application of the prime coat shall be around 1 lit per sq.m.
If the prime coat is to be applied in more than one lane, allowance shall be made for
overlapping of lanes by 150mm. Tentative temperature of application shall be around
50o-70o C.
For tack coat, the binder shall be a penetration grade bitumen applied hot immediately
prior to laying the bituminous mixture or alternatively a rapid curing cutback RC-800 or
medium curing cutback MC30, MC70 or MC-800 applied at sufficient time before laying
the bituminous mixture to allow the evaporation of the cutter (solvent); or a quick-
breaking emulsion K1-60 applied sufficiently before laying the bituminous mixture to
allow the emulsion to break and the water to evaporate and run off. The binder shall
comply with Section 600.
Blinding material shall consist of fine aggregate, or sand, or crusher dust as required and
shall contain not more than 15 per cent retained on a 6.3 mm sieve. The blinding
material, if required by the Engineer, shall be specified in the Special Specification.
(3) Preparation of Surface
The surface to be sprayed shall be thoroughly cleaned by sweeping with mechanical

brooms and/or washing or other approved means. All laitance of soil or binder material,
loose and foreign material shall be removed.
All loose material shall be swept clear of the layer to expose the full width of the layer
upon which prime/tack coat shall be applied. The surface to be sprayed shall be
checked for line, camber and level, and the surface corrected, made good as necessary
and approved by the Engineer before any bituminous spray is applied. The Engineer’s
approval, or otherwise, of the surface shall be given immediately prior to the Contractor’s
intention to start spraying.
Unless otherwise directed by the Engineer, immediately prior to the application of prime
coat, the surface of the layer shall be lightly sprayed with water to dampen the surface,
but in no case the surface shall be made saturated. If the water is over applied, the
surface shall be allowed to dry until dampness is uniform over the entire surface.
In order to bring the surface to be primed to the condition required, water shall be applied
in small increments by a distributor. Any water on the surface after spraying shall be
allowed to drain away before the prime coat is applied.
No traffic shall be allowed on the prepared surface.
(4) Spraying of Prime Coat and Tack Coat

Soon after the surface to be sprayed has been prepared as specified in Sub-clause 1302
(3) and approved by the Engineer, the edges of the area shall be marked out with a line
of string or wire pegged down at intervals not exceeding 15 m on straights or 7.5 m on
curves. The prime or tack coat shall be sprayed on to it at the specified rate. Spraying
shall be carried out not later than 12 hours after the surface has been prepared.
The quantity of binder used shall give complete coverage of the surface with a slight
trace of run-off in places. Shall the specified rate of spray appear to be incorrect; the
Contractor shall immediately stop spraying, inform the Engineer and amend the spray
rate as instructed by the Engineer.
The temperature for storage and spraying shall be as given in the Table 13.3.
Table 13.3: Temperature for Storage
Maximum storage temperature 0C

Type of Prime Up to 24 hrs. Over 24 hrs.
Cutback bitumens
MC-30 65 40
MC-70 80 50
Bitumen shall be sprayed from a pressure distributor complying with the requirements
of Sub-clause 1303 (6) and no hand spraying shall be permitted except in small areas, or
to make good a defective area caused by a blocked nozzle.
The nozzles shall be arranged to give a uniform spray and shall be tested prior to
spraying by discharging on to suitable material (such as building paper, metal sheets,
etc.,) or into special troughs made for this purpose. Testing shall not take place on the
road, and any bitumen spilt on the ground shall be cleaned off.
If during spraying, a nozzle becomes blocked or develops a defect, the spraying shall be
made good with a hand spray, and the machine repaired before further spraying is
commenced.
When commencing and stopping spraying, sheets of building paper or metal at least 2m
wide shall be spread across the full width to be sprayed to give a clean sharp edge.
The metal sheets used for stopping and starting work shall be cleaned after each run
and the troughs used for testing shall be cleaned at the end of each day’s work.
During spraying all kerbs, road furniture, culvert headwalls, tree boles and the like which
are liable to be disfigured by splashing of bitumen shall be protected, and any such
feature which is accidentally marred by bitumen shall be cleaned off with a suitable
solvent or made good.
(5) Curing and Blinding of Prime Coat

If, after the application of the prime coat, the bituminous material fails to penetrate within
the time specified or if the road must be used by traffic, blinding material shall be spread
in the amount required to absorb any excess bituminous material and to protect the
primed surface.
Blinding material shall be spread from trucks in such a manner that no wheel shall travel
on uncovered bituminous material.
Unless the Engineer permits otherwise, all loose material on the sprayed surface,
including any blinding material shall be removed before any further layer of the pavement
is laid.
(6) Tolerances
The actual rate of application of bituminous binder across the width of each spray run
shall not vary by more than ±5% of the rate ordered and the actual rate of application of
binder for each single run of the spray shall not vary from this specified rate by more than
0.03 litres per square metre.
(7) Testing
Tray tests shall be taken at least twice a day during priming operation to check
calculations based on dipping of spray trucks.
The minimum testing frequency for the purpose of process control shall be as given in
the Table 13.4.
Table 13.4: Minimum Testing Frequencies
Test Minimum number of tests

Quality of binder The Contractor shall produce certificates
from concerned suppliers to the effect that
all materials supplied by them comply with
the relevant Specifications.
In addition, one set of tests for each 50,000
litres of supply of binder
At regular close intervals

Binder temperature for application Two tests per run
Rate of application of binder
(8) Measurement
Binding material shall be measured in litre. For computation of the quantity following
methods shall be adopted.
(a) Designed/instructed rate of application times specified area sprayed,

computed in litres corrected to 15.6 o C
(b) Actual rate of application measured through tray tests times specified area
sprayed, computed in litres corrected to 15.6 o C
(c) Actual consumption in the specified area sprayed measured in litres corrected
to 15.6oC by dip stick reading of the distributor.

The lowest value of the above three methods shall be adopted for payment. However,
if the rate of actual spray of binder is much less or more than the designed/instructed
rate of spary so as to impair quality of prime/tack coat, the Engineer shall reject the
work or shall ask for appropriate rectification which the contractor shall execute at his
own cost.
Emulsion/bitumen and cutter shall be measured on the basis of their percentage
actually used in the work.
(9) Payment
Emulsion/bitumen and cutter shall be paid at the respective contract unit rate which
shall be the full and the final compensation for compliance of all requirements specified
in Clause 1301 and 1302 in addition to those specified in Clause 112.
1303 SURFACE DRESSING
(1) Scope and Definitions
This clause covers the application of one or more coats of surface dressing, each coat
consisting of a layer of bituminous binder sprayed on a base prepared previously,
followed by a cover of stone chippings properly rolled to form a wearing course to the
requirements of these Specifications.
A single surface dressing means an application of bituminous binder to the road surface
followed immediately by a single layer of uniform sized chippings.
A multiple surface dressing means two or more surface dressings placed one on the
other.
(2) Materials
(a) Binder
The binder shall be a suitable cationic quick-breaking emulsion such as K1-60 or

K1-70 from a source approved by the Engineer with the bitumen content of not
less than 60 and viscosity (Degrees Engler at 20 o C) between 6 and 20 or a
medium-curing cut-back MC 3000 or MC-800 or a penetration grade 80/100
bitumen.
The type of binder shall be specified in the Special Specification or in the Bill of
Quantities.
(b) Chippings
(i) Hardness, Soundness, Shape and Cleanliness
The chippings shall consist of crushed stone or natural screened gravel,

apparently cubical in shape and free from visible stone dust and harmful
material such as clay, salt, organic matter or other deleterious

substances. The percentage passing the 0.075 sieve shall not exceed
0.5% by weight.
The chippings shall comply with the requirements specified in Table
13.5, for the appropriate class as specified in the Special Specification
or in the Bill of Quantities.
Table 13.5 Physical Requirements of Chippings
Chipping Class *HP A B C1 C2
LAA max. 20 25 30 35 35
AIV max. 20 20 20 25 20
SSS max. 12 12 12 12 12
CR max. 100 100 100 80 -
FI max. 20 20 20 25 -
Degradability <5 <5 <5 <5 <5
* means high performance aggregate.
The minimum size of the stone to be crushed to produce the chippings shall be
at least 4 times the maximum size of the chippings.
(ii) Grading
The grading requirements of chippings shall be as specified in the Table

13.6.
Table 13.6: Grading Requirements of Chippings
Sieve Percentage passing by weight

Size Nominal Sizes
(mm) 14/20 10/14 6/10 4/6
25.00 - - - -
20.00 85 - 100 100 - -
14.00 0 - 20 80 - 100 100 -
10.00 0-3 0 - 15 80 - 100 100
6.30 - 0-3 0 - 15 85 - 100
4.75 - - 0 - 10 -
2.80 - - 0-2 0 - 10
1.18 0-2 0-2 - -
0.60 - - - 0-2
0.075 0-0.5 0-0.5 0-0.5 0-0.5
The Engineer shall reject the chippings not conforming to the above
requirements.
(3) Rate of Application of Binder and Chippings

The rate of spray of binder and the size and rate of spread of chippings shall be as
specified in the Special Specification, BOQ or as instructed by the Engineer.
Tray tests shall be carried out at least twice per run during surface dressing operations to
check spray and spread rates calculated from spray truck dippings and chip-spreader
coverage, and more frequently when a number of short lengths are being surface
dressed. Spray truck dippings and chip-spreader coverage shall be checked for each
length sprayed.
(4) Crushing, Screening, Washing and Stockpiling Chippings
The construction plant provided and the methods of operating it, shall be such as to
produce chippings which shall meet the specified requirements of Sub-clause 1303 (2)
(b). This may require washing the chippings to meet the cleanliness requirements.
The Contractor shall comply with Section 800 when chippings are stockpiled. If required,
the stockpile area shall be surfaced with 100 mm thickness of gravel or other material,
acceptable to the Engineer. Any contaminated chippings shall not be used in the Works.
After use the stockpile area shall be cleared, topsoiled and left neat and tidy.
(5) Precoated Chippings
The bituminous binder used for precoated chippings shall be a medium curing cut-back
MC-30 or a semi-stable or stable emulsion such as anionic A2 or A3 or cationic K2 or K3
unless otherwise instructed by the Engineer. The amount of bituminous binder used to
precoat chippings shall be specified in the Special Specification or shall be as instructed
by the Engineer.
Precoating shall be carried out in a mixing machine acceptable to the Engineer. The
precoated chippings shall not be tacky and liable to agglomerate. The chippings
precoated with cut-back or emulsion shall be stockpiled for the lapse of time required by
the solvents or water to evaporate.
The precoated chippings shall be kept free of contamination by dust or other deleterious
matter.
(6) Construction Plant for Pavement Works
(a) Bitumen Distributors
Bitumen distributors shall be truck mounted and shall have sufficient power to
maintain uniform speeds for the proper application of the binder. The truck shall
be equipped with an accurate tachometer showing the driver the speed in
metres per minute. The truck shall be fitted with a gauge bar and chain or any
other acceptable device clearly visible to the driver to enable him to follow the
required edge. The distributor tank shall have a capacity of at least 4,000 litres
and shall be fitted with a device for indicating the quantity in the tank at any time.
It shall be equipped with heaters capable of maintaining temperatures up to
200oC and be fitted with an accurate thermometer.
The circulation system shall permit pumping around the tank and around the spray bar without
actually spraying. Spray bars shall be available for spraying in widths varying
SECTION 1300 BITUMINOUS SURFACE AND BASE COURSE Page 13

10
from 0.5m to 4m and shall be adjustable transversely so that the operator can
follow the required edge independently. The spray nozzles shall be arranged to
give a uniform spray and the shut-off shall be quick-acting with an antidrip
device. The pressure in the spray bar shall be sufficient to give a good
distribution and spraying of the binder.
Distributors shall be capable of applying bituminous binder within the limits of ±5% of the
specified rate of application over any portion of the surface.
Distributors shall be checked and calibrated before starting any work or when required by the
Engineer. This shall include the calibration of all the metering devices and
checking the uniformity of the transverse distribution of spray. All distributors
shall be furnished with a “rate of spray/machine speed” chart.
(b) Chip-spreaders
Mechanical chip-spreaders shall be capable of spreading the chippings uniformly over variable
widths, from 0.5 to 3.5 m, at the rates specified.
The number and output of chip-spreaders shall be sufficient to ensure that chippings are spread
immediately after the bituminous binder has been applied.
Chip-spreaders shall be checked and calibrated before starting any work or when required by the
Engineer.
(c) Rollers
The main rolling shall be carried out with self-propelled pneumatic tyred rollers, having a wheel-
load of more than 2 tonnes. The tyres shall be smooth and their pressure shall
be more than 0.4 N/mm2.
Where approved by the Engineer steel-wheeled rollers shall be used in tandem with pneumatic
tyred rollers after all excess chippings have been removed and insufficiently
chipped areas have been chipped over. Only steel-wheeled rollers weighing less
than 8 tonnes (total weight) shall be accepted.
The number and output of rollers shall be sufficient to ensure that rolling does not lag behind
spreading. To the extent possible, two pneumatic tyred rollers shall be used for
each chip-spreader.
(d) Miscellaneous Equipment
Sufficient trucks and loading machinery shall be employed to ensure an adequate, prompt and
continuous supply of chippings.
Rubber tyred mechanical rotary brooms towed by or mounted on rubber tyred vehicles shall be
provided.

11
Immediately before spraying, all loose material and foreign matter shall be removed by
thorough brushing with mechanical brooms and/or washing or by use of compressors or
by other methods acceptable to the Engineer. All hardened mud or other foreign matter
shall be loosened by scraping before sweeping. The debris shall be deposited well clear
of the surface to be sprayed. Road furniture (manholes covers etc.) shall be covered with
adhesive paper or similar materials. Kerbstones, roadside, and any other objects what
shall not benefit from binder spray shall be protected in a manner approved by the
Engineer.
Any defect of the surface shall be made good as instructed by the Engineer and no
binder shall be sprayed until the surface has been approved by the Engineer. The
Engineer’s approval or otherwise of the surface shall be given immediately prior to the
Contractor’s intention to start spraying.
(8) Application of Surface Dressing
Soon after the surface has been prepared and approved, the quantity of binder,
chippings, requirement of equipment and other resources shall be worked out so that
any operation is not delayed due to lack of required material or resources.
The binder shall be uniformly sprayed at the specified rate. Spraying of the binder shall
be in accordance with the requirements specified in Sub-Clause 1301 (4). Spraying shall
not be carried out later than 12 hours after the surface has been prepared.
Building paper of sufficient width (not less than 600mm) or other approved protective
material shall be used at the start and finish of each spray run to enable the distributor to
reach its calibrated road speed. Each spray jet shall be kept open before discharging
binder onto the pavement under treatment.
Ends of previous surface treatment run shall be trimmed back to make the traverse edge
straight and to clean it. This shall form the start point of the subsequent spray run. The
spray run shall be limited to 300 m of length unless the Contractor demonstrates his
ability to plan and execute longer length without impairing quantity of work. Spray width
shall be calculated allowing for 150mm longitudinal overlap with adjoining spray passes
and for the width that the following chipping spreader is able to cover. Longitudinal
sprayed butt joint shall not be permitted. The Contractor shall submit his spray width and
length proposals to the Engineer for approval.
The spraying width shall normally be of one lane width so that construction traffic may
run over the other lane.
Immediately after the binder has been sprayed, clean and dry chippings shall be
uniformly applied at the specified rate by the use of mechanical chip-spreaders. The
elapsed time between the spraying of binder and the spreading of chippings shall in no
case exceed one minute. It become apparent that the supply of chippings is about to fail,
the binder spraying shall be immediately stopped and shall not resume until and
adequate supply of chippings is assured.
The correct rate of spread is generally assessed visually, as providing complete

coverage, with the film of binder still visible between the chippings. Shall the coverage
appear to be incorrect, the Contractor shall immediately inform the Engineer, who shall
amend the rate of spread accordingly. Any excess of chippings shall be removed by

12
hand and any insufficiently chipped area shall be chipped over by hand, so that
adequate coverage is obtained. Brooming of the material to effect redistribution of
chippings shall not be permitted.
Rolling shall begin immediately after the chippings have been spread and, in no case,
later than two minutes after the application of binder.
Rolling shall continue until all chippings are firmly embedded into the binder and until all
excess chippings have been removed or insufficiently chipped areas have been chipped
over. The number of passes shall be agreed with the Engineer. Usually, each point shall
receive at least 6 passes of the pneumatic tyred roller.
Excessive rolling, resulting in the crushing of chippings, shall be avoided. The roller
speed shall not exceed 8 km/h, unless otherwise directed by the Engineer. Additional
rolling on a previously completed section shall be given later in the heat of the day by
pneumatic tyred rollers in tandem with steel three wheeled rollers unless otherwise
(9) Aftercare and Control of Traffic
The road shall not be opened to traffic until the binder has attained sufficient viscosity to
prevent the stones being whipped off.
The Contractor shall erect temporary traffic restriction signs, barriers and removable
bumps or any other device, as instructed by the Engineer, to prevent vehicles travelling
too fast over the newly laid surface dressing. Vehicle speed shall be restricted to a
maximum of 30 km/h, until there is sufficient adhesion to ensure that the chippings shall
not be dislodged by faster vehicles.
Where possible, the traffic shall be distributed across the road so as to obtain uniform
polishing of the road surface.
After traffic has been permitted to run on the surface dressing for a period of at least two
weeks and when instructed by the Engineer, all loose chippings shall be swept and taken
away. Windrows of loose chippings shall not be allowed to accumulate at the sides of the
road.
(10) Rectification of Defects
If any defect in surface dressing work is found, the reasons of the defect shall be
established and keeping them in view the defect shall be rectified as per direction of
the Engineer. If required, the Engineer shall ask the contractor for redoing the defective
portion. The Contractor shall rectify or redo the defective work at his own expense.
(11) Tolerances
The final average overall width of the surface dressing measured at six equidistant points
over a length of 100 m shall be at least equal to the width specified or instructed. At no
point shall the distance between the centreline of the road and the edge of the surface
dressing be narrower than that instructed by more than 13mm.

13
The actual rate of application of binder across the lane width shall not vary by more than
±5% of the rate ordered and for each single run of the spray it shall not vary from the
specified rate by more than 0.03 lit per square metre.
The actual rate of application of chippings along and across the lane width for each
single run of the chip-spreader shall not vary by more than ±5% of the rate ordered.
(12) Testing
(a) Process Control
The minimum testing frequency required for the process control shall be as

MATERIALS :
AGGREGATE:
Grading One test every 50 m3 or part of it and in every change of source
Flakiness Index (FI) " " " "
Los Angeles (LAA) " 250 m3 " "
Aggregate Impact Value (AIV) " " " "
Crushing Ratio (CR) " " " "
Degradability Test " 500 m3 " "
Sodium Sulphate Soundness " " " "
Stripping Value Initially one set of 3 specimens for each source of supply.
Subsequently when warranted by change in the quality of
aggregates
Rate of Application Two per day
BITUMINOUS BINDERS:
Quality of Binder The Contractor shall produce certificates from the
concerned all suppliers to the effect that all materials
supplied by them comply with the relevant Specifications.
In addition, one set of tests for each 50,000 litres or part of it of
supply of binder
Binder Temperature for Application At close intervals
Rate of Application of binder Two tests per run
CONSTRUCTION TOLERANCES :
Width One test each and every spray run
Smoothness All apparently rough areas to be checked
Routine inspection and testing shall be carried out to test the materials and
workmanship for compliance with the requirements specified in this Section.
Any materials or workmanship not complying with the requirements specified,

shall be replaced or redone with the materials or workmanship complying with
the Specifications or, be repaired so as to comply with the requirements
specified.
(13) Measurement

14
Binding materials (emulsion/bitumen and cutter) shall be measured seperately in litre.

For computation of the quantity the following methods shall be adopted.
(a) Designed/instructed rate of application times specified area sprayed computed

in litres corrected to 15.6o c
(b) Actual rate of application measured through tray tests times specified area
sprayed, computed in litres corrected to 15.6 o c
(c) Actual consumption in specified area sprayed measured in litres corrected to
15.6oC by dip stick feading of the distributor.
The lowest value of the above three methods shall be adopted for payment. However,
if the rate of actual spray of binder is much less or more than the designed/instructed
rate of spray so as to impair quality of surface dressing, the Engineer shall reject the
work or shall ask for appropriate rectification which the contractor shall execute at his
own cost.
Bitumen and cutter shall be computed on the basis of percentage actually used in the
work.
Chippings of each nominal size shall be measured in tonne. For computation of

quantity the following methods shall be adopted.
(a) Design/instructed rate of application of chippings times specified area applied,

computed in tonne.
(b) Actual rate of application of chippings times specified area of application

computed in tonne.
The lower of these two values shall be adopted for payment. However, actual rate of
application shall not vary with designed/instructed rate of application to impair quality of
surface dressing. In such event the Engineer shall reject the work or ask the
Contractor to rectify at his own cost.
Measurement of precoated chippings shall be as stipulated in the contract.
(14) Payment
The binder i.e. emulsion/bitumen and the cutter shall be paid as per their respective
contract unit rate. The contractor unit rate shall be the full and the final compensation
for the cost of preparation of surface to receive binder, heating, mixing with cutter,
spraying, rectification wherever required, compliance of all provisions specified in
Clause 1301 and 1303 in addition to those specified in Clause 112.
Chippings of each nominal size as specified shall be paid at their respective contract
unit rate. The contract unit rate shall be the full and the final compensation for the cost
of compliance of all provisions specified in Clauses 1301 and 1303.
The pre-coated chippings shall be paid as stipulated in the contract.
1304 PENETRATION MACADAM. SEMI-GROUT

15
(1) Scope
This work shall consist of compacted crushed coarse aggregates with application of
bituminous binder and choke aggregates in accordance with the requirements of these
Specifications. Reference shall be made to Clause 1301, as provisions contained therein
shall be applicable in this Clause also.
(2) Materials
(a) Aggregate
The aggregate shall consist of crushed rock or crushed gravel. They shall be of
angular shape and of such character that it shall compact and interlock under
rolling. It shall be of reasonably uniform quality throughout and free from clay,
earth, dust or other deleterious matter. It shall comply with the following
requirements:
Los Angeles Abrasion (LAA) - Max. 40%

Aggregate Impact Value (AIV) - Max 30%
Sodium Sulphate Soundness (SSS) - Max 12%
The grading of course and choke aggregate shall be within the limits specified in
the Table 13.8.
Table 13.8: Grading of Aggregate for Penetration Macadam

Sieve Coarse Coarse Key Key Aggregate
Size Aggregate Aggregate Aggregate (Type II)
(mm) (Course 75mm (Course 50mm (Type I)
thick) thick)
75.00 100 - - -
63.00 90 - 100 100 - -
50.00 20 - 55 90 - 100 - -
37.50 0 - 15 40 - 75 - -
25.00 - 15 - 35 - -
20.00 0-5 0 - 15 100 100
12.50 0-5 90 - 100 90 - 100
10.00 40 - 70 40 - 75
4.76 0 - 15 5 - 25
2.36 0-5 0 - 10
1.18 0-5
When the emulsion is used in place of bitumen the aggregate shall be of the
composition as specified in the Table 13.9.
Table 13.9: Composition of Aggregate
Compacted thickness of layer Nominal size of aggregate Percentage

16
50mm 40mm 60%

28mm 30%
14-20mm 10%
65mm - 75mm 50mm 60%
40mm 30%
14-20mm 10%
The aggregates of various sizes shall be thoroughly mixed and shaped before
compaction.
(b) Binder
The binder shall be straight run bitumen of 80/100 penetration, or cut-back

bitumen of RC-3000 grade or emulsion of class A1-60, A1-55, K1-60 or K1-70 as
specified in the Special Specification or in the Bill of Quantities.
(3) Rate of Application of Binder and Aggregates
Unless otherwise specified the rate of spray of binder and aggregates shall be as given
in the Tables 13.10 and 13.11.
Table 13.10: Rate of Application of Binder and Rate of Spread of Aggregates per sq.m
Compacted thickness Binder Coarse Aggregate Key Aggregate

75 mm 6.8 litres 0.09 m3 0.018 m3
0.06 m3 0.015 m3
50 mm 5.0 litres
When emulsion is used, rate of application of emulsion shall be as specified in the Table
13.11.
Table 13.11: Rate of Application of Emulsion
Thickness of layer (mm) Rate of application l/m2

50 3.0-5.5
(4.0)*
65 4.0-7.0
(5.5)*
75 5.5-8.0
(6.5)*
* Rate given in the bracket is the nominal rate of application.
(4) Preparation of Existing Surface
The surface containing holes or depressions shall be repaired by removal of all loose
materials and replacement with a suitable patching mixture or other material approved by
the Engineer. This shall be compacted to produce a tight surface conforming with the

17
adjacent areas. Bumps and waves which impair the riding qualities of the surface, shall
be removed and required cross slope and grade shall be provided by scarification and
re-compaction or by other such means as shall be agreed or ordered by the Engineer.
The base shall then be swept clean of all loose and foreign materials.
For use of emulsion clean sand or quarry fines shall normally be laid upon the
prepared base to a depth not exceeding 13 mm.
(5) Application of Coarse Aggregate
Immediately following preparation of the base (if this is not practicable the base must be
re-cleaned of loose and foreign material) coarse aggregate shall be spread in loose
depth so as to provide the specified thickness of surface course with required cross
slope and grade after compaction. The aggregate shall be spread by hand or by an
approved spreading device. Dumping in mass on the base shall not be permitted. The
shallers at the edge of the surface course shall be prepared in advance of spreading the
aggregate to allow the roller to roll the shaller edge and the edge of the loose aggregate
simultaneously. Precautions shall be taken to prevent the coarse aggregate from
becoming mixed or coated with earth or other deleterious matter both before and after
spreading. The surface of the loose aggregate shall be carefully shaped and all high and
low spots shall be remedied by removing or adding aggregate. The coarse aggregate
shall then be dry rolled with a three wheel roller weighing not less than 8.00 tonnes.
Rolling shall start longitudinally at the sides and proceed towards the centre of the
pavement overlapping on successive passes by at least one half the width of the rear
wheel. The compacted coarse aggregate shall then be tested with a straight-edge and
camber template to ensure that it has a firm, even surface true to cross-section and
having a texture which shall allow uniform penetration of the binder.
The aggregate shall be spread to the required contour and to such a thickness that,
after being compacted its minimum thickness shall not be less than specified.
In case of hand spreading, each load of aggregate shall be unloaded outside the area
upon which it is to be spread, and precaution shall be taken to prevent the aggregate
becoming contaminated with dust or foreign matter during the whole of the operations.
The spreading shall be carried out with shovels and not with forks, care being taken to
avoid segregation of the different sizes of aggregate. In case of mechanical spreading,
the aggregate shall be spread by mechanical means such as a spreader box.
Where emulsion is used, it is preferred to spread first the coarse aggregate of larger
size and to superimpose 14 mm to 20 mm material as a separate operation. The
minimum quantity of water shall be applied during rolling to bring up slurry evenly in the
aggregates within such a depth of the surface of the road as may be specified. It is
preferable that the lower or slurried layer, which is thus waterbound, shall not exceed
two thirds of the total thickness of the compacted thickness of the aggregate.
(6) Application of Binder
Binder shall be applied to the rolled coarse aggregate by means of an approved binder
distributor complying with the requirements of Sub-clause 1303 (6) or such other means
as the Engineer shall approve. The quantity of binder to be applied shall be as specified

18
in Tables 1301 and 1311 and it shall be applied at the temperatures specified in Sub-
clause 1301 (4). At the time of applying straight run bitumen or cut back bitumen binder,
the aggregates shall be dry for the full depth of layer.
(7) Application of Key Aggregate
Immediately after the binder has been applied to the coarse aggregate, key aggregate
shall be sprinkled lightly over the surface in sufficient quantity to prevent sticking of the
roller wheels. Then this shall be rolled and simultaneously with the rolling additional key
aggregate shall be added in small quantities and lightly broomed over the surface while
rolling continues until the surface interstices between the coarse aggregate have been
filled but without covering the coarse aggregate itself. The surface shall then be rolled
until the stone is thoroughly imbedded into the binder and anchored in place. Rolling
shall be continued until the surface is hard and smooth and shows no perceptible
movement under the roller.
(8) Seal coat
The surface shall be swept clean of all loose material and treated with a second coat of
binder and cover aggregate as specified in Clause 1303.
(9) Protection of Pavement
The seal coat shall be applied as soon as practicable after the application of the choke
aggregate and the surface course shall be protected from all traffic (other than that
essential to the construction) until the completion of the seal coat.
(10) Tolerances
Penetration macadam course shall be set out and constructed to the tolerances given in
Section 1100 of this Specification.
The actual rate of application of binder across the lane width shall not vary by more
than ±5% of the rate ordered and for each single run of the spray it shall not vary from
the specified rate by more than 0.03 litre per square metre.
The actual rate of application of chippings for each single run of the chip-spreader shall
not vary by more than ±5% of the rate ordered.
(11) Testing
(a) Process Control
The minimum testing frequency for the purpose of process control shall be as

MATERIALS :

19
AGGREGATE:
Grading One test every 100 m3 or part of it and in every change in source
Los Angeles " 500 m3 " "
Aggregate Impact Value " " " "
Sodium Sulphate Soundness " " " "
BITUMINOUS BINDERS: The Contractor shall produce certificates from all suppliers
Quality of Binder to the effect that all materials supplied by them comply with
supply of binder
Temperature of binder at Application At close intervals

Rate of Application of binder and chippings Two tests per run
Width 200m or at close intervals

Surface levels 10m " "
Layer thickness 500m " "
Smoothness All apparently rough areas to be checked
Any materials or workmanship that does not comply with the requirements
specified shall be replaced with materials and workmanship complying with the
Specifications or, be repaired so that after being repaired it shall comply with the
requirements specified.
(12) Measurement
Penetration macadam course shall be measured as finished work in square meters.
Seal coat shall be measured as per Sub-clause 1303.
(13) Payment
The penetration macadam shall be paid as per contract unit rate which shall be the full
and the final compensation to the Contractor for the cost of preparation of existing
surface, providing, hauling and spraying bituminous binder, coarse and choke
aggregates and complying with Clauses 1301 and 1304 in addition to those specified in
Clause 112.
Seal coat shall be paid as provided in Clause 1303.
(14) Adjustment in Contract Unit Rate
Should there be any variation between the specified (nominal) rate of application of
binder, coarse aggregate and/or chok aggregate and their respective rate of
application actually used in the work as per direction of the Engineer, the contract unit

20
rate for penetration macadam shall be adjusted based on contract unit rate of the
respective material quoted by the Contractor for the purpose of this adjustment.
The varied penetration macadam shall be paid as per adjusted rate.
1305 SAND SEAL
(1) Scope
This Clause covers the materials, method of construction and requirements for the
construction of sand seal.
(2) Definition
A sand seal means an application of bituminous binder covered with aggregate as

specified hereunder.
(3) Materials
(a) Binder
The binder shall be a medium-curing cut-back MC-800 or MC-3000 or K1-60

cationic emulsion unless otherwise specified.
(b) Fine Aggregate
The aggregate shall consist of sand, or fine screenings, free from organic matter,
clay and other deleterious materials. The fines (passing a 0.425 mm sieve) shall
be non-plastic. The grading shall be as specified in the Table 13.13.
Table 13.13: Grading of Aggregate
Sieve (mm) Percentage passing by weight

10.00 100
4.75 70 - 90
2.36 45 - 70
0.60 15 - 35
0.15 0-2
The material shall be wet screened to ensure all material greater than 10 mm is
eliminated together with dust and foreign matter.
(4) Rate of Application of Binder and Fine Aggregate
The rate of spray of binder and the rate of spread of the fine aggregate shall be as
specified in the Special Specification or as provided in the BOQ or as instructed by the
Engineer.

21
During the sand sealing operation tray tests to determine spray rate of binder and spread
rate of fine aggregate shall be carried out at least twice per spray run.
(5) Construction
The surface to be covered shall be prepared in accordance with Sub-clause 1307 (7).
The binder shall be uniformly sprayed at the specified rate. After this, the fine aggregate
shall be uniformly spread and rolled, all in accordance with Sub-clause 1303 (8).
(6) Aftercare and Control of Traffic
The road shall be opened to traffic when instructed by the Engineer.
Traffic speed shall be restricted as per Sub-clause 1303 (9) for as long as the Engineer
may require.
Any whipped-off aggregate shall be broomed back onto the road, as many times as are
necessary for it to adhere fully to the binder.
(7) Tolerances
Sand seal shall be constructed within the same width tolerance as given in Sub-clause
1303 (11) for surface dressing.
The actual rate of application of binder across the lane width shall not vary by more
than ±5% of the rate ordered and for each single run of the spray shall not vary from
the specified rate by more than 0.03 litre per square metre.
The actual rate of application of fine aggregate along and across the lane width for
each single run of the chip-spreader shall not vary by more than ±5% of the rate
ordered.
(8) Testing
(a) Process Control
The minimum testing frequency required for the process control shall be as

Grading One test for every 50 m3 or part of it and every change of source
Plasticity Index " " " "
Quality of Binder The Contractor shall produce certificates from all suppliers to
the effect that all materials supplied by them comply with the
relevant Specifications.
In addition, one set of tests for each 50,000 litres or part of it of supply
of binder

22
Temperature of binder at Application At regular close intervals

Rate of Application of binder Two tests per day
specifications or, be repaired so that after being repaired it shall comply with the
(9) Measurement
Sand seal shall be measured as finished work in square metre.
(10) Payment
Payment for sand seal shall be as per contract unit rate which shall be the full and the
final compensation for the cost of compliance of all requirements specified in Clause
1301 and 1305 in addition to those specified in Clause 112.
Should there be any variation between the specified rates of binder and/or aggregate
and their actual rate of application as per the instruction of the Engineer respectively, the
contract unit rate for sand seal shall be adjusted based on contract unit rates of these
materials quoted by the Contractor for the purpose of adjustment.
The varied work shall be paid as per adjusted rate.
1 306 SLURRY SEAL
(1) Scope
This clause covers the materials, method of construction and requirements for the
construction of emulsion slurry seal.
(2) Definition
Slurry seal means a mixture of bitumen emulsion, fine aggregate, cement or lime and
water prepared in a mixer and then spread on the road surface.
(3) Materials
(a) Emulsion
The emulsion shall be either an anionic emulsion A4 (slow setting) or a slow-

acting cationic emulsion K3 unless otherwise instructed by the Engineer.

23
(b) Aggregate
The aggregate shall be free of organic matter, clay, silt or other deleterious
matter. It shall have a Sand Equivalent of at least 50.
The grading curve shall be within one of the envelopes provided in the Table
13.15 or as specified in the Special Specification or in the Bill of Quantities:
Table 13.15: Grading Envelopes of Aggregate
Sieve Percentage passing by weight

Size (mm) Type I (Fine) Type II(General) Type III (Coarse)
10.000 - - 100
4.750 100 90-100 70-90
2.360 90 - 100 65-90 45-70
1.180 65-90 45-70 28-50
0.600 40-60 30-50 19-34
0.300 25-42 18-30 12-25
0.150 15-30 10-21 7-18
0.075 10-20 5-15 5-15
(c) Cement/Lime
Cement and lime shall comply with the requirements of Section 600.
(4) Preparation of the Slurry Mix
The proportion by weight of dry aggregate, bitumen emulsion and cement or lime shall
be specified in the Special Specification or in the Bill of Quantities. This shall be termed
the nominal proportions of bitumen emulsion and cement or lime.
Water shall be added in sufficient quantity to obtain the correct slurry consistency as
The slurry mixture shall be prepared in the presence of the Engineer in a slurry mixer
acceptable to him. The mixer shall be charged with materials in the proportions specified.
The mixing cycle shall be sufficient to produce a uniform coating of the aggregate and a
uniform consistency of the slurry. It shall continue until the slurry mixture is discharged
into the spreader box or onto the road surface. The entire batch shall be discarded, if
there is evidence that the emulsion has broken. The slurry, ready for application, shall be
a smooth, free flowing mixture throughout.
(5) Rate of Application of Slurry Mixture
The rate of application of the slurry mixture shall be as specified in the Special
Specifications or as instructed by the Engineer.
Tray tests shall be carried out at least two tests for every 1000 square metre of spray
during slurry seal operations.
(6) Construction

24
Where a slurry seal is to be applied to a surface dressing, the surface dressing shall be
trafficked for a period of at least two weeks prior to the application of the slurry seal.
The surface to be covered shall be prepared in accordance with Sub-clause 1303 (7).
Unless otherwise agreed by the Engineer, the slurry mixture shall be evenly spread by a
slurry machine at the specified rate.
The surface immediately ahead of the spreader shall be slightly dampened, unless
otherwise instructed by the Engineer. Slurry seal shall receive at least 6 passes of the
pneumatic tyred roller unless otherwise directed by Engineer. The rolling shall
commence as soon as the slurry has set sufficiently to ensure that no rutting or pick up
will occur.
The finished slurry seal shall be of uniform surface texture and colour throughout the
work. The finished surface shall be free from blow-holes and irregularities.
(7) Curing and Control of Traffic
All traffic shall be kept off the slurry seal until it has cured to a firm condition to prevent
pick-up of the mixture. Where two applications of slurry are required, the initial treatment
shall be cured thoroughly prior to placing the succeeding application.
(8) Tolerances
Slurry seal shall be constructed within the same width tolerances given in Sub-clause
1303 (11).
The rate of application of slurry seal across the width of a lane sealed in a single pass
shall not vary by more than ±5% of the rate ordered, and the average rate of application
along the length of a single pass shall be not less than the rate ordered.
(9) Testing
(a) Process Control
The minimum testing frequency for the process control shall be as given in the
Table 13.16.

Grading One test for every 50 m3 or part of it and every change of source
Sand Equivalent " 200 m3 " "
Quality of Binder The Contractor shall produce certificates from all suppliers
to the effect that all materials supplied by them comply with
the relevant specifications.
supply of binder

25
Rate of Application of slurry mixture Two tests per 1000 sq.m or part of it
workmanship for compliance with the requirements specified in this section.
specifications or, be repaired so that after being repaired it shall comply with the
(10) Measurement
Slurry seal shall be measured as finished work in square metre.
(11) Payment
Slurry seal shall be paid as per contract unit rate which shall be the full and the final
compensation for the costs of compliance of all requirements of Clause 1301 and 1306 in
addition to those specified in Clause 112.
Should there be any variation between the specified rates of binder, aggregate and/or
cement/lime and their actual rate of application as per the instruction of the Engineer,
respectively, the contract unit rate for slurry seal shall be adjusted as per contract unit
rate of these materials quoted by the Contractor for the purpose of this adjustment.
The varied work shall be paid as per adjusted rate.
1307 GENERAL REQUIREMENTS FOR ASPHALT CONCRETE, SAND ASPHALT, EMULSION

AGGREGATE MIX AND COLD ASPHALT
(1) Scope
This Clause comprises all the general requirements for bituminous mixes which shall
apply to Clause 1308 to Clause 1311.
(2) Construction Plant
(a) General
The Contractor shall submit to the Engineer full details of the construction plant
he proposes to use and the procedures he proposes to adopt for carrying out
the permanent works.
The Engineer shall have access at all times to construction plant for the
purposes of inspection. The Contractor shall carry out regular calibration checks
in the presence of the Engineer and shall correct forthwith any faults found.

26
All construction plant used in the mixing, laying and compacting of bituminous
mixes shall be of adequate capacity, in good working condition and shall be
acceptable to the Engineer.
(b) Mixing Plant
Bituminous materials shall be mixed in a plant complying with ASTM Designation

D995 and shall be located on the Site unless otherwise agreed by the Engineer.
It shall be equipped with at least three bins for the storage of heated aggregates
and a separate bin for filler. All bins shall be covered to prevent the ingress of
moisture.
The plant may be either batch-mix type of the continuous-mix type and shall be
capable or regulating the composition of the mixture to within the tolerances
specified in Sub-clause 1307 (13).
The bitumen tank shall be capable of maintaining its contents at the specified
temperature within a tolerance of plus or minus 5°C and shall be equipped with
a thermostat to prevent the temperature rising above 180°C and a fixed
thermometer easily read from outside the tank. Any bitumen which has been
heated above 180°C or has suffered carbonisation from prolonged heating shall
be removed from the plant and disposed off.
(c) Laying Plant
Bituminous materials shall be laid by a self propelled spreader finisher equipped

with a hopper, delivery augers and a heated adjustable vibrating screed. It shall
be capable of laying bituminous materials with no segregation, dragging, burning
or other defects and within the specified level and surface regularity tolerances.
Delivery augers shall terminate not more than 200 mm from the edge plates.
(d) Compaction Plant
The Contractor shall provide sufficient rollers of adequate size and weight to
achieve the specified compaction. Prior to commencing the laying of bituminous
mixes in the permanent works the Contractor shall carry out site trials in
accordance with Section 500 to demonstrate the adequacy of his plant and to
determine the optimum method of use and sequence of operation of the rollers.
Immediately before placing the bituminous mix in the pavement, the existing surface shall
be cleaned of all loose materials and foreign matter with mechanical brooms or by other
approved methods. The debris shall be deposited well clear of the surface to be covered.
Any defect of the surface shall be made good and no bituminous mix shall be laid until
the surface has been approved by the Engineer.

27
If instructed by the Engineer a tack coat shall be applied in accordance with Clauses
1301 and 1302. If the Engineer considers a tack coat is required prior to laying the
bituminous mix or between layers of the bituminous mix, due solely to the Contractor's
method of working, then such tack coat shall be at the Contractor's expense.
(4) Design and Working Mixes
The Contractor shall demonstrate that he can produce aggregates meeting the grading
requirements of the Specification.
At least two months prior to commencing work using a bituminous mix, the Contractor
shall, having demonstrated that he can produce aggregates meeting the grading
requirements of the Specification, submit samples of each constituent of the mix to the
Engineer.
The maximum size of the aggregate for wearing course shall equal to or less than the
thickness of wearing course divided by 2.5 and that for binder course shall equal to or
less than thickness or binder course divided by 2.
The Contractor shall then carry out laboratory tests in order to propose the proportions of
each constituent of the initial mix or mixes to be used for site trials to be carried out in
accordance with Sub-clause 1307 (5).
Shall the Engineer conclude from the site trials that the mix proportions or aggregate
gradings are to be changed; the Contractor shall submit further samples of the
constituents, carry out further laboratory and site trials as directed by the Engineer.
The Engineer may instruct the alteration of the composition of the aggregates passing
through 0.075 mm by the addition or substitution of mineral filler.
The Contractor shall make the necessary adjustments to his plant to enable the revised
mix to be produced.
Following laboratory and site trials the determined proportions of the mix agreed by the
Engineer shall become the basis of the working mix and the Contractor shall maintain
this composition within the tolerances given in Sub-clause 1307 (13).
Any changes in the nature or source of the materials, the Contractor shall inform the
Engineer accordingly. The procedure set out above shall be followed in establishing the
new mix design also.
(5) Site Trials
Full scale laying and compacting site trials shall be carried out by the Contractor on all
asphalt pavement materials proposed for the works using the construction plant and
methods proposed by the Contractor for constructing the works. The trials shall be
carried out at a location approved by the Engineer in his presence.
The trials shall be carried out to enable the Contractor to demonstrate the suitability of his
mixing and compaction equipment to provide and compact the materials to the specified

28
voids content and confirm that the other specified requirements of the completed asphalt
pavement layer can be achieved.
Each trial area shall be at least 100 metres long and to the full construction width and
depth for the material. It may form part of the Works provided it complies with this
Specification. Any areas which do not comply with this Specification shall be removed.
The Contractor shall allow in his programme for conducting site trials and for carrying out
the appropriate tests on them. The trial on any pavement layer shall be undertaken at
least 21 days ahead of the Contractor proposing to commence the full scale work on that
layer.
The Contractor shall compact each section of trial over the range of compactive effort the
Contractor is proposing. The following data shall be recorded for each level of
compactive effort at each site trial:-
(a) The composition and grading of the material including the bitumen content and
type and grade of bitumen used.
(b) The moisture content of aggregate in the asphalt plant hot bins.
(c) The temperature of bitumen and aggregate immediately prior to entering the
mixer, the temperatures of the mix on discharge from the mixer and the
temperature of the mix on commencement of laying, on commencement of
compaction and on completion of compaction. The temperatures of the mixture
are to be measured in accordance with BS 598, Part 109.
(d) The type, size, mass, width of roll, number of wheels, wheel load, tyre pressures,
frequency of vibration and the number of passes of the compaction equipment,
as appropriate for the type of roller.
(e) The target voids and other target properties of the mix together with the results of
the laboratory tests on the mix.
(f) The density and voids achieved.
(g) The compacted thickness of the layer.
(h) Any other relevant information as directed by the Engineer.
At least eight sets of tests shall be made by the Contractor on each 100 metres of trial for
each level of compactive effort and provided all eight sets of results over the range of
compactive effort proposed by the Contractor meet the specified requirements for the
material then the site trial shall be deemed successful. The above data recorded in the
trial shall become the agreed basis on which the particular material shall be provided and
processed to achieve the specified requirements.
During the execution of the Works, if the construction control/process control tests
indicate that the requirements for a material are not consistently achieved, then work on
that layer shall be stopped until the cause is investigated by the Contractor. Such
investigation may include further laboratory and/or site trials on the material to determine
a revised set of data as described above which, when agreed, shall be the basis on
which all subsequent material shall be provided and processed to achieve the specified
requirements.
Agreement of the Engineer to a set of data recorded in a site trial shall not relieve the
Contractor of any responsibility to comply with the requirements of this Specification.
(6) Mixing of Aggregates and Bitumen

29
The bitumen shall be heated so that it can be distributed uniformly. Care shall be taken
not to overheat it. The temperature shall never exceed 170°C for 80/100 or 60/70
bitumen.
The aggregates shall be dried and heated so that they are mixed at the following
temperatures unless otherwise specified in Clauses 1308 to 1311:
125° - 165°C when 80/100 bitumen is used,

130° - 170°C when 60/70 bitumen is used.
The dried aggregates shall be combined in the mixer in the amount of each fraction of
the agreed mix and the bitumen shall then be introduced into the mixer in the amount
specified. The materials shall then be mixed until a complete and uniform coating of the
aggregate is obtained.
The mixing time shall be the shortest required obtaining a uniform mix and thorough
coating. The wet mixing time shall be determined by the Contractor and agreed by the
Engineer for each plant and for each type of aggregate used. It shall normally not exceed
60 seconds.
(7) Transportation of the Mixture
The bituminous mix shall be kept free of contamination and segregation during
transportation. Each load shall be covered with canvas or similar covering to protect it
from dust and adverse effect of the weather.
(8) Laying of the Mixture
Immediately after the surface has been prepared and approved, the mixture shall be
spread to line and level by the laying plant without segregation and dragging.
The mixture shall be placed in widths of one traffic lane at a time, unless otherwise
agreed by the Engineer. The compacted thickness of any layer shall be at least 2.5 times
the maximum size of the aggregate for wearing course and at least 2 times the maximum
size of the aggregate for binder course.
Only on areas where irregularities or unavoidable obstacles make the use of mechanical
laying impracticable, the mixture may be spread and compacted by hand.
(9) Compaction
Immediately after the bituminous mixture has been spread, it shall be thoroughly and
uniformly compacted by rolling.
The layer shall be rolled when the mixture is in such a condition that rolling does not
cause undue displacement or shoving.
The number, weight and type of rollers furnished shall be sufficient to obtain the required
compaction while the mixture is in a workable condition. The sequence of rolling
operations shall be as agreed with the Engineer.

30
Initial rolling with a steel tandem or three-wheeled roller shall follow the laying plant as
closely as possible. The rollers shall be operated with the drive roll nearest the laying
plant, at a slow and uniform speed (not exceeding 5 km/h).
Rolling shall normally commence from the outer edge and proceed longitudinally parallel
to the centreline, each trip overlapping one half of the roller width. On superelevated
curves, rolling shall begin at the low side and progress to the high side. Where laying is
carried out in lanes care must be taken to prevent water entrapment.
Intermediate rolling with a pneumatic tyred or vibratory roller shall follow immediately.
Final rolling with a steel wheeled roller shall be used to eliminate marks from previous
rolling.
To prevent adhesion of the mixture to the rollers, the wheels shall be kept lightly
moistened with water.
In areas too small for the roller, a vibrating plate compactor or a hand tamper shall be
used to achieve the specified compaction.
(10) Finishing, Joints and Edges
Any mixture that becomes loose and broken, mixed with dirt or foreign matter or is in any
way defective, shall be replaced with fresh hot mixture, which shall be compacted to
conform with the surrounding area.
Spreading of the mixture shall be as continuous as possible. Transverse joints shall be

formed by cutting neatly in a straight line across the previous run to expose the full depth
of the course. The vertical face so formed shall be painted lightly with hot 80/100
penetration grade bitumen just before the additional mixture is placed against it.
Longitudinal joints shall be rolled directly behind the paving operation. The first lane shall
be placed true to line and level and have an approximately vertical face. The mixture
placed in the abutting lane shall then be tightly crowded against the face of the previously
placed lane. The paver shall be positioned to spread material overlapping the joint face
by 20 - 30 mm. Before rolling, the excess mixture shall be raked off and discarded.
When the abutting lane is not placed in the same day, or the joint is destroyed by traffic,
the edge of the lane shall be cut back as necessary, trimmed to line and painted lightly
with hot 80/100 penetration grade bitumen just before the abutting lane is placed.
Any fresh mixture spread accidentally on the existing work at a joint shall be carefully
removed by brooming it back on to uncompacted work, so as to avoid formation of
irregularities at the joint. The finish at joints shall comply with the surface requirements
and shall present the same uniformity of finish, texture and density as other sections of
the work.
The edges of the course shall be rolled concurrently with or immediately after the
longitudinal joint. In rolling the edges, roller wheels shall extend 50 to 100 mm beyond
the edge.
(11) Sampling of Bituminous Mixtures

31
The sampling of bituminous mixtures shall be carried out in accordance with ASTM
Designation D979.
(12) Quality Control Testing
During mixing and laying of bituminous mixtures, control tests on the constituents and on
the mixed material shall be carried out in accordance with Section 600 and relevant
Clauses of Section 1300.
If the results of any tests show that any of the constituent materials fail to comply with this
Specification, the Contractor shall carry out whatever changes may be necessary to the
materials and/or to the source of supply to ensure compliance.
If the results of more than one test in ten on the mixed material show that the material
fails to comply with this Specification, laying shall forthwith cease until the reason for the
failure has been found and corrected. The Contractor shall replace any faulty material
laid with material complying with this Specification all at his expense.
(13) Tolerances
Surfacing and base shall be constructed within the geometric tolerances specified in
Section 1100.
The Contractor shall maintain the composition of the mixture as determined from the
laboratory and site trials within the following tolerances, per single test:-
(a) Bitumen content :  0.3% of (Total weight of
bitumen in total mix)

(b) Aggregates
(i) Passing through 10 mm sieve and larger sieves :  6%of (Total

weight of
(ii) Passing through 10 mm sieve and retained on 1mm sieve :  4% of dry
aggregate
(iii) Passing through 1 mm sieve and retained on 0.075 mm sie ve :  3% of including
mineral
(iv) Passing through 0.075 mm sieve :  2% of filler)
The average amount of bitumen in any length of any layer, calculated as the product of
the bitumen contents obtained from single tests and the weight of the mixture
represented by each tests, shall not vary beyond the limit of tolerance of the amount
specified.
The average amount of bitumen for each day's production calculated from the check
weights of mix shall not vary beyond the limit of tolerance of the amount specified.
The final average overall width of the upper surface of a bituminous mix layer measured
at six equidistant points over a length of 100 m shall be at least equal to the width
specified. At no point shall the distance between the centreline of the road and the edge
of the upper surface of a bituminous mix layer be narrower than that specified by more
than 13 mm.

32
(14) Measurement and payment
No separate measurement and payment shall be made for complying with the
requirements of the Clause 1307. The Contractor shall allow compensation for
compliance of the Clause 1307 in the rates of items covered by Clauses from 1308 to
1311.
1308 ASPHALT CONCRETE
(1) Scope
This Clause covers the materials, method of construction and requirements for the
construction of Asphalt Concrete.
(2) Definition
Asphalt concrete means a thoroughly controlled, hot-mixed, hot-laid, plant mixture of well
graded dried aggregate and penetration grade bitumen, which, when compacted, forms
a dense material.
(3) Materials
(a) Penetration Grade Bitumen
Bitumen shall be 80/100 or 60/70 penetration grade as specified in Section 600.
(b) Aggregate
Coarse aggregate (retained on a 4.75mm sieve) shall consist of crushed stone

free from clay, silt, organic matter and other deleterious substances. The coarse
aggregate shall comply with the requirements given in the Table 13.17.
Table 13.17: Requirement of Coarse Aggregates
Coarse Aggregate (retained on 4.75 mm sieve)

Aggregate Class A B
LAA Max. 25 30
ACV Max. 20 20
SSS Max. 12 12
FI Max. 20 25
The coarse aggregate shall be entirely crushed. The aggregates shall be clean,
free from weathered or decomposed stone, organic matter, shale, clay and other
substances which, in the opinion of the Engineer may be deleterious to the
mixture.
Fine aggregate (passing a 4.75 mm sieve) shall be free from clay, silt, organic
and other deleterious matter and shall be non-plastic. It shall consist of entirely
crushed rock produced from stone having a Los Angeles Abrasion of not more

33
than 30. The Sand Equivalent of the fine aggregate shall be not less than 60 and
the SSS not more than 12.
(c) Mineral Filler
Mineral filler shall consist of finely ground particles of limestone, hydrated lime,
ordinary Portland cement or other non-plastic mineral mater. It shall be
thoroughly dry and free from lumps. At least 75% (by weight) shall pass a
0.075mm sieve and 100% shall pass a 0.425mm sieve. It shall have a bulk
density between 0.5 and 0.9 g/ml measured in accordance with BS 812 -2 .
(4) Grading Requirements

The grading of the mixture of coarse and fine aggregate shall be within and
approximately parallel to one of the grading envelopes given in Table 13.18 or as
specified in the Special Specification or in the Bill of Quantities.
Table 13.18: Grading Requirements of the Mixture of Coarse and Fine Aggregates

Sieve size Wearing course Binder course
(mm) Type I (0/16) Type II (0/10) 0/20
20.000 - - 100
16.000 100 - 96-100
10.000 76-82 100 75-100
4.750 54-59 64-70 48-90
2.360 33-37 39-47 24-62
0.600 16-21 21-28 12-24
0.075 6-9 6-9 3-8
(5) Requirements for Asphalt Concrete

Asphalt concrete i.e. the mixture of binder, coarse and fine aggregates and mineral filler,
if any, shall comply with the requirements given in the Table 13.19.
Table 13.19.: Requirements for Asphalt Concrete
Asphalt Concrete Wearing Course Binder Course

Marshall Stability 50 blows (N) Min 8 000 Min 6 000
Flow Value (mm) 2-3 2-3
Voids in total Mix (%) 2- 4 3-7
Compression/Immersion Ratio >0.75 >0.75
The proportion, by weight of total mixture, of bitumen shall be stated in the Special
Specification or in the Bill of Quantities. This shall be termed the nominal binder content.
The binder content of the working mix shall be instructed by the Engineer following
laboratory and site trials.
(6) Mixing and Laying of Asphalt Concrete

34
The temperature of the bitumen when mixed with the aggregate shall be between 120oC
and 140oC.
The minimum temperature of the mixture at the commencement of compaction shall be

125oC. The minimum temperature at completion of compaction shall be 80oC.
The minimum thickness of the compacted layer in wearing course shall be 25mm or
40mm when or 0/10 or 0/16 aggregate is used respectively and that binder course shall
be 40mm when 0/20 aggregate is used.
(7) Compaction
Rolling shall be continued until the voids measured in the completed layer are within the
appropriate ranges tabulated in the Table 13.19. Rolling shall be carried out by a
sequence of rollers in such a manner that it shall ensure the full specified compaction
and at the same time it will provide a finished surface within the tolerance laid down in
this Specification.
The average density after compaction shall not be less than 98% of the average density
obtained from Marshall Specimens (50 blows) made during laboratory trials on the
mixture used for site trials. No individual density shall be below 95% of the average of
the laboratory specimens.
(8) Testing
(a) Sampling
Prior to use the Contractor shall supply the Engineer with samples of all
materials proposed to be used. The Contractor shall carry out all the specified
tests as the Engineer may require to satisfy himself that the materials and
proportions satisfy this Specification. No material shall be used, nor job mix
adopted until they are approved in writing by the Engineer.
Sampling of mixes shall normally be carried out at the mixing plant or from lorries
conveying the materials from the mixing plant to the paver, but the Engineer may
direct for sampling to be carried out from the paver, if there is any danger of
segregation of the mix during transportion and spreading process.
(b) Process Control
The minimum frequency of testing required for process control shall be as
provided in the Table 13.20.

AGGREGATE:
Grading One test for every 100 m3 or part of it and change of source
Aggregate Crushing Value " " " "
Flakiness Index " 100 m3 " "
SSS " 500 m3 " "
Sand Equivalent " " " "

35
Quality of Filler " 50 tonnes " "

BITUMEN:
Quality of Binder The Contractor shall produce certificates from all
suppliers to the effect that all materials supplied by them
comply with the relevant Specifications.
supply of binder
Penetration Test Daily
MIXTURE
Grading and bitumen content One test for each 100 tonnes of mix or part of it
Marshall stability, flow and voids " " "
Control of Temperature As required
Compaction One test per 500 m2 or part of it
Surface levels Every 10 m or at close intervals
Smoothness " 50 m2 "
(9) Measurement
Asphalt concrete shall be measured in cubic metre calculated as the product of the
length and the compacted cross-sectional area of the asphalt concrete laid as per
Drawing or as instructed by the Engineer.
(10) Payment
The asphalt concrete shall be paid as per contract unit rate which shall be the full and
the final compensation for the cost of compliance of all requirements of Clauses 1307
and 1308 in addition to those specified in Clause 112.
binder, coarse aggregate, fine aggregate and/or mineral filler and their respective rate of
application actually used in the work as per the direction of the Engineer, the contract unit
rate for asphalt concrete shall be adjusted as per contract unit rate of the respective
material quoted by the Contractor for the purpose of this variation.
The varied asphalt concrete shall be paid as per adjusted rate.
1309 SAND ASPHALT
(1) Scope
This Clause covers the materials, method of construction and requirement for the
construction of Sand Asphalt.
(2) Definition
Sand asphalt means a controlled, hot-mixed, hot-laid, plant mixture of sand and
penetration grade bitumen.

36
(3) Materials
(a) Sand
Sand shall consist of clean, tough, screened or crushed rough surfaced grains.
As delivered to the mixer it shall be free from lumps or loosely bonded
aggregations and the individual particles shall be free from adhering dust. It shall
be non-plastic and Sand Equivalent shall be not less than 40. The grading shall
be within the limits set out in the Table 13.21.
Table 13.21: Grading Requirements of Sand
Sieve Size (mm) Percentage passing by weight

4.750 100
2.360 76 - 100
0.600 27 - 90
0.075 6 - 14
Sand which fails to meet this requirement may be used provided it is first mixed
with other mineral products to produce a mixture which falls within the grading
limits of Table 13.21 and has the specified Marshall test stability.
(b) Mineral Filler
The mineral filler shall comply with Sub-Clause 1308 (3) (c).
(c) Binder
The binder shall be straight-run bitumen of 80/100 penetration complying with

the requirements specified in Section 600.
(4) Requirements for Sand Asphalt
The mixture shall comply with the following requirements:
 Marshall Stability 50 blows (N): Min. 3,500
The binder content of the working/job mix shall be instructed by the Engineer following
laboratory and site trials. The Contractor shall carry out such tests as the Engineer may
require to determine the optimum mix composition of the job mix.
(5) Mixing and Laying Sand Asphalt
The mixture shall be transported, laid and compacted in accordance with Clause 1307.
The minimum temperature of the mixture at the time of completion of rolling shall be not
less than 80oC.

37
(6) Compaction
Rolling shall be carried out by a sequence of rollers in such a manner that it will ensure
the full specified compaction and at the same time will provide a finished surface within
the tolerance laid down in this Specification.
The minimum in-situ density shall be 87% of the density of the Marshall specimens
compacted from the Approved Job Mix.
(7) Testing
(a) Sampling
materials proposed to be used. He shall carry out all the specified tests as the
Engineer may require satisfying himself that the materials and proportions satisfy
this Specification. No material shall be used nor shall job mix be adopted until
they are approved in writing by the Engineer.
Sampling of mixes shall normally be carried out at the mixing plant or from lorries
conveying the mix from mixing plant to the paver, but the Engineer may direct for
sampling to be carried out from the paver, if there is any danger of segregation
of the mix during transporting and spreading process.
(b) Process Control
The minimum frequency of testing for process control shall be as given in the
Table 13.22.

AGGREGATE:
Grading One test per 100 m3 or part of it and change of source
Sand Equivalent " 500 m3 " "
BITUMEN:
Quality of Binder The Contractor shall produce certificates from all
supply of binder
Penetration Test At close intervals as directed by the Engineer
MIXTURE
Grading and bitumen content One test each 100 tonnes of mix or part of it
Control of Temperature As required
Compaction One test per 500 m2 or part of it

38

Smoothness " 50 m2 " "
(c) Routine Inspection and Testing
completed work for compliance with the dimensional tolerances, quality of
material, density of compaction and any other requirements stated in this
Specification.
Any material and workmanship that do not comply with the requirements
specified, shall be replaced by materials and workmanship complying with their
respective Specifications.
(8) Measurement
Sand asphalt shall be measured in cubic meter as the product of the length and the
compacted cross-sectional area of the sand asphalt laid as per drawing or as instructed
by the Engineer.
(9) Payment
The sand asphalt shall be paid as per contract unit rate which shall be the full and the
final compensation for the cost of compliance of all requirements of Clause 1307 and
1309 in addition to those specified in Clause 112.
binder, sand and/or mineral filler and their respective rate of application actually used in
the work as per the direction of the Engineer, the contract unit rate for asphalt concrete
shall be adjusted as per contract unit rate of the respective material quoted by the
Contractor for the purpose of this adjustment.
The varied sand asphalt shall be paid as per adjusted rate.
1310 EMULSION AGGREGATE MIX
(1) Scope
This Clause covers the materials, method of construction and requirements for
construction of Emulsion Aggregate Mix.
(2) Definition
Emulsion aggregate mix means a cold-mixed, cold-laid plant mixture of graded

aggregate and emulsion. This material shall be designed, produced, laid and tested
generally in accordance with the documents listed below, except where otherwise added
to or amended in this Specification:

39
(a) A Basic Asphalt Emulsion Manual, Asphalt Institute, Manual Series 19, Second
Edition.
(b) Bitumen Emulsions, general information applications, Syndicate Des Fabricants

d’ Emulsion Routieres, March 1991.
(3) Materials
(a) Emulsion
Emulsion for the work shall be slow-setting K3-60 or A3-60 and produced from
penetration grade 80/100 or 180/200 bitumen. It shall comply with the
requirements specified in Section 600.
If emulsion is ordered ready-made, the manufacturer must provide a certificate

with each batch confirming compliance with these tests. For site production all
tests shall be carried out at least once before mix trials to confirm compliance.
It shall be preferable that the emulsion is used as soon as possible after its
production. If it is to be delivered to site and/or stored after delivery or after
production on site, this storage time shall not exceed the maximum indicated by
the storage ability results above, and appropriate facilities shall be provided to
re-homogenise the emulsion before use if it is found to have settled out during
storage.
(b) Water for Manufacture of Emulsion and Mix Production
This shall comply with all requirements for water of potable quality and be free of
all substances likely to adversely affect either process.
(c) Mineral Aggregates
Before approval is granted for the use of aggregates and fillers in laboratory mix
design of emulsion, aggregate mix samples shall be taken and submitted for the
tests prescribed in this clause to ensure that the aggregates and filler comply
with the specified requirements. Mineral aggregates for emulsion aggregate mix
shall consist of (i) coarse aggregate (ii) fine aggregate and (iii) added filler as
required.
(i) Coarse Aggregate
Coarse aggregate shall be the material passing 20 mm and retained on

4.75mm sieves and shall consist of clean, mechanically crushed rock or
gravel with a Crushing Index of 100% (i.e. the raw feed to the crusher
must be material retained on a 20mm sieve).
The coarse aggregate shall have the following properties:
 Los Angeles Abrasion Value: maximum 35%

 Sodium Sulphate Soundness: < 12%
 Particles with 2 or more fractured faces: at least 75% by weight.

40
(ii) Fine Aggregate
This shall be the material passing a 4.75mm sieve and shall consist of
crushed sand, or a combination of crushed and natural sand. It shall
comply with the following requirements:
 Sodium Sulphate Soundness: < 12%.
 Sand Equivalent: >40
(iii) Filler
Filler, if required, shall comply with Sub-Clause 1308(3) (c).
(iv) Combined Aggregate
Where coarse and fine aggregates are produced from the same
screening or crushing operation and laboratory test indicates that their
combined grading is inconsistent or unlikely to meet specified mix
requirements, they shall be stockpiled separately and re-blended later
as appropriate. The combined aggregate of the proposed mix, including
added natural sand or filler shall be clean, free from weathered or
decomposed stone, organic matter shale, clay and other substances
which in the opinion of the Engineer may be deleterious to the mixture.
The fraction passing the 0.425mm sieve shall be non-plastic.
The combined aggregate grading shall fall within the limits given in the
Table 13.23.
Table 13.23: Grading Requirements of the Combined Aggregate
Sieve size (mm) Percentage passing by weight

20 100
10 76 - 92
2.36 42 - 50
0.6 26 - 35
0.075 5 - 10
(4) Mix Design
The binder content of the working/job mix shall be instructed by the Engineer
following laboratory and site trials. The Contractor shall carry out such tests as the
Engineer may require determining the optimum mix composition of the job mix.
Mix design shall be carried out at least 30 days before production is intended to begin,
and shall be generally in accordance with the Duriez test procedure, with the exception
that optimum added water content is to be first determined in accordance with Chapter
XIV of Asphalt Institute Manual Series No. 19. Sufficient sets of Duriez samples shall be
prepared at each emulsion content (by weight of dry aggregates) to investigate effect on

41
mix properties of anticipated variation in the proportion passing through 0.075mm sieve
with a minimum of one set at each extreme of the range (e.g. 5% and 10% fines). The
required mix properties at 18oC are:
 Duriez Compactness : 88-95%
 Compression : > 3 Mpa
 Immersed/dry strength ratio : > 0.55
As an alternative, the Contractor may follow Marshall Mix Design Procedure. The
required properties are:
 Stability 50 blows (N) : Min. 5,000

 Flow (mm) : <4
These properties must be maintained within the anticipated range of fines content that
shall occur during production.
(5) Production and Laying Trials
When a satisfactory laboratory trial mix has been obtained, trials of this mix and the
production and laying processes shall be carried out.
Production plant shall be capable of:
 blending separate classes of aggregates, where necessary, accurately to the

required grading and providing a consistent flow of combined aggregate to the
mixing chamber.
 providing an accurately-controlled (+/- 10% of optimum water content) and
metered supply of extra free water as required, and allowing sufficient time for
thorough mixing to occur before the addition of emulsion.
 providing an accurately-controlled (+/- 10% of optimum water content) and
metered supply of emulsion to the mixing chamber and sufficient time for
thorough mixing and aggregate coating to occur before discharge. The emulsion
pump must be of centrifugal or other type not prone to jamming and/or clogging.
All pipework must be regularly cleaned and maintained to ensure that fencing and/or
clogging do not occur.
The mix shall not be prone to segregation. Handling and placement methods shall be
such as to avoid segregation.
When the Contractor is satisfied that the plant is producing a consistent mix, he shall
propose the laying of a trial area for the Engineer’s approval to demonstrate that the
properties of the mix produced in the plant are within the specified limits, that the
handling and laying processes are capable of laying the mix without segregation or other
imperfections to the required thickness, levels and tolerances and that the compaction
plant is capable of compacting the mix uniformly to the required density.
The required compaction is 88 - 95% of the Duriez density or 90- 95% of Marshall
specimens compacted from Approved Job Mix.

42
If the optimum moisture content for field compaction is found to be different from that
required for coating, the Contractor shall make adequate arrangements to achieve this
e.g. by aeration drying or addition of extra water as required.
If the Engineer is satisfied that the mixture meets the specified requirements and that the
Contractor's mixing, laying and compaction plant is suitable for and can produce
emulsion aggregate mix to the required standard as specified, he shall approve the mix.
Emulsion aggregate mix shall be protected from the weather and contamination by dust
etc. during transport, and shall not be laid on surfaces covered by standing water or
during rain. The moisture content of the mix shall be adjusted as necessary to ensure
that the moisture content at time of compaction is close to the optimum value (90 to
105% of optimum moisture content).
Emulsion aggregate mix may be laid by grader, provided the Contractor can demonstrate
in the site trials that he can achieve the geometric tolerances for the base with this
method. The minimum thickness of a single layer shall not be less than 80mm nor more
than 120mm.
Rolling shall be carried out by a sequence in such a manner of rollers that it shall ensure
the full specified compaction. Rolling shall be carried out by vibratory or pneumatic rollers
in a sequence predetermined and approved during laying of trial Sections and such
rolling shall be continued only for so long as it is effective and does not have detrimental
effect.
If results from any part of the production, laying and compaction operations fail to meet
the specified requirements, an immediate re-test shall be carried out. If the variations
continue for more than one day, all mixing shall cease and all plant, materials and
processes shall be checked. The Contractor shall make such adjustments or
modifications as are necessary to ensure that when mixing restarts the material
produced shall comply with these requirements. The cost of re-testing and any
necessary stoppages, adjustments and replacement of defective material shall be borne
by the Contractor.
Any segregated material formed on the edges and interior of the laid area during grading
of loose mix to level shall be dug out by hand and either scattered evenly back into the
mix or discarded before compaction begins.
(7) Testing
(a) Sampling
proportions satisfy this Specification. No material shall be used nor job mix shall
be adopted until they are approved in writing by the Engineer.

43
(b) Process Control
Table 13.24.

AGGREGATE:
Los Angeles Abrasion " 500 m3 " "
SSS " " " "
EMULSION:
Quality The Contractor shall produce certificates from all suppliers
to the effect that all materials supplied by them comply with
supply required.
Water Content One test for every 100 tonnes of mix or part of it
Sieve test " " "
MIXTURE
Grading and bitumen content One test for every 100 tonnes of mix or part of it
Marshall stability, flow or Duriez " " "
Test
Compaction One test for every 500 m2 or part of it
Specification.
specified shall be replaced by materials and workmanship complying with the
Specifications.
(8) Measurement
Emulsion aggregate mix shall be measured in cubic metre calculated as the product of
the length and the compacted cross-sectional area of emulsion aggregate mix laid as
per Drawing or as instructed by the Engineer.
(9) Payment

44
The emulsion aggregate mix shall be paid as per contract unit rate which shall be the full
and the final compensation for the cost of compliance of all requirements of Clause 1307
and 1310 in addition to those specified in Clause 112.
emulsion, coarse aggregate, fine aggregate and/or mineral filler and their respective rate
of application actually used in the work as per the direction of the Engineer, the contract
unit rate for emulsion aggregate mix shall be adjusted as per contract unit rate of the
respective material quoted by the Contractor for the purpose of this adjustment.
The varied emulsion aggregate mix shall be paid as per adjusted rate.
1311 COLD ASPHALT
(1) Scope
This Clause covers the materials, method of construction and requirements for
construction of Cold Asphalt for Surfacing, Base, Levelling and Patching.
(2) Definition
Cold asphalt means a cold-mixed, cold-laid, plant mixture of graded aggregate and
bituminous binder.
(3) Materials
(a) Bituminous Binder
For cold-asphalt to be used immediately, the bituminous binder shall be an

anionic emulsion A2 or A3 or a cationic emulsion K2 or K3, as specified in the
Special Specification or in the Bill of Quantities.
For cold-asphalt to be stockpiled, the bituminous binder shall be a slow-setting

emulsion A3 or K3, as specified in the Special Specification or in the Bill of
Quantities.
(b) Aggregates
Coarse aggregate (retained on a 4.75 mm sieve) shall consist of crushed stone

produced from rock or boulders. The minimum size of rocks or boulders to be
crushed shall be at least 4 times the maximum size of the crushed aggregate.
The coarse aggregate shall be free from clay, silt, organic matter and other
deleterious substances. The aggregate shall comply with the requirements given
in the Table 13.25:
Table 13.25: Requirement of Aggregate
Aggregate Class A B
LAA Max. 25 30

45
ACV Max. 20 20
SSS Max. 12 12
FI Max. 20 25
The fine aggregate (passing 4.75mm sieve) shall be free from clay, silt, organic
and other deleterious matter. Unless otherwise specified, it shall consist of at
least 90 percent entirely crushed sand produced from stone having a Los
Angeles Abrasion of not more than 30. The Sand Equivalent of the fine
aggregate shall be not less than 60 and the SSS not more than 12.
The mixture of aggregate shall be within and approximately parallel to the

grading envelope specified in the Table 13.26.
Table 13.26: Grading Envelope of Aggregate
Sieve size (mm) Percentage passing by weight

14.000 100
10.000 90 - 100
4.750 54 - 70
2.360 35 - 49
1.180 25 - 38
0.425 16 - 25
0.075 6-9
(c) Mineral Filler
The mineral filler shall consist of finely ground particles of limestone, hydrated
lime, Ordinary Portland cement or other non-plastic mineral matter as specified
in the Special Specification or in the Bill of Quantities. It shall be thoroughly dry
and free from lumps. At least 75% (by weight) shall pass a 0.075mm sieve and
100% shall pass a 0.425mm sieve. It shall have a bulk density between 0.5 and
0.9 g/ml measured in accordance with BS 812–2.
(4) Requirements for Cold Asphalt
The mixture shall comply with the requirements given in the Table 13.27.
Table 13.27: Requirements for Cold Asphalt
Description Requirements
Marshall Stability 50 blows (N) 7,000
Flow Value (mm) <4
Voids in total Mix (%) 2-4
Compression/Immersion Ratio 0.75
The proportion, by weight of total mix, of bitumen shall be stated in the Special
The binder content of the working/job mix shall be instructed by the Engineer following
laboratory and site trials.
(5) Mixing and Laying of Cold Asphalt

46
Cold asphalt generally shall be laid for surfacing, base, levelling and patching works.
The moisture content of the mixture shall be adjusted in the mixing plant to permit
optimum compaction. The aggregate shall have moisture content in the range 3% - 5%
at the time the emulsion is added.
Cold asphalt shall be placed at ambient temperature and may be laid by grader, provided
the Contractor can demonstrate in the site trials that he can achieve the specified
geometric tolerances with this method.
(6) Compaction
Rolling shall be carried out by a sequence of rollers in such a manner that it will ensure
the full specified compaction and at the same time it will provide a finished surface within
the tolerance laid down in this Specification.
The average density of the cold asphalt after compaction shall not be less than 98% of
the average density obtained from Marshall specimens (50 blows) made during
laboratory trials on the mixture used for site trials. No individual density shall be below
95% of the average of the laboratory specimens.
(7) Testing
(a) Sampling
proportions satisfy this Specification. No material shall be used nor shall job mix
be adopted until they are approved in writing by the Engineer.
(b) Process Control

Table 13.28.

AGGREGATE:
Aggregate Crushing Value " " " "
Flakiness Index " 100 m3 " "
SSS " 500 m3 " "
EMULSION:
Quality The Contractor shall produce certificates from all

47

supply required
Water Content One test for every 100t of mix or part of it

Sieve test " " "
MIXTURE
Grading and bitumen content One test for every 100 tonnes of mix or part of it
Compaction One test for every 500 m2 or part of it
Specification.
specified, shall be removed and replaced by materials and workmanship
complying with the specifications.
(8) Measurement
Cold asphalt shall be measured in cubic metre calculated as the product of the length
and the compacted cross-sectional area of cold asphalt laid as per drawings or as
(9) Payment
The cold asphalt shall be paid as per contract unit rate which shall be the full and the
final compensation for the cost of compliance of all requirements of Clause 1307 and
1311 in addition to those specified in Clause 112.
binder, coarse aggregate and/or mineral filler and their respective rate of application
actually used in the work as per the direction of the Engineer, the contract unit rate for
cold asphalt shall be adjusted as per contract unit rate of the respective material quoted
by the Contractor for the purpose of this adjustment.
The varied cold asphalt shall be paid as per adjusted rate.

48
SECTION 1400 - KERBS AND FOOTPATHS
Page No.
1401 CONCRETE KERBS 14–1

1402 CONCRETE/STONE FOOTPATHS 14–2
1403 BRICK PAVING IN FOOTHPATHS 14–3
1404 BITUMINOUS FOOTPATHS 14–4
1405 CYCLE TRACKS 14–5
SECTION 1400 – KERBS AND FOOTPATHS
1401 CONCRETE KERBS
(1) Scope
This Clause covers the works for the construction of kerbs in the central median and/or
along the footpaths or separators.
(2) Materials
The kerbs shall be provided in cement concrete of grade M 20/20 in accordance with
Section 2000. These shall be either precast concrete blocks or cast-in-situ concrete.
Cement sand mortar used for bedding and joints shall be in 1:3 ratio and shall comply
with the Sub-clause 2502 (2).
(3) Laying
The kerbs shall be laid on either concrete or compacted sand-gravel as indicated in

the Drawing. In the case of concrete, it shall consist of grade M 10/20 or M 10/40
(as defined in Section 2000) laid to the dimensions, lines and levels shown in the
Drawing and well compacted by ramming or other means. The foundation shall have a
projection of 50 mm beyond the kerb in plan. Before laying the foundation of lean
concrete, the base shall be levelled and slightly watered to make it damp.
In the case of sand gravel it shall consist of a material approved by the Engineer
having a property complying with Clause 1201. The kerbs shall then be laid out and
bedded on 12mm thick cement sand mortar of 1:3 ratio.
Concrete shall be tested in accordance with Section 2000 and shall meet the specified
criteria.
All kerbs shall be laid true to the lines and levels shown on the Drawing or as
(5) Measurement
Concrete kerbs shall be measured in linear meter. Concrete and/or sand-gravel

foundation shall be measured in cubic meters. Excavation for foundation shall not be
measured. It is deemed included in the measurement of kerbs.
(6) Payment
The concrete kerbs measured as above shall be paid at the contract unit rate which
shall be the full and the final compensation to the Contractor as per Clause 112
SECTION 1400 KERBS AND FOOTPATHS

including cost for excavation and backfilling, if any, and all other incidental costs so as
to complete the work as specified.
Concrete and/or sand-gravel foundation shall be paid for separately, as provided under
respective Sections of these Specifications.
1402 CONCRETE/STONE FOOTHPATHS
(1) Scope
This Clause covers the works for the construction of concrete/stone footpaths as
specified on the Drawing.
(2) Materials
The footpaths shall be constructed with any of the following types as provided in the
Bill of Quantities or shown on the Drawing.
(a) Cast-in-situ cement concrete of grades M20/20 as per Section 2000.
(b) Pre-cast cement concrete blocks of grade M20/20 as per Section 2000.
Unless otherwise specified or ordered by the Engineer they shall be 50 mm
thick of a uniform width of 600 mm and not less than 450 mm nor more than
900 mm in length.
(c) Natural stone slab cut and dressed from stone of good and sound quality,
uniform in texture and free from defects. The stones, when immersed in water
for 24 hours, shall not absorb water by more than 5% of their dry weight when
tested in accordance with IS:1124. The specific gravity of the stones shall be at
least 2.55. The minimum thickness of the natural stone slab shall be 25 mm
and minimum size shall be 300 mm x 300 mm.
Concrete and cement sand mortar shall meet the requirements specified in
Section 2000 and Sub-clause 2502 (2) respectively. Granular subbase shall
comply with Clause 1201. Bricks shall comply with the requirements of NS
1/2035. The class of the bricks shall be as specified in the contract.
(3) Laying
The base shall be prepared and finished to the lines, levels and dimensions as
indicated on the Drawing. Generally material for base shall be:
(a) 150 mm thick, compacted granular base as per Clause 1201 or

(b) 30 mm thick concrete base of grade M 15/20 or
(c) flat brick flat soling base.
Over the prepared base, precast concrete blocks, natural stone slabs and/or cast-in-
situ slab shall be laid/set as described below.
Precast Cement Concrete Blocks/Natural Stone Slabs

The blocks/slabs shall be set on a layer of average 12 mm thick 1:3 cement sand
mortar laid on the prepared base in such a way that there is no rocking. The gaps
between the blocks/slabs shall not be more than 12 mm and shall be filled with 1:3
cement sand mortar.
Cast-in- situ Cement Concrete
Unless otherwise specified, the thickness of cement concrete shall be 50 mm. It shall
be cast on the prepared base of specified size in staggered manner. Construction
joints shall be provided as per Section 2000.
Concrete shall be tested in accordance with Section 2000 and shall meet the specified
criteria. Granular subbase shall be tested in accordance with Clause 1201 and shall
meet the specified criteria. One set of test for specific gravity and water absorption (3
tests in a set) shall be carried for each source of stones and the results shall meet the
specified criteria.
All footpaths shall be constructed true to the lines and levels shown on the Drawing or
(5) Measurement
Concrete stone footpaths shall be measured in square meters. The area to be

measured shall be between inside of kerbs. No measurement for excavation and
providing base/subbase shall be made. It shall be deemed included in the
measurement of concrete/stone footpaths.
(6) Payment
The quantities of concrete/stone footpaths measured as provided above shall be paid

at the contract unit rate which shall be the full and the final compensation to the
Contractor as per Clause 112.
1403 BRICK PAVING IN FOOTPATHS
(1) Scope
This Clause covers the works for the construction of footpaths with bricks laid on edge
as shown on the Drawing.
(2) Materials
Burnt clay bricks shall comply with the requirements of NS 1/2035. The class of the
bricks to be used shall be as shown on the Drawing. They shall be free from cracks
and flaws and nodules of free lime. The brick shall have smooth rectangular faces with
sharp corners and emit a clear ringing sound when struck.

(3) Laying Bricks on Edge
Bricks shall be laid on a sand bed at least 50mm thick. In cases where two or more
layers of bricks are used each layer shall be separated by a layer of sand of 25 mm
thickness. Bricks shall be laid on edge in the pattern shown in the Drawing or specified
in the contract. Each brick shall be laid separately and tamped firmly into place on the
sand-bed. The top surface of the layer shall be smooth and even.
Bricks shall be regularly tested for water absorption and compressive strength. The
frequency of tests shall be minimum one test for every 10 cu.m. of bricks or part of it.
The test results shall meet the specified criteria.
Bricks shall be laid to the true lines and levels shown on the Drawing or instructed by
the Engineer.
(5) Measurement
Brick paving shall be measured in square meter for the completed and accepted work.
Excavation and sand bedding shall not be measured. They shall be deemed included
in the measurement of the paving.
(6) Payment
The brick paving as measured above shall be paid at the contract unit rate which shall
be the full and the final compensation to the Contractor as per Clause 112.
1404 BITUMINOUS FOOTPATHS
(1) Scope
This Clause covers laying hot/cold asphalt premix over a primed base/subbase as
shown in the Drawing.
(2) Materials
The stipulations contained in Section 1300 shall govern with regard to the scope and
materials of prime coat and premix except that the binder content (net bitumen) of the
premix shall be 6% by weight of the mix. The type of the mix to be used shall be as
described in the Bill of Quantities. The stipulations contained in Section 1200 shall
govern with regard to the scope and materials for base/subbase.
(3) Laying
The base/subbase shall be prepared in accordance with Section 1200. A prime coat
shall be applied at the rate of 0.75 litres per square meter conforming to Clause 1301.
Manual method or use of relatively small capacity equipment shall be also permitted.
The premix shall be prepared in suitable plant approved by the Engineer. Rolling shall
be done as per Clause 1308.

Base/subbase, prime coat and asphalt premix shall be tested in accordance with the
stipulations as provided under respective Clauses of these Specifications. The test
results shall meet the specified criteria.
(5) Measurement
Bituminous premix, prime coat and subbase/base shall be measured in square metres
as per stipulations of Section 1300. Subbase/base shall be measured as per
stipulations of Section 1200.
(6) Payment
Bituminous premix, prime coat and subbase/base shall be paid at the respective
contract unit rates which shall be the full and the final compensation to the Contractor
as per Clause 112.
1405 CYCLE TRACKS
(1) General
Cycle tracks shall be constructed in accordance with the relevant Clauses of Sections
1000, 1200 and 1300.
The requirement of materials and workmanship used in the construction of cycle tracks
shall conform to the requirements of relevant Sections/Clauses as applicable.
Measurement and payment shall be as per the relevant Clauses or as specified in the
contract.

SECTION 1500 - TRAFFIC SIGNS, ROAD MARKING, ROAD MARKER STONES
AND DELINEATORS
Page No.
1501 PERMANENT TRAFFIC SIGNS 15–1

1502 ROAD MARKINGS 15–2
1503 ROAD MARKER STONES 15–10
1504 DELINEATOR POSTS 15–12
SECTION 1500 - TRAFFIC SIGNS, ROAD MARKING, ROAD MARKER STONES

AND DELINEATORS
1501 PERMANENT TRAFFIC SIGNS
(1) Scope
This Clause covers the supply and erection of permanent road traffic signs along the
roadside, over the carriageway and crossroads, at interchanges and at the locations
indicated on the Drawing or as directed by the Engineer.
(2) Materials
(a) Mounting Posts
Mounting post shall be of either 50 mm internal diameter steel tube of “heavy”

category or 78 mm by 38 mm C channel. Structural steel shall comply with the
requirements of IS 2062. Steel tube shall comply with IS 1161. Posts
constructed from wood or reinforced concrete shall not be accepted.
(b) Bolts, Nuts and Washers
Steel bolts and nuts shall conform to IS 1367. All steel bolts, nuts and washers
shall have a hot-dip (galvanised) zinc coating.
(c) Back Support Frames
Unless otherwise specified sign plates shall be supplied with a back support
frame of a size and design to avoid the plate being deformed due to wind
pressure or manipulation by vandals. The frame shall be made of a steel angle
riveted or bolted to sign plate and shall incorporate brackets to enable the sign
plate to be bolted to the sign plate.
(d) Steel Plate
Steel plate shall be 2.00 mm thick and comply with the requirements of IS
1079. After any cutting, welding and punching has been completed all sharp
edges shall be uniformly rounded off and smoothed down. All physically
adhering contaminants shall be removed and then thoroughly cleaned.
(e) Aluminium Plate
Aluminium plates used for signs shall be of smooth, hard and corrosion
resistant aluminium alloy conforming to IS: 736 – Material Designation 24345
or 19000 and shall be 2.0 mm thick unless otherwise specified. After any
cutting, welding and punching have been completed all sharp edges shall be
uniformly rounded off and smoothed down. The plate shall be degreased
either by acid or hot alkaline etching and all scale/dust removed to obtain a
SECTION 1500TRAFFIC SIGNS, ROAD MARKING, ROAD MARKER STONES AND DELINEATORS
Page 15–1
smooth and plain surface. After cleaning, metal shall not be handled except by
a device or clean canvas glove.
(f) Retro-Reflective Sheeting
The reflective sheeting shall be either “Engineer” Grade or High Intensity

reflective sheeting, as specified in the contract. The retro-reflective sheeting
shall be of the enclosed lens type consisting of microscopic lens elements
embedded beneath the surface of a smooth, flexible, transparent, waterproof
plastic. The adhesive backing shall be either of pressure-sensitive aggressive
tack type requiring no heat, solvent or other preparation for adhesion, or tack-
free adhesive activated by heat in a Heat Lamp Vacuum Applicator in a
manner specified by the sheeting manufacturer. The adhesive shall form a
durable bond to smooth, corrosion and weather-resistant surface of the sign
plate such that it shall not be possible to remove the sign sheeting from the
sign plate.
The reflective sheeting shall conform to the following requirements:
(i) The sheeting shall have high reflectivity normal to vehicle headlights
dependent on the angle of incidence. The reflective material shall be
sharp and glareless and directed towards the light source at an
approved angle of incidence.
(ii) The surface of the sheeting shall be smooth and flexible. No cracking
shall occur when bent. Reflective sheeting shall have high durability
under all weather conditions, heat and moisture and be strongly
fungus-resistant.
(iii) The sheeting shall not delaminate, blister, crack, peel and chip during
the manufacturing process and during its service life.
(iv) The sheeting supplied shall be free from dirt, solid lumps, scales,
ragged edges and non-uniformity of colour.
(v) The colour of the sheeting shall be even and free from any spots or
loss of colour. The colour shall not fade under local weather
conditions during its expected service life.
(vi) Colours of sheeting used must correspond to the colours of the
sheeting supplied as samples.
(vii) The reflective surface of the sheeting shall be durable and remain
sharp during its expected service life. Bad weather conditions such
as rain, dew, etc. shall not reduce the reflectivity.
(viii) The reflective surface of the sheeting shall be easily cleaned with
soap and water with no adverse effect on its reflectivity and durability
when used on the roads.
(ix) The adhesive used on the backing of the sheeting shall give a high
quality bonding to clean, smooth and grease free aluminium or other
sign plates approved by the sheeting manufacturer. The adhesive
shall withstand the conditions without allowing the sheeting to peel.
(g) Paints
Page 15–2
Zinc chromate primer shall comply with the requirements of IS: 2074. Other
types of primer shall comply with NS 190/2045. Enamel paint shall comply with
NS 112/2042.
(3) Protective Painting
(a) Steel Surfaces
The prepared surface shall be given two coats of a zinc chromate primer
confirming to IS 2074. The first coat shall be applied within 12 hours in the
case of wash-primed surfaces and within 4 hours, but before any oxidation of
the surface takes place, in the case of abrasive blasted surfaces.
(b) Aluminium Surfaces
Part of the sign plate not covered by the sheeting, including the reverse of the
plate shall be applied with protective paint, applied by either stove-enamelling
or powder –coating process.
(4) Signs
The regulatory, warning and information signs shall be of the standard as detailed in
the Drawing or shown in the Traffic Signs Manual (latest publication) published by the
Department of Roads. The colour, configuration, size and location of all traffic signs
shall be in accordance with the same manual.
The signs shall be either reflectorised or non-reflectorised as shown in the Drawing or

(5) Manufacturing of Signs and Posts
(a) Non-reflective Sign Faces
Non-reflective sign faces shall be manufactured from steel plate.
The background shall be painted with air-brush technique. The legends,

borders, symbols, designs, etc. shall be screen printed.
(b) Retro-reflective Sign Faces
Retro-reflective sign faces shall be manufactured from aluminium plate.

The background, legends, borders, symbols, designs, etc. shall be made by
applying cut-outs. All the sheeting, except in black, shall be retro-reflective.
(c) Size and Shape of Signs
The size and shape of the signs shall be manufactured in strict accordance
with the details provided in the Traffic Sign Manual (latest publication).
Traffic sign faces shall be manufactured as one unit. Traffic signs which are too
large to be transported as one unit may, with the approval of the Engineer, be
manufactured in sections. The completed sections shall be assembled in the
Page 15–3
shop prior to delivery to ensure that all sections fit together properly and that
the legends are correctly spaced and aligned. Joints in sign faces shall only
be provided at locations and to details approved by the Engineer.
(d) Welding
All welding of steelwork shall be carried out in accordance with the standards
laid down in Section 2200. Welding shall be done before painting.
(e) Metal Extrusions
Metal extrusions for sign faces shall be joined together by rivets or bolts. They
shall not be joined longitudinally but, if this cannot be prevented without
excessive waste, they shall be joined neatly and joints staggered. No sections
shorter than 500 mm shall be used.
Where aluminium extrusion are to be faced with retro-reflective background

material, it shall be pre-applied to individual sections before assembly with the
material taken around the face edges of each extension for at least 10 mm.
Retro-reflective material shall be heated to facilitate binding around edges
without damaging the material. Unless otherwise instructed by the Engineer,
letters across the joint between two extrusions shall be avoided.
(f) Galvanising
Where the galvanising of structural steel plates, back support frames and
posts are specified, it shall be done after welding. Where, however, this is not
practicable, the steel sections shall be galvanised before assembly and then
welded. All welds shall be thoroughly cleaned, loose material removed and
dressed after which the welds shall be coated with two coats of an approved
zinc-rich paint. Unless otherwise specified in the contract, galvanised steel
shall not require painting.
Where details for the construction of sign faces, the framework of the sign
faces and the attachment thereof to the supporting framework are not shown
in the Drawing, the Contractor shall design these him and submit the details to
the Engineer for approval before manufacture.
(g) Posts
The total length of the post shall be determined in such a way that the bottom
side of the sign is 1.75 m above the carriageway surface. The section of the
post shall be as shown on the Drawing or as instructed by the Engineer.
(6) Painting
(a) Colours, Symbols and Legend
Page 15–4
Paint colours, symbols, legend, size of letterings and borders used on road
signs shall comply with the Traffic Sign Manual (latest publication).
(b) Preparation of Surfaces and Application of Paint
The preparation of surfaces and painting shall be carried out in a manner to

ensure that they are free from rust and scale.
Structural steel for sign face supports and framework shall be given a wire
brush surface preparation and painted. Unless otherwise specified, all
painting work shall be carried out in accordance with IS:1477.
(c) Time of Painting
Painting shall not be carried out more than six moths prior to erection.
(7) Storage and Handling
All sign faces shall be protected by an easily-removable liner after manufacture. The
liner shall be removable by peeling without soaking in water or other solvent and shall
be suitable for the type of material used as the sign plate.
All traffic signs or portions of traffic signs shall be carefully handled and stored in a
weather-proof storeroom to prevent any permanent deformation or damage to painted
surfaces.
Package for shipment shall be in accordance with commercially acceptable standard to

prevent movement and chafing. Sign faces shall be protected from scratching, rubbing
and other damages. Sign shall remain dry during shipment.
(8) Erection of Traffic Signs
(a) Position
Traffic signs shall be erected in the positions and in the manner as shown on
the Drawing or instructed by the Engineer.
(b) Excavation and Backfilling
Excavations for the erection of traffic signs shall be made according to the
dimensions shown on the Drawing.
Unless otherwise specified, the foundation for sign mounted on a single post
shall be 300 mm X 300 mm and 300 mm deep. The foundation for signs
mounted on two or more posts shall be 450 mm x 450 mm and 600 mm deep.
The concrete shall be of grade M10/40 as per Section 2000 of these
Specifications. The upper surface of the concrete shall be neatly finished with
sufficient fall to ensure proper drainage.
Page 15–5
(c) Erection
Traffic signs shall be erected as shown on the Drawing or directed by the

Engineer. During erection, the sign faces shall be firmly bolted and protected
in order that no buckling or damage is caused during erection, or by the
equipment used for erection. Posts to which traffic signs are to be fixed shall
be vertical, and the undersides of traffic signs shall be horizontal after
completion of erection.
(d) Field Welding
All welding done during erection shall comply with the requirements for
welding during manufacture.
(e) On Site Painting
All painting done after erection shall comply with the requirements for painting
during manufacture. All places where the painting work has been damaged
before or during erection shall be made good by the Contractor at his own cost
to the satisfaction of the Engineer.
(f) Time of Erection
Road traffic signs shall be erected immediately prior to the opening of the road
to public traffic unless otherwise decided by the Engineer.
(9) Tests and Standards of Acceptance
The materials shall be tested in accordance with the relevant standards specified and
shall meet the prescribed criteria. The Contractor shall furnish necessary test
certificates as required by the Engineer.
The work shall conform to the relevant Specifications and shall be to the true lines,
levels and dimensions as indicated on the Drawing or as directed by the Engineer.
(10) Measurement
The measurement of permanent traffic signs shall be in numbers of each type of signs
supplied and erected in accordance with these Specifications. Excavation, concrete for
foundations and backfill shall not be measured. They are deemed included in the
measurement of the traffic signs.
(11) Payment
The quantities measured as provided above shall be paid at the respective contract
unit rates for each type of signs. The contract unit rates shall be the full and the final
compensation to the Contractor as per Clause 112 and also for the cost of excavation,
Page 15–6
concrete for foundation, backfill and all other incidental works so as to complete the
work as specified.
1502 ROAD MARKINGS
(1) Scope
This Clause covers the permanent marking of the road surface with white or yellow
paint as indicated on the Drawing or instructed by the Engineer.
The colour, width and layout of road marking shall be in accordance with the DOR’s
Traffic Signs Manual (latest publication).
(2) Materials
Paint shall comply with the requirements of NS 408/054 or BS 6044 (1987) or as

specified in the contract. If specified in the contract, the paint may also be reflectorised
paint, in which case the paint shall be reflectorised by the addition of reflecting beads
(ballotini). The ballotini shall comply with BS 6088: 1981 (1993).
The paint shall be delivered to the site in sealed containers bearing the name of the
manufacturer and the type of paint.
The viscosity of the paint shall be such that it can be applied without thinning. Under
no circumstances thinning shall be allowed.
The colour to be used shall be bright white or yellow as shown on the Drawing or
indicated in the DOR’s Traffic Signs Manual (latest publication).
(3) Weather Limitations
Road marking paint shall not be applied to damp surfaces or when the relative
humidity exceeds 80%, or at temperatures lower than 10 0C, or when, in the opinion of
the Engineer, wind strength is such that it may adversely affect the painting operations.
(4) Tools and Equipment for Painting
The paint shall be applied by brush or machine. However, before ordering paint, the
Contractor shall inform the manufacturer the proposed method of application of paint to
ensure that correct type of paint is ordered.
(5) Surface Preparation
Road markings shall be applied to bituminous surfacing only after sufficient time has
elapsed to ensure that damage shall not be caused to the painted surface by volatile
substances evaporating from the bituminous surfacing. In no case shall road markings
be applied until at least 48 hours after the completion of the surfacing or any longer
period required by the Engineer, has expired.
Page 15–7
Before the paint is applied, the surface shall be clean and dry and completely free from
any soil, grease, oil, acid or any other material which shall be detrimental to the bond
between the paint and the surface. The portions of the surface where the paint is to be
applied shall be properly cleaned by means of watering, brooming or compressed air.
(6) Setting out of Road Markings
The lines or marks shall be set out by means of paint spots of the same colour as the
proposed final lines and marks. These spot marks shall be at such intervals as needed
to ensure that the road markings can be accurately applied, and in no case they shall
be more than 1.5 from each other.
After spotting, the positions of the proposed road markings such as dotted lines,
starting and finishing points shall be indicated on the road. Pre-marking shall be
approved by the Engineer prior to the commencement of any painting operations.
The positions and outlines of special markings shall be produced on the finished road
in chalk and shall be approved by the Engineer before they are painted. The use of
approved templates shall be permitted on the condition that the positioning of the
marking is approved by the Engineer before painting is commenced.
(7) Application of Paint
Where the paint is applied by means of a machine, it shall be applied in one layer.
Before the road marking machine is used on the permanent works, the satisfactory
working of the machine shall be demonstrated on a suitable site which is not part of the
permanent work. Adjustment to the machine operation shall be followed by further
testing. Only when the machine has been correctly adjusted, and the use thereof is
approved by the Engineer after testing, the machine may be used on the permanent
work. The operator shall be experienced in the use of the machine.
After the machine itself has been satisfactorily adjusted, the rate of application shall be
checked and adjusted, if necessary, before application on a large scale is commenced.
Where two or three lines are required next to each other, the lines shall be applied
simultaneously by the same machine. The paint shall be stirred before application in
accordance with the manufacturer's instructions. Where painting is done by hand, it
shall be applied in two layers, and the second layer shall not be applied before the first
layer has dried out completely. As most road marking paint reacts with the bitumen
surface of the road, the paint shall be applied with only one stroke of the brush or roller
at any one point on the road to prevent reaction with bitumen surface.
Ordinary road marking paint shall be applied at a nominal rate of 0.42 litre/sq.m. for
painted old surface, and 0.75litre/sq.m. for new surface, or as specified in the contract.
(8) Application of Retro-reflective Beads
Where retro-reflective paint is required by the contract, the retro-reflective glass beads
shall be applied by means of a suitable machine immediately after the application of
the paint in one continuous operation. The rate of application of the beads shall be 0.8
kg/litre paint or such other rate as is specified in the contract. Machines which apply
Page 15–8
the beads by means of gravity only shall not be used. The beads shall be sprayed
onto the paint layer.
(9) Tolerances Requirements
Road markings shall be constructed to accuracy within the tolerances given below:
(a) Width
The width of the lines and other markings shall not deviate from the specified
width by more than 5%.
(b) Position
The position of lines, letters, figures, arrows, and other markings shall not
deviate from the true position specified by more than 20 mm.
(c) Alignment of Markings
The alignment of any edge or a longitudinal line shall not deviate from the true
alignment by more than 10 mm in 15 m.
(d) Broken Lines
The length of segments of broken longitudinal lines shall not deviate from the
specified length by more than 150 mm.
(10) Faulty Workmanship or Materials
If any material not complying with the requirements is delivered on the site or used in
the works, or if any sub-standard work is carried out, such material or work shall be
removed, replaced or repaired as required by the Engineer at the Contractor's own
cost. Rejected road markings and paint which has been splashed or dripped on the
surfacing, kerbs, structures or other such surfaces, shall be removed by the Contractor
at his own cost, in such a way that the markings or split paint shall not show up again
later.
(11) Protection
After the application of paint, the road markings shall be protected against damage by
traffic or other causes. The Contractor is responsible at his own cost for the erection,
placing and removal of all warning boards, flags, cones, barricades and other
protective measures which may be necessary.
Page 15–9
The work shall conform to these Specifications and shall be to the true lines, levels and
dimensions as indicated on the Drawing or as directed by the Engineer, subject to the
tolerances as indicated in these Specifications.
(13) Measurement
The measurement of road marking shall be in linear meter for each type of marking.
(14) Payment
unit rate for each type of markings signs which shall be the full and the final
compensation to the Contractor as per Clause 112 for carrying out the work as
specified in these Specifications.
1503 ROAD MARKER STONES
(1) Scope
The work covers the supply, painting, lettering and fixing of road marker stones and
shall include:
(a) Standard (Kilometer) Marker Stones

(b) 5th Kilometer Marker Stones
(c) Node Point Marker Stones
The dimensions and other details of each type of marker stones shall be in
accordance with the details shown in the DOR’s “ Departmental Policy Document –
The Establishment of Road Marker Stones” (latest publication) .
(2) Materials
The marker stones shall be constructed of reinforced cement concrete of grade

M15/20 as per the requirements of Section 2000. The paint shall be of non-
reflectorised type and shall confirm to NS 112-2042.
(3) Construction
(a) Marker Stone Information Details
Each marker stone shall contain following road reference and location
information:
(a) Road Category Letter
(b) Road Number
(c) Road Link Number
(d) Distance in km from node point
(e) Distance to the next town or landmark
(f) The chainage from the start of the road
All the above details shall be shown as specified in the DOR’s “Departmental
Policy Document – The Establishment of Road Marker Stones” (latest
Page 15–10
publication). Colouring, size of letters and numerals and language shall also
be in accordance with the same policy document.
(b) Placing and Painting of Marker Stones
The location of the marker stones shall be as shown on the Drawing. They
shall be placed at right angles to the centre line of the carriageway. On
embankments they shall be located on the edge of the roadway at least 0.5m
outside the road shoulder. Where there is no shoulder the marker stones shall
be at least 1.5m outside the road edge, if necessary on specially erected
platforms. In cut sections they shall be fixed clear of the shoulders as well as
the side drains.
Marker stones shall normally be placed on the left hand side of the road as
one proceeds from East to West and from South to North. On divided roads
with a centre median the marker stones shall be placed on the left hand side
of the road in each direction of travel. In hilly areas, where the road has a
valley on one side and a hill slope on other, the marker stones shall be placed
on the valley side of the road.
Marker stones posts shall be bedded into the ground with concrete foundation
of grade M10/40 as shown in the Drawing. Marker stones shall be applied with
a coat of primer and two coats of enamel paint.
dimensions as indicated on the Drawing or as directed by the Engineer.
(5) Measurement
Each type of road marker stones shall be measured in number. Excavation, concrete
foundation and backfill shall not be measured. They are deemed included in the
measurement of marker stones.
(6) Payment
The road marker stones measured as provided above shall be paid at the respective
contract unit rate for each type of stone which shall be the full and the final
compensation to the Contractor as per Clause 112 and also for the cost of excavation,
backfilling concrete foundations and all other incidental works so as to complete the
work as specified.
1504 DELINEATOR POSTS
(1) Scope
Page 15–11
The work covers supplying and fixing of delineator posts. The design and painting of
the posts shall be in accordance with the Traffic Signs Manual (latest publication).
(2) Materials
The delineator posts shall be constructed of reinforced concrete of grade M20/20 in

accordance with Section 2000 or as shown in the Drawing. Paint shall be non-
reflectorised paint and shall be in accordance with NS 112-2042. Primer shall comply
with NS 190/2045.
(3) Manufacturing
Posts shall be manufactured to the dimension shown on the Drawing or as per Traffic
Signs Manual (latest publication). Forms shall be smooth and have accurate
dimensions. The concrete mix shall be placed in the forms and vibrated. The posts
shall be reinforced as detailed in the Drawing.
The posts shall be true to the shape, smooth and without honeycombing or other
blemishes. The posts shall be provided with recess.
(4) Erection and Painting
Posts shall be erected after the completion of pavement surfacing. Holes shall be
excavated at a distance of 600 mm from the road edge or at locations instructed by the
Engineer. The posts shall be placed vertically and square to the road center line.
Backfilling shall be compacted in layers not exceeding 150 mm thick right from the
bottom of the hole.
The posts shall be applied with a coat of white cement primer and two coats of
synthetic enamel paint. The paint shall be applied in 200 mm wide alternate strips of
white and black starting from the top.
The posts shall be painted immediately after placing. If specified in the contract or
shown in the Drawing the posts shall then be provided with 100 mm x 80 mm reflective
element.
(6) Measurement
Page 15–12
Each type of posts (with or without reflective element) shall be measured in number.
Excavation, preparation of foundation and backfilll shall not be measured. They are
deemed included in the measurement of posts.
(7) Payment
Delineator posts measured as provided above shall be paid at the contract unit rate for
each type of post. The contract unit rate shall be the full and the final compensation to
the Contractor as per Clause 112 and also for the cost of excavation, backfill, painting
reflecting elements (where specified) including all other incidental costs so as to
complete the work as specified.
Page 15–13
SECTION 1600 - PILING FOR STRUCTURES
Page No.
1601 SCOPE 16–1

1602 GENERAL 16–1
1603 TYPES OF PILES 16–1
1604 PENETRATION AND BEARING VALUE 16–1
1605 PRECAST CONCRETE PILES 16–2
1606 DELIVERY, HANDLING AND STORAGE OF PILES 16–2
1607 DRIVING EQUIPMENT 16–3
1608 PILE DRIVING 16–4
1609 CUTTING AND LENGTHENING OF PILES 16–5
1610 PILE HEAVE 16–5
1611 CAST-IN-SITU PILES 16–6
1612 BORED AND CAST-IN-SITU PILES 16–6
1613 DRIVEN SHELL CAST IN SITU PILES 16–13
1614 PILE TESTS 16–15
1615 PILE RECORDS 16–17
1617 PAYMENT 16–19
SECTION 1600 - PILING FOR STRUCTURES
1601 SCOPE
This Section covers the works connected with various types of piles required for structures.
1602 GENERAL
The requirements contained in these specifications and in the Drawing are the minimum
requirements. Strict compliance with these minimum requirements shall not relieve the
Contractor of the responsibility of adopting whatever additional measures which may be
necessary to ensure the completion of the work to the satisfaction of the Engineer. Unless
contradicted hereunder, the provision of IRC: 78-1983 shall be strictly followed.
In addition to submitting the records required under Sub-clause 1607(3) the Contractor shall
report immediately to the Engineer any circumstances which indicate that the ground
conditions differ from those expected by the Contractor from his interpretation of the soil survey
so as to materially affect the bearing capacity of the piles.
1603 TYPE OF PILES
Based on materials piles may be
(1) Timber piles

(2) Steel piles
(3) Concrete piles of normal or pre-stressed concrete
Based on method of construction piles may be
(1) Driven piles

(2) Bored/Drilled and cast-in-situ piles.
Timber, steel and pre-cast concrete piles are of driven type. Piles may be of solid or hollow
Section or steel cased piles filled with concrete. They may be of circular, square, hexagonal, H,
I or Z Section as applicable.
Timber and steel/ steel sheet piles shall comply with their Specifications as provided in the
contract.
1604 PENETRATION AND BEARING VALUE
The bearing vales of the piles shown on the Drawing or indicated in the contract are the minimum
bearing values to which piles must be driven or installed. The driving or installation of the piles
shall continue until the estimated penetration and set is reached or until the pile has been driven
to substantial refusal or to a penetration and set satisfactory to the Engineer. When water jets are
used the bearing capacity of a pile shall be determined from the results of driving with the
hammer after the water jets have been withdrawn. The bearing value and set for the purpose of
SECTION 1600 PILING FOR STRUCTURES

Page 16–1
this Clause shall be calculated from the appropriate formula as given in IS 2911 or such other
criteria as shall be indicated or described in the contract.
1605 PRECAST CONCRETE PILES
Specification for precast prestressed concrete piles shall conform to those contained in Clause
8 of IS: 2911 (part 1 Section 3), if not covered by Sections 1800, 2000 and 2100.
Every pile shall be marked with the date of casting and an identification number. Pre- stressed
piles shall also be marked with the pre-stressing force applied.
Precast concrete piles shall be of the size and shape as shown on the Drawing. If a square
Section is employed, the corners shall be chambered at least 25mm unless otherwise spcified
on the Drawing. The length of pile shall not normally exceed 25 metres. However, where
special equipments for handling and installation are avaialble to the satisfaction of the
Engineer, longer length shall be permitted.
Piles shall be cast with a driving point for hard driving and shall be cast with a metal shoe
approved by the Engineer.
1606 DELIVERY, HANDLING AND STORAGE OF PILES
(1) Number and Length of Piles
When testing of piles are specified in the contract, the pile lengths as shown on the
Drawing or described in the contract shall be used for tendering purposes only. The
number, Section and length of piles as specified shall be subject to change. No piles
except test piles, shall be ordered, delivered to site or manufactured on site for any
units of a structure until the Engineer has determined from the results of the driving of
the test pile. When the test piles are not specified, the number and lengths of piles to
be ordered, delivered to site or manufactured on site shall be as specified in the
contract.
(2) Handling and Storage
All piles shall be handled, transported and stored in such a way that they shall not be
damaged. The use of cant hooks, lifting tongs or other pointer tools shall not be
permitted. Precast concrete piles shall be supported at the indicated pickup points and
shall only be lifted with bridles or slings attached at such pickup points. If no pickup
points are indicated they shall be assumed to be at a distance of 0.207 times the length
of pile from each end for two points lifts. For three points lift it shall be at a distance of
0.145 times length of pile from each end with the middle point being at the centre. The
Contractor shall be responsible for any damage caused by handling or storage.
1607 DRIVING EQUIPMENT
(1) Pile Driving Frames on Leads
Leads shall be required for all types of hammers. Leads shall be so constructed as to
allow free movement of the hammer and shall be rigid enough to hold the pile in correct
alignment during the driving operation. The leads should be of such length, where

Page 16–2
practicable, that the use of followers shall not be necessary. The use of hanging leads,
guyed leads or other leads shall be subject to the approval of the Engineer, whose
approval, if given, shall not relive the Contractor of the responsibility of driving the piles
to the placing and verticality tolerances allowed in the contract.
(2) Piling Hammers
Pile Hammers, other than drop hammers shall be of approved steam, air or diesel
hammers, which develop sufficient energy per blow to drive the piles at a penetration
rate of not less than 5 mm per blow at the required bearing value. Steam or air
hammers shall be with boiler or air capacity at least equal to that specified by the
manufacturers of the hammers to be used. The boiler or compressor shall be equipped
with an accurate pressure gauge. The value, mechanism and other parts of the
hammers shall be maintained in good condition and working order so that the length of
stroke and number of blows per minute for which the hammer is designed shall be
obtained. Inefficient steam, air, or diesel hammers shall be removed from the site. As a
general guide the size of the hammer normally required for steel piles shall be one
which develops approximately 1100 kg metres energy per blow. Pre-cast concrete
piles and steel shell for cast in-situ piles longer than 15 metres shall normally require a
hammer which develops 1725 kg metres energy per blow. Drop hammers shall in no
case weigh less than the combined weight of the pile, dolly and helmet. The Contractor
shall, upon request, furnish the Engineer with such evidence of the weight of the drop
hammer as he requires.
(3) Pile Driving Helmets and Dollys
(a) For Steel Piles
Whether driving is done with gravity or a mechanical hammer, a special driving

helmet shall be used. It shall be recessed to fit closely around and have a full
bearing on the pile head. For Gravity Hammers it shall have a dolly of suitable
material on the upper side.
(b) For Pre-cast Concrete Piles
A driving helmet shall be used which fits closely over the head of the pile. A
cushion block of coir or wood shall be used between the pile head and the
helmet and the helmet shall have a dolly of suitable material on the upper side.
(c) Shells for cast in-situ piles, if not driven with an internal mandrel shall be driven
with a helmet as for steel piles. Shells driven with an internal mandrel shall
have a cushion of low water cement ratio green concrete placed in the bottom
of the shell. Fresh green concrete shall be added to the cushion after every 30
minutes of driving or after any break in driving of longer than 30 minutes.
(4) Water Tests
The jet or jets shall be capable of freely eroding the material under the pile. The nozzle
of each jet shall have a minimum diameter of 19 mm and shall generally be circular.
The pump supplying the water shall be of such size & type that it shall maintain a water
pressure of at least 9 kg/cm² at the orifice of each nozzle.

Page 16–3
1608 PILE DRIVING
(1) General
The Contractor shall notify the Engineer at least 24 hours before beginning any pile
driving operations and no piles shall be driven unless the Engineer or his Inspector is
present. Before any foundation piles are driven in any unit including test piles, the
excavation shall be made, approximately, to the planned footing level. Piles to be
driven through embankments over 1.5 m in depth constructed by the Contractor shall
be driven in holes excavated through the embankment of dimensions not less than the
pile dimensions plus 150 mm. After driving, the space around the pile shall be filled with
dry sand or single size gravel. During pile driving operations the water level in the
excavation shall be kept below the top of the pile. Under water pile driving shall only be
permitted when the contract calls for a concrete seal foundation. In such cases, the
piles shall be driven by a mechanical hammer equipped to drive when submerged.
When the top of the hammer is submerged during driving, it shall be equipped with
accurate measuring detachable measuring rods, for the purpose of recording pile
penetration. Care shall be taken to obtain accurate location and spacing of the piling. In
all cases of under water driving, the equipment and method to be used shall be
approved by the Engineer in writing. When satisfactory penetration of piles cannot be
obtained without damage to the pile from driving, and the character of the soil is
considered suitable, the Contractor may, with the Engineer's approval use water jets in
sufficient numbers to obtain the desired penetration. Before the desired penetration is
reached the jets shall be withdrawn and the pile shall be driven with the hammer to its
final penetration and set. No additional compensation shalll be allowed for jetting or the
provision of jetting equipment. Water jets shall not be used as an aid for driving steel
piling. The driving of piles by means of followers shall be avoided if practicable and
shall only be done with the written permission of the Engineer, who may require that
one pile from any group of 10 or less shall be a long pile driven without a follower to
determine the average bearing power of the group. Sawing or cutting the body of a pile
to assist in springing it to proper location shall not be permitted. If a pile vibrates
excessively or shows signs of buckling during driving it shall be braced or guyed as
directed by the Engineer. Broken, split or wrongly treated piles shall not be measured
for payment and if required by the Engineer they shall be completely withdrawn and
replaced by satisfactory piles.
(2) Installation
Installation of piles shall be carried out in accordance with the pile layout Drawing or as
The Engineer shall decide the sequence of the group of piles that the Contractor
should undertake for installation and shall follow this sequence. In a group the
installation shall proceed from those on the centre of the group towards those on the
periphery.
(3) Temporary Support

Page 16–4
The Contractor shall ensure that free standing piles are temporarily braced on stayed
immediately after driving to prevent loosening of the piles in the ground and to ensure
that no damage resulting from oscillation, vibration or movement of any free- standing
pile length can occur.
(4) Tolerance in Driving
During driving, the piles shall not deviate from the vertical or the specified rake (in the
case of raker piles) by more than 40 mm per metre of pile length, and after driving the
centre of the pile at cut-off level, shall be not more than 150 mm from its planned
location.
1609 CUTTING AND LENGTHENING OF PILES
(1) Pre-cast Concrete Piles
Concrete piles shall be cut off at such level that they shall extend into the cap or footing
as indicated in the Drawing. If piles are to be lengthened the main or splicing
reinforcement shall be stripped of concrete for the distance necessary to effect a lapped
reinforcement splice in accordance with Clause 2013. Alternatively, subject to the
Engineer's approval, the reinforcement shall be exposed for a minimum of 250 mm and
the extension reinforcement butt welded to the original reinforcement. Driving shall not be
resumed until the cube strength of the concrete in the extension is at least equal to the
28 days cube strength of the concrete in the original pile and approval of the Engineer to
resume driving has been obtained. In cases, where a substantial number of pile
extensions are expected, the Contractor may propose special extension methods and
procedures. In such cases, the Contractor shall submit full details of the method and
procedure proposed and carries out such tests as the Engineer may require to
substantiate the soundness, strength and durability of the extended piles and their
suitability to fulfil their function adequately.
(2) Steel Piles and Steel Cast in-situ Shells
Piles shall be cut off at the appropriate level for incorporation of the footing or cap as
shown in the Drawing. When driven to cut-off level without damage to the head a
tolerance of 25 mm from the true cut off level shall be allowed.
1610 PILE HEAVE
The Contractor shall take and maintain records of the levels of every pile immediately after
driving in accordance with the requirements of the Engineer. After all piles in the group have
been completed, the levels shall be checked to determine whether any of the piles has heaved.
Such heaved pile shall be re-driven and pile driving shall not be considered complete until all
heaved piles have been re-driven as directed by the Engineer.
1611 CAST IN-SITU PILES
Cast in situ concrete piles may be either installed by making a bore into the ground by removal
of material or by driving a metal casing with a shoe at the tip and displacing the material
laterally. The two types of piles are termed as bored and cast-in-situ piles and driven shell and
cast-in-situ piles respectively.

Page 16–5
1612 BORED AND CAST IN-SITU PILES
(1) Steel Casing
When permanent steel casing is shown on the drawing, the minimum thickness shall
be 10 mm. The minimum length shall be from 100 mm above the bottom of the pile cap
to 5 meter under the river bed or into the firm strata. Joints between casings shall be
approved by the Engineer. The casing shall be handled and stored in a manner that
shall prevent buckling and other deformation as well as accumulation of dirt, oil and
paint.
(2) Concrete
The concrete shall conform to the requirements sepcified in Section 2000.
Concrete placed under water or drilling mud by tremie shall have a cement content of
not less than 350 kg/m3. The density and consistency of the concrete shall conform to
the tremie casting method. Sufficient workability (slump) of all the concrete during the
casting and handling of casing including reasonably calculated delays shall be secured
by a design mix. Necessary retarders and plasticisers shall be tested by trial mixes
prior to the pile construction.
All relevant concrete properties such as slump, time of setting, temperature and
strength shall be measured on the trial mixes.
(3) Reinforcement
The reinforcement shall conform to Section 2000.
(4) Drilling Fluid
The following requirements shall be complied with, if benotonite mud is used to

stabilise the boreholes:
(a) Supply
A certificate shall be obtained by the Contractor showing the properties of the

consignment delivered to the site. This certificate shall be made available to
the Engineer for his approval.
The Contractor shall get approval of the Engineer for any other material
proposed by him for the drilling fluid.
(b) Mixing
Bentonite and any other material shall be mixed thoroughly with clean water to
make a suspension which shall maintain the stability of the pile excavation for
the period necessary to place concrete and complete the construction.
(c) Tests

Page 16–6
The frequency of testing drilling fluid alongwith method and procedure of

sampling shall be proposed by the Contractor for approved by the Engineer
prior to the commencement of the work. The frequency may subsquently be
varied as required, depending on the consistency of the results obtained.
The Contractor shall supply all equipments and experienced operators

required to carry out tests on the drilling mud. No additional payment shall be
made for these tests which shall be considered as an essential part of the
drilling operations.
(5) Construction Methods
The Contractors shall demonstrate to the satisfaction of the Engineer that his proposed
construction method for the pile does not weaken the pile shaft by contamination of the
concrete by sectional reduction, by washing out of cement, by breaking during pulling
of temporary casings or in any other way including the construction of neighbouring
piles.
(a) Procedure
The following construction procedure shall be followed:
(i) If permanent steel casings are not specified, a sufficient length of

temporary steel casing shall be used to stabilise the upper part of the
borehole.
(ii) Boring and excavation inside the steel casing shall be carried down to
the casing toe level or to a level approved by the Engineer. The
excavation shall be continued to final pile tip level using either
temporary casing under water or using drilling mud. The fluid level
inside casing shall at all times be at least 2 meters higher than outside
the casings.
(iii) All mud or sedimentation from the bottom of borehole shall be cleaned
up.
(iv) Reinforcement cage, inspection pipes etc. shall be placed as shown
on the drawing or instructed by the Engineer.
(v) Concreting underwater or drilling fluid shall be carried out
continuously using tremie method.
(vi) Withdrawing of the temporary boring casing to the instructed level
shall be carried out concurrently with concreting.
(vii) After hardening, the top Section of the concrete pile shall be broken to
reach sound concrete in the pile.
(b) Approval of Construction Method
The Contractor shall describe the construction method he proposes, including

name of proposed Sub-contractor (if any), information on boring equipment,
materials, method of boring and quality control.
After the contract has been awarded the Contractor shall prepare a detailed
programme and establish a procedure for the pile construction. The detailed
programme shall contain all required information on materials, equipment,
methods of work etc., and be approved in writing by the Engineer. Such

Page 16–7
approval shall not however relieve the Contractor of his responsibilities for pile
construction. The import of any boring equipment or materials by the
Contractor, before he has received the Engineer's approval of proposed
construction methods, shall be at the Contractor's risk.
The Contractor shall check the casing position for each pile during and
immediately after placing the casing, and agree it with the Engineer.
(c) Tolerances
The centre of the completed pile at cut off level shall not deviate more than 100
mm from the theoretically correct position shown on the drawing. The
inclination of the pile shall not deviate more than 1:100 from vertical. The
Contractor shall provide suitable equipment such as inverted pendulum, to
check the verticality of the boreholes at intervals during drilling and prior to
concreting.
(6) Boring
(a) Methods
Methods of excavation shall be proposed by the Contractor for approval of the

Engineer. Water or air jetting for boring of the piles shall not be allowed.
(b) Boring near recently cast Piles
Piles shall not be bored so close to other piles which are cast and contain
workable or unset concrete likely to flow.
Boring and excavation for a pile shall not commence until 24 hours after
completion of any pile within a radius of 6 meters center to center.
(7) Temporary Casings
Temporary casing of approved quality or an approved alternative method shall be used

to maintain stability of pile excavation which might otherwise collapse.
(8) Stability of Pile Excavation using Drilling Fluid
Piles through water and/or soft upper soil layers shall be provided with permanent
steel casing if shown in the Drawing.
The pile boring shall be carried out using temporary steel casing bored in pile toe, to
the level of side fall or to a level approved by the engineer. Before concreting the
temporary casing shall be gradually withdrawn. Under certain circumstances the
Contractor may be permitted to bore all part or the pile without casing under water or
using drilling fluid to stabilise the borehole.
Where a borehole is formed without casing under water or using drilling fluid for
maintaining the stability of a boring, the level of the water or fluid in the excavation shall

Page 16–8
be maintained so that the water or fluid pressure always exceeds the pressure exerted
by the soils and external ground water. The water or fluid level shall be maintained at a
level not less than 2 meters above the level of the river water level or any artesian
pressure level.
In the event of a rapid loss of water or bentonite suspension from the pile excavation,
the excavation shall be backfilled without delay and the instruction of the engineer shall
be obtained before excavation at that location is resumed.
(9) Pumping from Boreholes
Pumping from the borehole shall not be permitted unless a casing has been placed into
a stable stratum which prevents the flow of water from other strata in significant
quantities into the boring, or unless it can be shown that pumping shall not have a
detrimental effect on the surrounding soil or property.
(10) Removal of Obstruction
Where boulder or other obstruction render it impossible to bore the pile, excavation
operation inside pile casing as directed by Engineer shall be carried out to remove
obstructions. The Contractor shall be reimbursed for such operation only when the
largest dimensions of the obstruction exceeds 200 mm and the obstruction is found
more than 2 meters below river bed.
Disturbed and/or undisturbed samples of the soils from boreholes shall be submitted to
the Engineer. The Contractor shall allow for carrying out sampling and tests to check
soil strength including field tests like SPT tests as required by the Engineer.
(11) Final Toe Level of piles
The final toe level shall be as indicated on the drawing or as instructed by Engineer
after due consideration of the Contractor's proposals, boring logs and test results.
The final toe level of other piles may subsequently be altered according to the results
of the tests loading detail in the Section.
(12) Inspection and Cleaning bottom of Excavation
The time between final excavation including bottom cleaning and the start of concreting
shall be reduced as much as possible and in any case shall not exceed 6 hours.
The cleaning shall be done by an approved method. Before cleaning bottom of every
excavation, notice shall be given to the Engineer. The Contractor shall show, to the
satisfaction of the Engineer, that the bottom of the excavation is clean.
If boring without casing, the diameter of the borehole for a representative number of
piles shall be measured by caliper prior to the placing of concrete.
These measurements shall be done by the Contractor using approved equipment and
no reimbursement shall be made for this.

Page 16–9
(13) Placing Reinforcement
The reinforcement shall be placed as indicated on the Drawing. Reinforcement in the

form of a cage shall be assembled with additional support, such as spreaders forks
and lacings, necessary to form a rigid cage. Hoops, links or helical reinforcement shall
fit closely around the main longitudinal bars and be bound to them by approved wire,
the ends of which shall be turned into the interior of the pile or pour. Reinforcement
shall be placed and maintained in position. The cover to all reinforcement shall be not
less than 75 mm.
Joints in longitudinal bars in piles with tension (for instance for test loading) shall be
carried out by welding unless another method has been approved by the Engineer.
(14) Placing Concrete
(a) Approval from the Engineer
No concreting shall take place before the bottom of excavation has been
cleaned. The Contractor shall get borehole inspected and obtain approval in
writing from the Engineer.
(b) General Requirements
While placing concrete, these requirements shall be complied with
(i) The method of placing and the workability of the concrete shall be
such that a continuous monolithic concrete shaft of the full cross
Section is formed.
(ii) The concrete shall be placed continuously and without such
interruption as would allow the previously placed batch to have
hardened. In this respect the Contractor shall submit details of his
contingency plans, standby plants etc. to be utilised in the event of an
equipment failure.
(iii) The use of pumped concrete and the methods in its use shall be
approved.
(iv) The Contractor shall take all precautions in the design of the mix and
placing of the concrete to avoid arching of the concrete in a casing.
No spoil, liquid or other foreign matter shall be allowed to contaminate
the concrete.
(v) Concrete to be placed under water or chilly fluid shall be placed by
tremie and shall not be discharged freely into the water or drilling fluid.
(vi) Before placing concrete, measures shall be taken to ensure that
there is no accumulation of silt or other material at the base of the
boring. The Contractor shall ensure that heavily contaminated
bentonite suspension, which could impair the free flow of concrete
from the pipe of the tremie, has not accumulated in the bottom of the
hole.
(vii) A sample of the bentonite suspension shall be taken from the base of
the boring using an approved sampling device. If the specific gravity of

Page 16–10
the suspension exceeds 1.25, the placing of concrete shall not

proceed. In this event the Contractor shall modify the mud quality. The
concrete shall be a rich and coherent mix of high workability in
accordance with the requirement of Section 2000.
(viii) The concrete shall be placed in such a manner that segregation does
not occur.
(ix) During and after concreting damage to the concrete from pumping
and dewatering operations shall be avoided.
(x) The hopper and pipe of the tremie shall be clean and watertight
throughout. The pipe shall extend to the base of the boring. A sliding
plug or barrier shall be placed in the pipe to prevent direct contact
between the first charge of concrete in the pipe of the tremie and the
water of drilling fluid. At all times the pipe shall penetrate the concrete
placed and shall not be withdrawn from the concrete until completion
of concreting. The bottom of the tremie pipe shall be kept at least 1.5
metres under the surface of concrete. At all times a sufficient quantity
of concrete shall be maintained within the pipe to ensure that the
pressure from it exceeds that from the water or drilling fluid. The
internal diameter of the pipe tremie shall not be less than 150 mm for
concrete made with 20 mm agregate and not less than 200 mm for
concrete made with 40 mm aggregate. It shall be so designed that
external projection are minimised, allowing the tremie to pass through
reinforcing cages without causing damage. The intenal face of the
pipe of the tremie shall be free from projections.
(xi) The Contractor shall maintain a continuous record of the volume of
concrete used and the level of the concrete in the pipe. Any deviations
from the theorotical, or expected, volume/ level relationship shall be
immediately reported to the Engineer.
(c) Workability of Concrete
Slump measured at the time of discharge into the pile shall be in accordance
with that given in the Table 16.1
Table 16.1: Slump of Concrete for Pile Boring
Slump
Piling mix workability Minimum Range Typical conditions of use
mm mm

Page 16–11
A 75 75-150 Placed into water free unlined or

permanently lined bore of 600 mm
diametre or over or where casting
level lies below temporary casing:
reinforcement widely spaced,
bearing ample room for free
movement of concrete between
bars.
B 100 100-200 where reinforcement is not spaced
widely where cut off level of
concrete is within temporary casing
where pile bore is water free and
the diameter is less than 600 mm.
C 150 150 where concrete is to be placed by
tremie under water or chilly mud or
by pumping
(15) EXTRACTION OF TEMPORARY CASING

(a) Workability of Concrete
Temporary casing shall be extracted while the concrete within them remains
sufficiently workable to ensure that the concrete is not lifted.
(b) Concrete Level
When the casing is being extracted a sufficient quantity of concrete shall be

maintained in it to ensure that pressure from external water, drilling fluid or soil
is exceeded and that the pile is neither reduced in Section nor contaminated.
The toe of the temporary casing shall be kept at a minimum of 2 metres under
the outlet of the tremie.
Adequate precautions shall be taken in all cases where excess head of water
or drilling fluid exists.
The pile shall be concreted with certain overheight to allow for chiseling off the
top concrete down to sound hard concrete.
(c) Vibrating Extractors
The use of vibrating casing extractors shall be permitted for the extraction of
the casing.
(d) Reinforcement Cage
During concreting and puling the casing, the reinforcement cage shall be
secured against uplift and the top shall be kept under close monitoring.
(e) Supervision
The execution of the pile concreting shall be supervised by a qualified and

experienced person of the Contractor, who shall keep records on the relation
between quantity of concrete used, level of concrete and withdrawal of casing.

Page 16–12
(16) Measures Incase of Rejected Piles
If any pile is found unsatisfactory in the opinion of the Engineer for utilisation in the
structure, it shall be cut off below the pile cap, if so ordered by the Engineer. The piles
shall be replaced as directed by the Engineer. All extra expenses shall be borne by the
Contractor and the payment shall be made for original piles only considering that no
replacemnt piles are bored.
When by test, the safe allowable bearing value of any pile is found to be less than the
design load, longer piles or additional piles shall be installed as ordered in writing by
the Engineer.
1613 DRIVEN SHELL CAST IN-SITU PILES
(1) Shells for Cast In-Situ Piles
Steel shells may be of any type which has a tip diameter of not less than 300 mm, a
thickness of not less than 3mm, and a top diameter not less than that required in the
contract, which shall satisfactorily withstand the required driving without distortion or
damage to the pile, and which can be filled with concrete for it's entire length without
placing concrete in or under water. The capacity of the pile frame shall be selected
after considering the size and weight of the casing tube to be handled, the location of
the work and the hardness of driving. Detachable shoes used with the temporary steel
casings shall be cast iron, double rimmed and of requisite strength, standard and sizes
to be used with the respective steel casing. The shoe shall be coaxial with the steel
casing. However, mild steel pile shoes also shall be accepted. They should have been
fabricated out of mild steel plates conforming to IS 2062. Casings distorted from the
true and uniform shape, whether caused by driving or earth and water pressure
resulting in a reduction of the cross sectional area of the pile in excess of 10 percent
shall not be used in the work.
Steel shells for concrete in-situ piles which protrude above ground or bed level shall be
as shown on the Drawing, specified in the contract or ordered by the Engineer.
(2) Construction
Before commencement of work the Contractor shall submit to the Engineer

construction method and details of driving equipment for his approval.
(a) Driving of steel Casing:
Steel casings shall be driven as per layout plan shown on the drawing or as
directed by the Engineer. Sequence of driving steel casing in pile group shall
be as ageed by the Engineer.
After commencement of driving all times, prior to the placing of concrete in the
driven shells or casings, the Contractor shall provide a suitable light for the
inspection of the shell or casing throughout its length. Any improperly driven,
broken or defective shell shall be replaced, or an additional pile shall be driven
at the expense of the Contractor. Any reduction in the cross-sectional area in
casings or shells in excess of 15% shall be cause for rejection. The insertion of
internal casing to remedy defects shall not be permitted. No concrete shall be

Page 16–13
placed in cast in-situ piles until all driving within a radius of 6.0 m has been
completed, nor until the shells, for any area sub-structure unit or bent, have
been completely driven. If this cannot be done, all driving within a 6.0m
distance shall be discontinued until the concrete in the last pile cast is at least
7 days old.
(b) Clearing and Inspection
Before placing reinforcement accumulation of water or debris in the shells shall

be removed and thoroughly inspected throughout its length. It shall be ensured
that reduction of the Section, if any, shall not be excess of 15% of the specified
Section and the toe level shall be the same as shown on the drawing or
(c) Placing of Reinforcement
The reinforcement shall conform to the requirements of Section 2000.
The reinforcements shall be prepared and placed as described in Clause

1612.
(d) Placing of Concrete
The piles shall be cast with the concrete using design mix as specified in the
contract.
Care shall be taken to preserve correct cover and alignment of reinforcement

throughout the whole operations of placing the concrete.
Before placement of concrete care shall be taken to ensure that the inside of
the casing is free from sludge or any foreign mater. Water inside the casing, if
any, shall be removed by bailing or pumping. Where this is not possible, the
under water concreting shall be done with necessary precautions after
receiving the specific approval of the Engineer.
The concrete shall be so placed to fill the entire volume of the casing without
the formation of voids caused by entrapped air. Proper compaction shall be
employed to obtain a dense and high quality concrete. The concrete shall be
vibrated immediately after placing each lift and lifts shall not exceed 1.25 m in
height. The filling of piles in conjunction with the placing of concrete in the
footing shall not be permitted. The volume of concrete placed shall be
observed in the case of few piles initially cast and the average figure obtained
shall be used to check, whether there is any deviations in the volume of
concrete placed for the subsequent piles.
Consistency of concrete to be used for cast-in-situ piles shall be suitable to the

method of installation of piles. Concrete shall be so designed or chosen as to
have a homogeneous mix having a slump/workability consistent with the
method of concreting under the given condition of pile driving. The minimum
slump shall be 100 mm when the concrete in the pile is not compacted. The
slump shall not exceed 180 mm. in any case. The Contractor shall submit mix

Page 16–14
design report including calculations and carry out adequate number of tests to
ensure the minimum strength in accordance with the Specifications.
The top of the pile shall be brought above the required finished level and any
defective concrete removed to ensure satisfactory bonding of the pile head to
the substructure.
Withdrawal of casing shall be carried out in stages and utmost care shall be
exercised in maintaining an adequate head of concrete above the bottom of
casing at each stage of withdrawal so as to prevent the inflow of soil and water
into the casing.
(e) Miscellaneous
The requirements for placing reinforcements and concrete, workability of

concrete, extraction of temporary casing, tolerance, etc. as described in
Clause 1612 shall be met with, as applicable.
1614 PILE TESTS
(1) Test Piles

The Contractor shall furnish test piles of the type, number and length specified in the
contract. Generally the test piles shall be located so as to permit their use in the
finished structure and they shall be installed at the positions shown on the Drawing or
specified in the contract.
In order to obtain the best possible data from the test piling the Engineer shall have the
right to change test piles from their planned location to any other location in that group
or any other group of the structure without any adjustment in the Contract Prices.
The installation shall be done using the same equipment as is to be used for installing
the other piles in the works. The Contractor shall co-operate with and assist the
Engineer in obtaining data for bearing for the full length of the installation.
When using driven piles in soft or plastic soils, the Engineer may require test piles to
be
re-driven. In such cases the driving shall be stopped at a point when the top of the pile
is 600 mm to 1500 mm above cut off level and driving shall be resumed after a
minimum of 24 hours.
(2) Loading Tests
Loading Tests shall be made on those piles shown in the Drawing or ordered by the
Engineer. All labour, materials, equipment and attendance required to complete the
tests shall be furnished by the Contractor.
The piles shall be tested as follows:
(a) The test load shall generally be 200% of the bearing required in the contract
and be applied by a method approved by the Engineer. It shall be measured

Page 16–15
within an accuracy of plus or minus 2%. Settlements shall be measured within

an accuracy of plus or minus 0.25 mm.
(b) The test load shall be applied in the increments as specified or approved by
the Engineer. These shall generally be those recommended in IS 2911.
(c) The load after each increment shall be kept constant until the rate of settlement
does not exceed 0.25 mm per hour.
(d) The value of settlement shall be recorded before the next increase of load.
(e) The full test load shall be maintained for 48 hours and the total settlement shall
be recorded.
(f) The load shall be reduced in decrements equal to the increments with which it
was applied.
(g) The load after each reduction shall be kept constant until the rate of recovery
does not exceed 0.25 mm per hour.
(h) The amount of recovery shall be recorded before the next decrease of the
load.
(i) The Contractor shall, within 24 hours of the completion of the test, submit to
the Engineer for each pile tested, graphs showing;
(i) Load plotted against settlement and time.
(ii) Settlement and recovery plotted against load.
(j) The settlement of the pile under the test load and recovery of the pile after the
removal of the load shall be within the limits required in the contract or ordered
by the Engineer.
(3) Other Requirements of Loading Tests
(a) A load test shall consist of the application of a load equal to twice the specified
bearing capacity or as otherwise provided for herein or as directed by the
Engineer. Unless otherwise permitted by the Engineer the load tests shall be
completed before the remaining piles in the same structure are driven or cast.
(b) Load tests shall be performed on the day indicated by the Engineer. The
Engineer may order load tests to be performed on piles other than test piles and
may also specify different increments of load, more frequent loadings of gauges
and different period of loadings than specified herein or in Sub-clause 1614 (2).
Such changes shall not continue any claim by the Contractor for any additional
payment or compensation other than payment for test pile and load test in
accordance with the contract unit price quoted by the Contractor in the Bill of
Quantities.
(c) Load tests shall be made by methods approved by the Engineer. The Contractor
shall submit to the Engineer detailed plans of loading system and apparatus he
intends to use at least 3 weeks in advance. The apparatus shall be so
constructed so as to allow the various increments of the load to be placed
gradually without causing vibration to the test piles. Tension anchor piles, if used,
shall be of a design and driven to a depth satisfactory to the Engineer. Steel
shells or piles whose walls are not of adequate strength to withstand the test
loading when empty, shall have the required reinforcement and concrete placed
before loading.
(d) The load test shall not be started until the concrete has attained a minimum
compressive strength of 95% of specified strength. If the Contractor so selects,
he may use high early strength cement (but not high alumina cement) in the

Page 16–16
concrete of the load test pile and the tension piles in order to decrease the time
for load testing.
(e) Suitable approved apparatus for determining accurately the load on the pile and
the settlement of the pile under each increment of load shall be supplied by the
Contractor. The apparatus shall have a working capacity of three times the
design load for the pile being tested. Reference points for measuring pile
settlement shall be sufficiently removed from the pile to preclude all possibility of
disturbance.
(f) All pile load settlements shall be measured by adequate devices, such as
gauges, and shall be checked by means of an engineer's level. Increments of
deflection shall be recorded just after application of each load increment and at
15 minutes intervals thereafter. The safe allowable load shall be considered as
50 percent of the load which, after 48 hours of continuous application, has
caused not more than 6 mm of permanent settlement, measured at the top of
this pile.
(g) The first load to be applied to the test pile shall be 50% of the pile design load
and the first increment shall be up to the pile design load. The load on the pile
shall be increased to twice the design load by applying additional loads in three
equal increments. A minimum period of 2 hours shall intervene the application of
each increment. If there is a question as to whether the test pile shall support the
test load, the load increments shall be reduced by 50 percent, at the direction of
the Engineer, in order that a more closely controlled failure curve may be plotted.
(h) When directed by the Engineer load tests shall be continued beyond twice the
design load in 10-ton increments to failure or to a maximum of 3 times the
design load.
1615 PILE RECORDS
The Contractor shall keep records as indicated below for the installation of each pile and shall
submit two signed copies of these records to the Engineer not later than noon of the next
working day after the pile was installed. The signed records shall form a record of the work.
The following data shall be recorded.
(a) Pile reference number
(b) Pile location
(c) Pile type
(d) Nominal cross sectional dimensions or diameter
(e) Date and time of boring
(f) Date and time of concreting
(g) River bed level at commencement of installation of pile
(h) Working level
(i) Pile toe level
(j) River water levels
(k) Pile head level
(l) Length of temporary casing with top level
(m) Length of permanent casing with top level
(n) Soils samples taken and in situ tests carried out.
(o) Standing water level
(p) Length and details of reinforcement

Page 16–17
(q) Concrete mix

(r) Volume of concrete supplied to pile and corresponding levels of concrete and casings.
(s) All information regarding obstruction delays and other interruptions to the sequence of
work.
(t) Sequence of driving/boring shown in plan of pile group.
(u) Final set of last ten blows.
(v) Type and weight of hammer.
(w) type and condition of helmet and dolly.
(x) Details of any interruption in driving, boring and/or concreting.
(y) Other information as requiored by the Engineer.
Those information which are not applicable for the given type of piling work may be ommitted.
1616 MEASUREMENT
The piles shall be measured in linear metres of pile as completed and accepted in the structure.
Pay lengths of the accepted piles shall be measured from the butt of the shoe to the cut-off level
of the pile shown on the Drawing or as instructed by the Engineer. No allowance shall be made
for cut-offs or reinforcing steel projecting into the concrete structure as called for in the Drawing.
Any additional pile lengths that may be necessary to suit the Contractor's method of operation or
for any other reason shall not be included in the measurements.
Test piles shall be measured per numbers of load test carried out including the complete
installation of the pile. Piles driven by the Contractor for his own information or for calibrating
diesel hammers shall not be measured as test piles.
1617 PAYMENT
The quantities of piling left in place in the accepted structure, measured as provided above, shall
be paid at the contract unit rate. The contract unit rate shall be the full and the final compensation
to the Contractor for all expenditures incurred by the Contractor for incidentals and for doing all
the works involved in driving, placing filling materials for cast in-situ or driven piles, cutting off
piles as specified in this specification in addition to those specified in Clause 112.
Pile shoes when called for on the Drawing or by the Engineer shall not be paid for separately, but
full compensation for all the work involved in supplying and fitting pile shoes shall be considered
as included in the unit rate for pre cast concrete piles and no additional compensation shall be
allowed.
Splicing of piles, when allowed, shall not be paid for separately but full compensation for all the
work involved shall be considered as included in the unit rate for pre cast concrete piles.
Additional quantities of concrete, reinforcement and form work, caused by incorrect location of
piles or additional piles necessary to replace defective piles shall be at the Contractor's expense.
Test piles shall be paid at contract unit rate which shall be full and final compensation for the cost
of all operations and incidental costs associated with supply of piles in place and testing there of
in addition to those specified in Clause 112.

Page 16–18
SECTION 1700 - WELL FOUNDATION
Page No.
1701 SCOPE 17–1

1702 GENERAL 17–1
1703 CUTTING EDGE AND CURB 17–1
1704 STENING 17–1
1705 SINKING 17–2
1706 BOTTOM PLUGGING 17–4
1707 SAND FILLING 17–4
1708 TOP PLUG 17–5
1710 PAYMENT 17–5
SECTION 1700 - WELL FOUNDATION
1701 SCOPE
This work shall consist of construction of well, taking it down to the indicated levels, plugging the
bottom and top including filling inside of the well in accordance with the details shown on the
Drawing or as approved by the Engineer.
When the Drawing do not include details of the ground tests made on or near the centre line of
wells the Contractor shall carry out at his own expense one bore/drill hole per well with penetration
tests (or similar approved tests). The depth to which the bore/drill holes and tests are carried out
shall be determined by the Engineer. A bore/drill hole log and a record of the tests and bagged or
bottled samples of material shall be supplied to the Engineer for determining foundation depth of
the wells.
1702 GENERAL
The well curb shall be of reinforced cement concrete. The well steining shall be of plain or
reinforced cement concrete as indicated on the Drawing. The Specifications for plain and
reinforced cement concrete, steel reinforcement and structural steel work and cutting edge shall
be as given in the relevant sections of these Specifications.
1703 CUTTING EDGE AND CURB
The dimension and shape of the cutting edge and curb shall be strictly in conformity to Drawing or
as directed by the Engineer. The well curb shall be placed truly in position and level. It may be
precast or cast-in-situ, if it is cast in situ, all concreting in the well curb shall be done in one
continuous operation. The well curb shall be allowed to set for at least 7 days before sinking is
started.
When the curb is to be laid in dry beds, the site shall be excavated upto 300 mm above the sub-
soil water level before the cutting edge is placed.
For wells which are to be pitched in water, an earthen/sand island where possible, shall be
constructed and curb shall be placed or cast on this island. In case of any deep or fast flowing
water where an island may not be possible to construct the curb may be precast, floated and
lowered in its final position with the help of necessary equipment.
For wells going through bouldery strata requiring use of explosives as an aid for well sinking, the
entire inside surface of the well curb and steining upto a minimum height of 1 metre above the well
curb, shall be protected by a 6mm thick mild steel plate which shall be suitably stiffened.
The cutting edge shall be designed by the Contractor to the satisfaction of the Engineer, if
otherwise not specified in the contract.
1704 STEINING
SECTION 17 WELL FOUNDATION

Page 17–1
The dimensions and shape of the well steining shall strictly conform to those shown on the
Drawing.
The steining of the well shall be built in one straight line from bottom to top, the work being
checked carefully with the aid of straight edges of lengths approved by the Engineer. Steining built
in the first stage shall not be more than 2 metres and in subsequent stages it shall not exceed the
diameter of the well or the depth of well sunk below the adjoining bed level at a time. As far as
possible, the stages of work shall not be kept at the location of joints in the vertical steining bars.
The height of steining shall be calibrated by at least 4 gauges on the outer periphery and at centre
lines of the well drawn at right angle to each other. The gauge shall be marked each in the form of
a 100mm wide strip painted on the well, with every 500 mm mark shown in black paint. The
gauges shall start with zero at the bottom of the cutting edge. Marking of the gauges shall be done
carefully with a steel tape.
After sinking of a stage is complete all damaged portions of steining at top of the previous stage
shall be properly repaired before constructing the next stage.
1705 SINKING
(1) General
The well shall be maintained in plumb and in the correct position during sinking and
immediate steps shall be taken to remedy any deviations. The well shall be sunk by
excavating material uniformly from inside the dredge hole. Sinking or loading of the well
with kentledge shall be commenced only after the steining has been cured for at least 48
hours or as specified in the approved Drawing. The Contractor shall supply all grabs,
water jetting equipment, pumps, diving gear and other equipment required for the sinking
and founding of the wells and shall allow the Engineer and his nominees for the use of
diving suit and apparatus for inspection purposes. Details of the equipment to be used in
construction of the well shall be submitted to the Engineer for approval within 28 days of
the award of the contract.
(2) Kentledge or Sinking Load
Kentledge shall be placed in an orderly and safe manner and in such a way that it does
not interfere with the excavation of the material from inside the dredge hole and also does
not in any way damage the steining of the well.
(3) Dewatering of Well
Normally dewatering of well shall not be permitted as a means for sinking the well. It also
shall never be resorted to if there is any danger of sand-blowing under the well. If
permitted, dewatering shall be carried out from points outside the well. Dewatering from
within a well being excavated shall not be allowed other than in rock. Measures of
controlling the effects of dewatering shall be adopted. When dewatering is permitted,
adequate standby pumps shall be available at any time during well excavation in case of
break down.
(4) Water Jetting

Page 17–2
Water jetting may be employed for well sinking wherever necessary.
(5) Use of Explosives
Explosives shall not be generally used as an aid for well sinking. However, in cases
where explosives are to be used, they shall be of mild charges and prior approval of the
Engineer shall be obtained. Blasting of any sort shall only be done in the presence of
Engineer and not before the concrete/masonry in the steining has hardened sufficiently
and is more than 7 days old.
If blasting has been used for setting the well after it has reached the design foundation
level, normally 24 hours shall be allowed to lapse before the bottom plug is laid.
The charges shall be exploded well below the cutting edge by making a sump so as to
avoid chances of any damage to the curb or to the steining of the well.
All prevalent laws concerning handling, storing and using of explosives shall be strictly
followed.
(6) Precautions during Sinking
The Contractor shall submit to the Engineer at least 28 days prior to the commencement
of well sinking construction proposals to ensure safety of persons working on or liable to
enter into the well excavation.
Notwithstanding guard rails and toe boards shall be provided around the top of well
excavation at all times.
When the wells have to be sunk close to each other and distance between them is not
greater than the diameter of wells, sinking shall be taken up on all wells and they shall be
sunk alternately so that sinking of all wells proceeds uniformly and together.
In sinking dumb-bell or double-D shaped wells, the excavation in both the dredge holes
should be carried out simultaneously and equally to facilitate even sinking.
All wells on which sinking is in progress shall be sunk to sufficient depth below the
designed scour level before the start of seasonal floods. Further, they shall be temporarily
filled and plugged before the onset of the floods so that they do not suffer any tilt or shift.
All necessary precautions shall be taken against any possible damage to the foundations
of existing structures in the vicinity of the wells, prior to commencement of dredging from
inside the well.
The dredged material shall not be allowed to accumulate over the well. It shall be
dumped, as far way from the well as possible, and then it shall be simultaneously
removed to a safer place.
In case the river stream flows along one edge of the well being sunk, the dredged material
shall not be dumped on the dry side of the bank but on the side on which the river current
flows.

Page 17–3
Very deep sump shall not be made below the well curb, as it entails risk of jumping
(sudden sinking) of the well; normally the depth of sump shall not exceed 3.0 metres
below the level of the cutting edge unless otherwise specifically permitted by the
Engineer.
In case a well sinks suddenly and with a jerk, the steining of the well shall be examined to
the satisfaction of the Engineer to see that no damage has occurred to it.
(7) Tilts and Shifts
Tilt and shift of each well shall be measured regularly during the entire sinking operation.
Observations to this effect shall be taken at each stage of casting of the steining.
Simultaneously as the sinking proceeds, necessary corrective measures be taken to
contain the tilts and shifts within the permissible limits.
Unless otherwise specified the tilt of any well shall not exceed 1 in 80 and the shift shall
not be more than 150 mm.
1706 BOTTOM PLUGGING
Before bottom plugging is resorted to, the Contractor shall take from the bottom of the excavation
an undisturbed soil or rock sample (in the form of a core 3m long and at least 70mm diameter). In
case the soil encountered is inferior to that adopted in design, the well shall be redesigned by the
Engineer adopting the soil properties actually encountered and the founding level of the well duly
revised.
Each well, after being sunk to its final position shall be insured that the whole steining has not
developed cracks for its entire length. The sum shall be checked that it is uniform. If required, it
shall be made uniform by resuming minor excavation in the dredge hole.
Before commencing bottom plugging, all the loose material from the bottom of the well shall be
removed and the depth of the bulb so formed more than 1/6th diameter of the well shall be filled up
with sand and then with concrete.
The concrete mix used in bottom plug shall have a minimum cement content of 330 kg/m 3 and a
slump of about 150 mm to permit easy flow of concrete through tremie to fill up all cavities.
Concrete for the plug shall be laid by ‘Tremie Pipe’ method, by skip boxes or by any other method
if stipulated in the contract. Concrete shall be laid evenly inside the well.
Least disturbance shall be caused to the water inside the well while laying concrete in the bottom
plug. Where concreting is placed under the water this shall be carried out in accordance with
Clause 2007.
Concreting shall be done in one continuous operation till dredge hole is filled upto the required
height and thereafter sounding shall be taken or other approved method of measurement shall be
applied to ensure that the concrete has been laid to the required height.
Concrete as laid shall not be disturbed in any way for at least 14 days.

Page 17–4
In order to check any rise in the level of the bottom plug, soundings should be taken at the close of
concreting and for 3 days thereafter once every day.
1707 SAND FILLING
When the bottom plugging is approved by the Engineer the well shall be filled with sand. A
minimum of 3 days after the bottom plug has been laid shall elapse before the well is filled with
sand.
Before filling with sand, the height of the bottom plug shall be verified.
Sand to be filled shall be clean and free from earth, clay clods, roots and boulders.
1708 TOP PLUG
After filling the sand upto the required height, top plug shall be laid over it. The thickness of this
plug and the cement concrete mix to be used shall be as indicated on the Drawing.
1709 MEASUREMENT
Cutting edge shall be measured in tonnes inclusive of its connections. For computation of
weight the specific gravity of steel shall be adopted 7.85 tonne per cubic metre.
Concrete for bottom plug shall be measured in cubic metre as per actual consumption of
cement, sand and aggregate.
Concrete for curb, well steining and top plugging shall be measured in cubic metre as specified
in Clause 2017.
Reinforcement used in the well shall be measured in tonne as specified in Clause 2017.
Formwork shall be measured in square metre inclusive of struts, sports, scaffolding etc.
necessary as to complete the item as specified in Section 1800.
Sand filling shall be measured in cubic metre.
Boring/drilling shall be measured in running metres as specified in Section 3000.
Well sinking shall be measured in linear metres as described below.
From 0 m upto 3 m
From 3 m upto 6 m
From 6 m upto 9 m
From 9 m upto 12 m
From 12 m upto 15 m
From 15 m upto 18 m
Below 18 m at the rate of each metre
The depth of measurement shall be started considering level of the bottom of cutting edge as
zero.

Page 17–5
1710 PAYMENT
Cutting edge, concrete for bottom plugging, various classes of concrete for curb, well steining
and top plugging, reinforcement, sand filling, formwork and boring/drilling shall be paid at their
respective contract unit rates.
The well sinking shall be paid as per contract unit rate for different depths.
The contract rate shall be the full and the final compensation to the Contractor as per Clause
112 and also include cost of formation of island, dewatering, excavation, bailing out materials,
providing, placing and removal of kentledge and other operations including incidental costs
necessary to complete the item as per this Specification.

Page 17–6
SECTION 1800 - FALSEWORK, FORMWORK AND SURFACE FINISH FOR CONCRETE
STRUCTURES
Page No.
1801 SCOPE AND DEFINITIONS 18–1

1802 GENERAL 18–1
1803 FALSEWORK 18–1
1804 FORMWORK FOR CONCRETE 18–5
1805 SURFACE FINISH ON FORMED SURFACES 18–8
1806 FINISHES ON UNFORMED SURFACES 18–10
1807 REMEDIAL WORK TO DEFECTIVE SURFACES 18–11
1809 PAYMENT 18–13
SECTION 1800 - FALSEWORK, FORMWORK AND SURFACE FINISH FOR

CONCRETE STRUCTURES
1801 SCOPE AND DEFINITIONS
This section covers the preparation, construction and removal of falsework and formwork for
concrete structures. It also covers the quality requirements for surface finish on formed and
unformed surfaces.
Definitions used in this Clause and other relevant Clauses of this Section and other relevant
Sections of these Specifications are as follows:
 Formwork means the surface against which concrete is placed to form a face. All the
immediate supports necessary to retain the surface in position while concrete is
placed, shall be treated an integral part of formwork.
 Falsework means the structural elements supporting both the formwork and the
concrete until the concrete becomes self supporting.
 A formed face is one which has been cast against formwork.
 An unformed surface means an horizontal or nearly horizontal surface which is not
cast against formwork.
 An exposed face is one which will remain visible when construction has been
completed.
1802 GENERAL
The Contractor shall be responsible for designing and constructing falsework and formwork so
that they will support the loads imposed on them by the fresh concrete together with additional
stresses imposed by vibrating equipment and by construction traffic, and so that after the
concrete has hardened the formed faces shall be in the positions shown on the Drawing within
the tolerances set out in Clause 1805.
Before construction begins, the Contractor shall submit to the Engineer Drawing showing
details of the proposed formwork and falsework in accordance with this Section and other
relevant Sections of these Specifications.
1803 FALSEWORK
(1) Design and Drawing
The design of all falsework for structures with span lengths of 6 metres or more and the
design of all falsework where traffic openings are specified shall conform to the
requirement of this Clause.
Detailed working Drawing in triplicate and design calculations for falsework shall be
furnished by the Contractor to the Engineer.
No falsework construction shall start until the Engineer has reviewed and approved the
Drawing. The Contractor shall provide sufficient time for the Engineer to complete this
SECTION 1800 FALSE WORK, FORMWORK AND SURFACE FINISH FOR CONCRETE STRUCTURES
Page 18 – 1
review. Such time shall be proportionate to the complexity of the falsework design and
in no case shall be less than two weeks. The Contractor may revise the falsework
Drawing at any time, provided sufficient time is allowed for the Engineer's review and
approval, before construction is started on the revised portion.
(a) Falsework Drawing
The falsework Drawing shall include but not be limited to the following:-
(i) The traffic openings.

(ii) A superstructure placing diagram, showing proposed concrete placing
sequence and construction joints location.
(iii) Assumed values of soil bearing capacity for both wet and dry
conditions, as determined by the Contractor.
(iv) Anticipated total settlements of falsework and forms.
(v) Details of drainage, if any.
(vi) Details of drainage protection (or scouring/undermining protection) of
footing and/or foundations, including locations of existing utilities,
excavations, recent fills if any.
(vii) Details of all elements required to insure the free movements of
concrete due to shrinkage.
(viii) Proposed cambers to compensate deflections, and falsework
adjustments according to the various stages of the construction and
the concrete placing sequence.
(ix) Details of joints, joists, bracings and major arrangements to insure
vertical and horizontal stability in all directions and at all stages of
operations.
(x) Manufacturers' recommendations and/or other operating
recommendations as required for the justification of the design.
When a schedule for placing concrete is shown on the contract plans, no

deviation shall be permitted therefrom unless approved in writing by the
Engineer.
Anticipated total settlement shall not exceed 25 mm. This shall include
falsework footing settlement and joints take-up. Deck slab forms between
girders shall be constructed with no allowance for settlement relative to the
girders.
(b) Falsework Calculations
The calculations must show the stresses & deflections of all supporting
members. The design of falsework shall be based upon the maximum loads,
the maximum stresses and deflections and the conditions listed below. The
stresses listed are based upon the use of undamaged high quality materials
and such stresses shall be reduced by the Contractor if lesser quality materials
are to be used. The Contractor shall be responsible for the proper evaluation of
his falsework material and design of falsework to carry safely the actual loads
imposed:
Page 18 – 2
(i) The design loads for falsework shall consist of the sum of dead and
live vertical loads and horizontal load.
(ii) The vertical design loads for the combined live and dead loads shall
not be less than the actual required loads with due allowance for
dynamic loads. However, it shall not be less than 0.5 t/m².
(iii) Dead loads shall include the weight of concrete, reinforcing steel,
forms and falsework.
(iv) Live loads shall consist of the actual weight of the equipment to be
supported by falsework, applied as concentrated loads at the points of
contact and a uniform load of not less than 0.1t/m² applied over the
area supported, plus 0.11 t/lm applied at the outside edges of deck
overhangs.
(v) The horizontal loads to be resisted in any direction by diagonal
bracing, ties or other means approved by the Engineer shall not be
less than 2 percent of the total dead load.
(vi) Falsework footings shall be designed to carry the load imposed upon
them without exceeding the estimated soil bearing capacity and
anticipated settlements.
(vii) If the concrete is to be prestressed, the falsework shall be designed to
support increased or readjusted loads caused by the prestressing
forces.
(viii) Joists supporting slabs and overhangs shall be considered as
falsework and they shall be designed for the maximum loadings and
deflections loading and deflections permissible on jacks, brackets,
columns joists and other manufactures devices shall not exceed the
manufacturer's recommendations and in all cases their deflections
shall be less than 1/270 of their clear span.
If requested by the Engineer, the Contractor shall furnish catalogue data listing
the manufacturer's recommendations for manufactured devices and perform
tests as necessary to demonstrate the adequacy of any such device proposed
for use.
Falsework designed for prestressed concrete shall allow for the required free
movements during prestressing operations.
When footing foundations are to be used, the bearing capacity of the soils shall
be determined by the Contractor using the Plate Load Test method. The soil
surface must be prepared adequately to allow for a relevant implementation of
this test. Tests shall be carried out in both dry and wet conditions
(c) Falsework over or Adjacent to Roadways

In addition to the minimum requirements specified above, falsework over or
adjacent to roadways, where falsework opening are specified, shall be
designed and constructed so that the falsework will be stable if subjected to
impact by vehicles. The falsework design in such cases shall include, but not
be limited to the following minimum provisions:
(i) The vertical design load of falsework bents, including footings and
caps which support the portion of the falsework over openings shall
Page 18 – 3
be increased to not less than twice the design load calculated in

accordance with Sub-clause 1803 (1) (b).
(ii) Each falsework post adjacent to openings shall be securely anchored
to its supporting footing or otherwise laterally restrained at its base so
as to withstand a 0.9t force applied at the base of the post in any
direction except toward the road track.
(2) Construction
The falsework shall be constructed to substantially conform to the falsework Drawing.
The materials used in the falsework construction shall be of the quality necessary to
sustain the stresses required by the falsework design.
The workmanship used in falsework construction shall be of such quality that the
falsework will support the loads imposed on it without excessive settlement to take-up
beyond that shown on the falsework Drawing. Falsework shall be founded on a solid
footing safe against undermining, protected under softening, and capable of supporting
the loads imposed on it. When falsework is supported on piles, the piles shall be driven
to a bearing value determined in accordance with IS 2911.
When falsework is over or adjacent to roadways or waterways, all details of the

falsework system which contribute to horizontal stability and resistance to impact shall
be installed at the time each element of the falsework is erected and shall remain until
the falsework is removed.
Suitable jacks or wedges shall be used in connection with falsework to set the forms at
the required grade and to take up excessive settlement in the falsework either before
or during the placing of concrete.
Camber strips shall be used as approved by the Engineer, to compensate the

falsework deflection, vertical alignment and anticipated structure deflection. The
Contractor shall provide tell-tales attached to the soffit forms and readable from the
ground, in enough systematically placed locations to determine the total settlement of
the entire portion the structure where the concrete is being placed.
Should unanticipated events occur, including settlements that deviate more than plus
or minus 10 mm from those indicated on the falsework Drawing, which in the opinion of
the Engineer would prevent obtaining a structure conforming to the requirements of this
Specification, the placing of concrete shall be discontinued until corrective measures
satisfactory to the Engineer are provided. In the event satisfactory measures are not
provided prior to the initial set of the concrete in the affected area, the placing of
concrete shall be discontinued at a location determined by the Engineer. All
unacceptable concrete shall be removed.
The Contractor shall be responsible for the maintenance of falsework throughout the
construction.
(3) Removal
Page 18 – 4
Falsework shall not be released before the requirements of Sub-clause 1804 (3) are
fulfilled.
Falsework for cast-in situ prestressed concrete shall be released according to the
prestressing sequences shown on the Drawing.
Falsework shall be removed uniformly and gradually to permit the structure to take its
load slowly and evenly.
All falsework material shall be removed. Falsework piling shall be removed upto at
least 600 mm below the surface of the original ground or the bottom or side slope of
excavated areas.
(4) Falsework for Steel Structures
Falsework for steel structures shall comply to the requirements of Sub-clauses 1803
(1) to 1803 (4) in addition to the requirements of this Sub-clause.
Falsework and forms shall be constructed so that any loads applied to girder webs
shall be applied within a distance to a flange or stiffener approved by the Engineer and
shall be distributed in a manner that will not produce local distortion of the web.
Temporary struts and ties shall be provided as necessary to resist lateral loads applied
to the girder flanges and to prevent appreciable relative vertical movement between
the edge of deck forms and the adjacent steel girder.
1804 FORMWORK FOR CONCRETE
(1) Construction of Formwork
Joints in formwork for exposed faces shall, unless otherwise specified, be evenly
spaced and horizontal or vertical and shall be continuous in a regular pattern.
All joints in formwork shall be water tight. Where reinforcement projects through
formwork, the form shall fit closely round the bars.
Formwork shall be so designed that it may be easily removed from the work without
damage to the faces of the concrete. It shall also incorporate provisions for making
minor adjustments in position, if required, to ensure the correct location of concrete
faces. Due allowance shall be made in the position of all formwork for movement and
settlement under the weight of fresh concrete.
Surfaces at slopes less than 20° may be formed by screeding. Surfaces at slopes
between 20° and 30° shall generally be formed if the Contractor can demonstrate to
the satisfaction of the Engineer that such slopes can be screeded with the use of
special screed boards to hold the concrete in place during vibration.
Horizontal or inclined formwork to the upper surface of concrete shall be adequately

secured against uplift due to the pressure of fresh concrete. Formwork shall also be
tied down or otherwise secured against floating within the body of the concrete.
Page 18 – 5
The internal and external angles on concrete surfaces shall be formed with fillets and
chamfers of the sizes shown on the Drawing unless otherwise instructed by the
Engineer.
Supports for formwork may be bolted to previously placed concrete provided the type
of bolt used is acceptable to the Engineer. If metal ties through the concrete are used
in conjunction with bolts, the metal left in shall not be close to the face of the concrete
by less than 50mm.
Formwork shall not be re-used after it has suffered damage which is sufficient to impair
the finished surfaces of the concrete.
Where circumstances prevent easy access within the form, temporary openings shall
be provided through the formwork for cleaning and inspection.
Shear keys of the size and shape as indicated on the Drawing shall be provided in all
construction joints.
Where precast concrete elements are specified for use as permanent formwork, or
proposed by the Contractor and agreed by the Engineer, they shall comply with the
requirements of formwork as specified in the Specifications in respect of surface finish,
strength and rigidity. Such elements shall be set true to line and level within the
tolerances prescribed for the appropriate class of finish in Clause 1806 and fixed so
that they cannot move when concrete is placed against them.
(2) Preparation of Formwork
Before any reinforcement is placed into position within formwork, the latter shall be
thoroughly cleaned and then dressed with a release agent. The agent shall be either
suitable oil incorporating a wetting agent, an emulsion of water suspended in oil or low
viscosity oil containing chemical agents. The Contractor shall not use an emulsion of
oil suspended in water nor any release agent which causes staining or discoloration of
the concrete, air holes on the concrete surface, or retards the set of the concrete or
affects the strength of concrete.
In order to avoid colour differences on adjacent concrete surfaces, only one type of
release agent shall be used in any one section of the works.
In cases where it is necessary to fix reinforcement before placing formwork, all surface
preparation of formwork shall be carried out before it is placed into position. The
Contractor shall not allow reinforcement or prestressing tendons to be contaminated
with formwork release agent.
Before placing concrete all dirt, construction debris and other foreign matter shall be
removed completely from within the placing area.
Before concrete placing commences, all wedges and other adjusting devices shall be
secured against movement during concrete placing and the Contractor shall maintain a
watch on the formwork during placing to ensure that no movement occurs. If any
movement noticed, the formwork shall be set right immediately.
Page 18 – 6
(3) Removal of Formwork
Formwork shall be carefully removed without shock or disturbance to the concrete. No

formwork shall be removed until the concrete has gained sufficient strength to
withstand any stresses safely to which it may thereby be subjected.
The minimum periods which shall elapse between completion of placing concrete and
removal of forms are given in Table 18-1 and apply to ambient temperatures higher
than 10°C. At lower temperatures or if cement other than ordinary Portland are
involved, the Engineer may instruct longer periods.
Alternatively, formwork may be removed when the concrete has attained the strength
set out in Table 18.1, provided that the attained strength is determined by making test
cubes and curing them under the same conditions as the concrete to which they refer.
Compliance with these requirements shall not relieve the Contractor of his obligation to
delay removal of formwork until the removal can be completed without damage to the
concrete.
If the Contractor wishes to strip formwork from the underside of arches, beams and
slabs before the expiry of the period for supports set out above, it shall be designed so
that it can be removed without disturbing the supports. The Contractor shall not
remove supports temporarily for the purpose of stripping formwork and subsequently
replace them.
As soon as the formwork has been removed, bolt holes in concrete faces other than
construction joints which are not required for subsequent operations shall be
completely filled with mortar sufficiently dry to prevent any slumping at the face. The
mortar shall be mixed in the same proportions as the fine aggregate and cement in the
surrounding concrete and with the same materials and shall be finished flush with the
face of the concrete.
After removal of the formwork, the date of casting of concrete shall be marked on the
surface of related concrete by water proof paint/marker for estimation of curing time.
Table 18.1: Minimum Periods for Formwork Removal
Minimum Strength to
Position of Formwork period be attained
for
temperatures
over 10° C
Vertical or near vertical faces of mass concrete
24 hours 0.2 fck
Vertical or near vertical faces of reinforced walls, beams columns
48 hours 0.3 fck
Underside of arches beams and slabs (formwork only)
Page 18 – 7
4 days 0.5 fck

Supports to underside of arches, beams and slabs
14 days fck
Arched linings in tunnels and underground works
24 hours 4 N/mm²
Note: fck is the Characteristic Strength for the class of concrete used.
1805 SURFACE FINISH ON FORMED SURFACES
Classes of Finish
The surface finish to be achieved on formed concrete surfaces shall be as shown on the
Drawing and are defined hereunder:-
(1) Class Fl Finish
This finish is for surfaces against which backfill or further concrete will be placed.
Formwork may be sawn boards, sheet metal or any other suitable material which will
prevent the loss of laitance from the concrete being placed.
(2) Class F2 Finish
This finish is for surfaces which are permanently exposed to view but the highest
standard of finish is not required. Forms to provide a Class F2 finish shall be faced with
wrought thicknessed tongued and grooved boards with square edges arranged in a
uniform pattern and close jointed or with suitable sheet material. The thickness of
boards or sheets shall be such that there shall be no visible deflection under the
pressure exerted by the concrete placed against them.
Joints between boards or panels shall be horizontal and vertical unless otherwise
directed. In this type of finish pitting, fins, surface discoloration and other minor defects
shall be remedied at the time and by methods agreed by the Engineer.
(3) Class F3 Finish
This finish is for surfaces which will be in contact with water flowing at high velocity,
and for surfaces prominently exposed to view where good appearance is of special
importance. To achieve this finish, which shall be free of board marks, the formwork
shall be faced with plywood or equivalent material in large sheets. The sheets shall be
arranged in an approved uniform pattern. Wherever possible, joints between sheets
shall be arranged to coincide with architectural features or changes in direction of the
surface.
All joints between panels shall be vertical and horizontal unless otherwise directed.
Suitable joints shall be provided between sheets to maintain accurate alignment in the
plane of the sheets. Unfaced wrought boarding or standard steel panels will not be
permitted for Class F3 finish. The Contractor shall ensure that the surface is protected
from rust marks, spillages and stains of all kinds.
(4) Curved Surfaces
Page 18 – 8
For curved surfaces where F2 or F3 finishes are called for, the formwork face shall be
built up of splines cut to make a tight surface which shall then be dressed to produce
the required finish.
Alternatively single curvature surfaces may be faced with plastic or plywood linings
attached to the backing with adhesive or with escutcheon pins driven flush. Linings
shall not bulge, wrinkle or otherwise deform when subjected to temperature and
moisture changes.
(5) Tolerances
All parts of formed concrete surfaces shall be in the positions shown on the Drawing
within the tolerances set out in Table 18.2.
In cases where the Drawing call for tolerances other than those given in Table 18.2 the
Drawing shall rule.
Where precast units have been set to a specified tolerance, further adjustments shall
be made as necessary to produce a satisfactory straight or curved line. When the
Engineer has approved the alignment, the Contractor shall fix the units so that there is
no possibility of further movement.
Table 18.2: Tolerances
Class of finish Tolerances in mm (See Note)

A B C
F1 10 10 + 25 to - 10
F2 5 10  15
F3 2 5  10
Note: The tolerances A, B and C given in the table are defined as follows:
A is an abrupt irregularity in the surface due to misaligned formwork or

defects in the face of the formwork.
B is a gradual deviation from a plane surface as indicated by a straight
edge 3 m long. In the case of curved surfaces the straight edge shall
be replaced by a correctly shaped template.
C is the amount by which the whole or part of a concrete face is displaced
from the correct positions shown on the Drawing.
1806 FINISHES ON UNFORMED SURFACES
Horizontal or nearly horizontal surfaces which are not cast against formwork shall be finished
to the class shown on the Drawing and defined hereunder.
(1) UF 1 Finish
All surfaces on which no higher class of finish is called for on the Drawing or instructed
by the Engineer shall be given a UF 1 finish.
Page 18 – 9
The Concrete shall be levelled and screeded to produce a uniform plain or ridged
surface, surplus concrete being struck off by a straight edge immediately after
compaction.
(2) UF 2 Finish
This is a floated finish for roof or floor slabs and other surfaces where a hard trawled
surface is not required.
The surface shall first be treated as a Class UF 1 finish and after the concrete has
hardened sufficiently, it shall be floated by hand or machine sufficient only to produce a
uniform surface free from screed marks.
(3) UF 3 Finish
This is a hard trowelled surface for use where weather resistance or appearance is
important, or which is subject to high velocity water flow.
The surface shall be floated as for a UF 2 finish but to the tolerance stated below in
Sub-clause 1806 (5). When the moisture film has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, it shall be
steel-trowelled under firm pressure to produce a dense, smooth uniform surface free
from trowel marks.
(4) Finishing of Bridge Decks
A smooth riding surface of uniform texture true to the required grade and cross section
shall be obtained in all bridge roadway decks.
The placing the concrete in bridge roadway decks shall not be permitted until the
Engineer is satisfied that appropriate methods, equipment such as concrete finishers
and experienced operators, are employed to finish the deck, and all necessary
finishing tools and equipment are available on site and in satisfactory condition for use.
Bridge deck surfaces shall be within the tolerances stated below in Sub-clause 1806
(5) for UF3 finish and comply with the following additional requirements:-
The finished surface of the concrete shall be tested by means of a straightedge 3 m

long and when the surface is not to be covered by bituminous surfacing or other cover,
the surface of the concrete shall not vary by more than 3 mm measured from the lower
edge of the straightedge.
(5) Tolerances
All parts of unformed concrete surfaces shall be in the positions shown on the Drawing
within the tolerances set out in Table 18.3.
In cases where the Drawing call for tolerances other than those given in Table 18.3 the
Drawing shall rule.
Page 18 – 10
Class of finish Tolerances in mm (see Note)

A B C
UF1 Not applicable 10 + 20 to - 10
UF2 Nil 10 + 20 or - 10
UF3 Nil 5 +12.5 or - 7.5
Note: The tolerances A, B and C given in the table are defined as follows:
A is the maximum allowable value of any sudden change of level in the

surface.
B is the maximum allowable value of any gradual irregularity of the

surface, as indicated by the gap between the surface and a three metre
long straight edge or correctly shaped template placed on the surface.
C is the maximum allowable value of the difference in level or position

between a three meter long straightedge or correctly shaped template
placed on the surface and the specified level or position of that surface.
1807 REMEDIAL WORK TO DEFECTIVE SURFACES
If on removal of any formwork the concrete surface is found to be defective in any way, the
Contractor shall make no attempt to remedy such defects prior to the Engineer’s inspection
and the receipt of any instructions which the Engineer may give.
Defective surfaces shall not be made good by plastering.
Areas of honey combing which the Engineer agrees, shall be repaired after cutting back to
sound concrete when the concrete is no more than 3 day old. Care shall be taken that
reinforcement and sheathing ducts are not damaged. The cavity shall have sides at right
angles to the face of the concrete. After cleaning out with water and compressed air, a thin
layer of cement grout shall be brushed on to the concrete surfaces in the cavity. It shall then be
filled immediately with the concrete of the same class as the main body. The concrete shall be
prepared from the aggregate of maximum size 0.5 times the depth of the cavity or 20 mm
whichever is the smaller. A form provided with a lip to enable concrete to be placed shall be
used against the cavity. The form shall be filled above the top edge of the cavity.
After seven days the lip of concrete shall be broken off and the surface shall be ground
smooth.
When the concrete is more than three day old, areas of honey combing shall be repaired using
an epoxy bonding agent with a method approved by the Engineer.
Surface irregularities which are outside the limits of tolerance set out in Clause 1806 shall be
ground down in the manner and to the extent instructed by the Engineer.
Blowholes in vertical surfaces shall be filled with laitance or mortar using fine aggregate not
larger than 0.3 mm, rubbed over the affected area with a rubber face float and finished with
polythene.
Defects other than those mentioned above shall be dealt with as instructed by the Engineer.
Page 18 – 11
1808 MEASUREMENT
Except as stated below, formwork shall be measured in square metre of formwork actually in
contact with the finished face of the concrete. No deduction shall be made in the measurement
for openings, pipes, ducts and the like, provided that the area of each is less than 0.50 square
metres. Unless otherwise stated, if the volume or area of concrete has not been deducted
when measuring the concrete, formwork to form box or the void shall not be measured.
Formwork less than 300 mm high to edges of slabs shall be measured in linear metre.
Inclined formwork shall be measured in accordance with the following classification:
(i) Horizontal; 85 to 90° inclination from vertical

(ii) Sloping; 10 to 85° inclination from vertical
(iii) Battered; 0 to 10° inclination from vertical
(iv) Vertical; 0°
(v) Slopping upper surfaces inclined at more than 15° from the horizontal.
Formwork required for lean concrete, to form construction joints and shear keys for future
concrete and other construction surfaces shall not be measured and the costs shall be
included in the rates for other work.
Formwork to contraction and expansion joints shall be measured in square metre on one face
only. The rates shall include for the costs stated below and for forming recesses for sealant and
channels for grout.
The measurement of formwork is inclusive of the measurement for formwork finished surface,
shoring, staging, scaffolding and other accessories required for erection and removal of the
formwork.
Formwork less than 300mm high to edges of slab shall be measured in the linear metre.
1809 PAYMENT
The formwork shall be paid as per the contract unit rate. In addition to those specified in Clause
112 the rates for formwork shall include the cost of submission of details, transportation and
use of all materials for formwork and falsework, erection including provision of supports, fillets
and chamfers 75 mm and less in width, bolts, ties, fixings, cutting to waste, drilling or notching
the formwork for reinforcement where required, working around pipes, ducts, conduits and
waterstops, temporary openings, cleaning, dressing, removal of formwork and falsework, filling
bolt holes and any remedial work and for complying with Clauses 2007, 2009, 2012, 1902, and
Section 1800 including all incidental works required to complete the work as per Specification.
The payment for unformed surfaces of concrete shall be deemed included in the contract unit
rate of the relevant concrete.
Page 18 – 12
SECTION 1900 - BEARINGS AND EXPANSION JOINTS
Page No.
1901 EXPANSION JOINTS 19–1

1902 BEARINGS 19–12
SECTION 1900 - BEARINGS AND EXPANSION JOINTS
1901 EXPANSION JOINTS

(1) Scope
This Clause covers the works in connection with the fabrication and placing of
expansion joints as shown on the Drawing, conforming to this Specification or as
Expansion joints are defined as joints placed in gaps between the deck ends or the
deck and the back wall. The purpose of the expansion joint is to permit free movement
of the bridge deck due to thermal effect and rotational articulation, to prevent cracking
in the surface layer by effectively supporting the surfacing and to prevent water and
water-borne contaminants from invading the bearing area and substructure.
(2) General Requirement
(a) The expansion joints shall be robust, strong, durable, watertight and
replaceable. It shall be provided over the full width of the deck and follow the
profile including kerb, footpath and facia. Expansion joints shall be obtained
only from the approved manufacturers and be of proven type. Site fabricated
expansion joints shall be prohibited.
(b) The expansion joints shall be strong enough to withstand the movements,
displacements and rotations specified on the Drawing in conjunction with the
loads prescribed in the Code of Practice adopted for the design of the
structure without over-stressing any part in terms of "working load"
requirements or exceeding the requirement of serviceability for limit state
design. Any strengthening of the supporting members required to resist forces
imparted by the joint to the structure shall be at the Contractor's own expense.
(c) The expansion joints shall be vibration free, resistant to mechanical wear and
other forms of abrasion and shall resist corrosion. It shall have good riding
characteristics, be skid resistant and silent. It shall have provision of the
disposal of water or grit collecting in the joint and be of such construction so as
to facilitate easy inspection, maintenance and repair.
(d) Prior to manufacture of the joints, the Contractor shall submit detail Drawing
showing exact positions of all elements. Only after the approval of the
Drawing by the Engineer, the Contractor shall start fabricating those parts.
(e) The Contractor may offer proprietary expansion joints already tested
elsewhere in lieu of the type specified in the contract. The proprietary joints
offered by the Contractor shall comply in all respects with the manufacturer's
specifications and meet the required range of movements and rotations and
be fit for the purpose of ensuring satisfactory long term performance in the
bridge.
(f) The compression seal (for slab seal expansion joint) and strip seal (for strip
seal expansion joint) shall only be obtained from the reputed manufacturers.
Following types of Expansion Joints are covered by this Specification:
 Steel Plate Sliding Expansion Joints
SECTION 1900 BEARINGS AND EXPANSION JOINTS Page 19–

1
 Buried Joints
 Elastomeric Slab Seal Joint
 Strip Seal Joint
(3) Steel Plate Sliding Expansion Joints

(a) In this type of joint, the wearing coat shall be made continuous over the joint.
The other alternative shall be to keep a gap in the wearing coat, which is filled
up with a seal, and filler, to be provided in extremely hot areas.
(b) Materials for steel plates shall conform to IS: 2062. The exposed metallic
components shall be galvanized or coated with approved anti-corrosive paint.
The thickness shall be 20 mm or so for obtaining satisfactory performance.
(c) Plates shall be placed to the line, grade and expansion gap shown on the
Drawing with any adjustment required for temperature, care being taken with
the top of the plates.
(d) Plates shall be firmly held in place during concreting by methods approved by
the Engineer.
(e) Any temporary bolts or other fixing to hold the expansion plates in their
correct positions which prevent relative movement of the adjacent parts of the
joint shall be removed as soon as the concrete has set sufficiently. In any
case, temporary bolts or other fittings shall be removed within 6 hours of
placing concrete unless otherwise directed by the Engineer.
(f) Care shall be taken to prevent damage to expansion joint plates or its coating
(g) If any damage occurred to the plates and coatings, shall be restored by the
Contractor to the satisfaction of the Engineer.
(4) Buried Joints

(a) The components of this type of joint shall be at least 2 mm thick corrugated
copper plate placed slightly below the wearing coat, 20 mm thick compressible
fibre board to protect the edges, 20 mm thick pre-moulded joint filler filling the
gap upto the top level of the wearing coat, sealed with a joint sealing
compound.
(b) 8 mm dia, 100 mm long nails spaced at 300 mm c/c along the centerline of the
plate shall be welded to the bottom surface of the copper plate to protrude
vertically into the joint gap in order to prevent dislodging of the plate.
(c) The plate and the nails shall be protected against corrosion by galvanizing or
any approved anti-corrosive coating with a minimum thickness of 100 micron.
These shall be completely free of oil, rust, loose paint or other similar material
before application of anti-corrosive coating.
(d) The material used for filling expansion joint shall be bitumen impregnated felt
elastomer or any other suitable material, as specified on the Drawing.
Impregnated felt shall conform to the requirements of IS: 1838, and shall be
got approved from the Engineer. The joint filler shall consist of large pieces.
Assembly of small pieces to make up the required size shall be avoided.
(e) Expansion joint materials shall be handled with care and stored under cover
by the Contractor to prevent damage.
(f) Any damage occurring after delivery shall be made good to the satisfaction of
the Engineer at the expense of the Contractor.

2
(g) Joint gaps shall be constructed as shown on the Drawing. Surfaces of joint
grooves shall be thoroughly cleaned with a wire brush to remove all loose
materials, dirt and debris, and then washed or jetted out.
(h) Pre-moulded expansion joint filler shall not be placed in position prior to the
placing of the abutting material. If the two adjacent surfaces of the joint are to
be placed at different times, this type of joint filler shall not be placed until the
second face is about to be placed.
(i) Sealant shall be installed in accordance with the manufacturer's
recommendations and all appropriate requirements for joint face priming.
(j) Sealant spilt or splashed onto finished surfaces of the bridge during joint filling
operations shall be removed and the surfaces made good to the Engineer's
approval.
(k) No joint shall be sealed until inspected by the Engineer and approval is given
to proceed with the work.
(5) Elastometric Slab Seal Expansion Joint
(a) Material
(i) Steel inserts shall conform to IS:2062. Use of any other materials like
fibre-glass or similar material shall not be permitted.
(ii) Elastomer for elastomeric slab unit (ESU) shall conform to clause
915.1 of IRC:83 (Part 2), compounded to give hardness IRHD 60±5,
subject to the following additional stipulations:
 Chloroprene (CR) only shall be used in the manufacture of
elastomeric expansion joints. No reclaimed/natural rubber or
vulcanized wastes shall be used.
 The chloroprene material used in the manufacture of
elastomeric (expansion joints) shall be Neoprene WRT,
Bayprene 110, Skyprene BS or Denka S-40V
 The chloroprene content of the compound shall not be lower
than 60 percent by weight. The ash content shall not exceed
5 percent (as test conducted in accordance with ASTM D-
297).
 EPDM and other similar candidate elastomers for expansion
joints shall not be permitted.
(iii) Elastomeric plugs.
(iv) Spacer bars, marked with center to center distance of fixing holes.
(v) Fixing bolts and nuts made of stainless steel.
(vi) Anchor bars comprising hooked anchor stiffeners welded with lower
steel inserts and sinusoidal anchor bars welded with horizontal leg of
the edge steel inserts. The elaborate anchoring arrangements of steel
inserts shall be permanently welded/tied with the steel reinforcement.
(b) Fabrication
(i) Steel inserts shall be grit blasted and provided with epoxy paint.
(ii) Edges of reinforcing steel sections shall be rounded.
(iii) Expansion joints shall be fully moulded to the required size in one
single vulcanizing operation including the encasing layers as integral
and homogeneous part.

3
(iv) Tolerances of fabrication shall be as follows:

 Plan dimension ± 5 mm
 Total height ± 3 mm
(c) Supply and Handling
(i) The Contractor shall supply all steel-reinforced elastomeric expansion

joints including bolts, nuts, sealant, plates and all other accessories
for the effective installation of the joints including angled jointing
sections for kerbs.
(ii) Expansion joint material shall be handled with care and stored under cover to
prevent damage. Any damage occurring after delivery shall be made good at the
expense of the Contractor to the satisfaction of the Engineer.
(d) Installation
Expansion joints shall be installed as per Drawing. Steel inserts, spacer bars,
concreting of pockets, fixing of elastomer slab unit and presetting, etc., shall
be done as per the followings:
Steel Inserts
(i) Deck casting shall be done leaving pockets or recess for steel inserts
and anchors of the expansion joint as per the Drawing.
(ii) Steel inserts shall be lowered at the appropriate location inside the
pocket.
(iii) The top of the insert shall be flush with the finished level of wearing
course maintaining the camber.
(iv) Spacer bars shall be fitted under proper supervision.
(v) Anchor rods shall be tied/welded with the existing deck main
reinforcement, maintaining level and alignment.
(vi) Welding between anchor rods and deck reinforcement is preferable. If
welding is not possible, strong steel tie wires shall be used for
fastening, under proper supervision.
Spacer Bar
(i) Spacer bars shall be used to ensure proper positioning of bolts and
also leveling of the steel inserts during fixing of the same with the deck
reinforcement and casting second stage concreting in the pocket
thereafter.
(ii) The second stage concreting operation shall be started within 24
hours of fixing the steel inserts. Spacer bars shall be removed just
after concreting is finished. If there is a substantial time lag between
fixing of inserts and concreting, then any one of the following methods
shall be adopted, depending on the support condition:
 For simply supported bridge resting on simple elastomeric bearings,
(with no dowel pins), insert shall be placed in position with spacer
bars at every alternate joints. Such joints shall be called restrained
joints hereafter. In other words, inserts shall not be fixed
simultaneously at two ends of one span. If the above condition is

4
satisfied, inserts with spacer bars shall be kept in position for a

substantially longer period at such restrained joints. Spacer bars shall
be removed after concreting of such restrained joints and inserts
placed in position with spacer bars at the other unrestrained joints
thereafter.
 For bridges resting on other than elastomeric bearings (including
bearings with dowel pins at one end), after placing and aligning the
inserts and securing the same, the spacer bars shall be removed.
Concreting shall be done with great care so that insert are not
dislocated or distorted.
(iii) While removing the spacer bar after concreting, care shall be taken to
see that the concrete is not damaged during withdrawal of spacer bar.
If the spacer bar happens to be snugly fitted, it shall not be pulled by
any means: it shall be gas cut in two pieces and then removed.
Concreting of Pocket
(i) Concreting of pocket shall be done with great care using proper mix
conforming to grade similar to that of the deck casting besides
ensuring efficient bonding between deck and steel insert. Care shall
be given for ensuring efficient bonding with the already cast concrete.
(ii) Needle vibrations shall be used. Care shall be taken so that the
position of steel inserts is not disturbed during vibration.
(iii) Spacer bar shall be removed within an appropriate time before the
joint is required to permit movement.
Fixing of Elastomeric Slab Unit (ESU)
(i) Special jig shall be used to pre-set the ESU during installation.
(ii) ESU (mounted on the jig) shall be lowered to position.
(iii) The line and level on the ESU shall be adjusted.
(iv) ESU shall be removed and coated with special adhesive
(v) ESU shall be placed in position again, ensuring waterproof joining at
required faces.
(vi) ESU shall be tightened with stainless steel nuts and lock washers in
position. Tightened nuts shall be locked with lock washers.
(vii) Special sealant shall be poured inside the plugholes.
(viii) The elastomeric plugs shall be pressed in position after applying
adhesive on the appropriate surface.
(ix) ESU shall be fitted in position after completion of wearing course.
While completing this part of the wearing course, adequate care shall
be taken to ensure a waterproof joining with the already existing
wearing course.
Pre-Setting
The steel insert unit of expansion joint can be fixed in any month of the year.
The expansion gap between bridge superstructures may vary from time to
time; hence initial fixing distance between fixing points shall depend on the
month of installation of steel insert. The c/c distance between stainless steel

5
fixing of bolts as indicated on the Drawing shall be taken as only nominal. The
same shall be modified by pre-setting depending on:
(i) The difference between the mean temperature of the month of fixing of
steel insert and the annual average temperature
(ii) The elapsed period between the casting and/or pre-stressing and
fixing of steel inserts for calculating the remnant creep and shrinkage.
Special Requirements for Installation
(i) Prior to construction of bridge deck area adjacent to the joint, the
Contractor shall provide detailed working Drawing showing the
location of all bolts, recesses and holes necessary for the installation
of the joint. Reinforcing bars in superstructure shall be amended as
required to ensure that there will be no interference in the installation
of the joint.
(ii) All bearing surfaces and recesses, which are in contact with the joint
assembly, shall be checked with a straight edge to ensure flatness of
profile.
(iii) No holes shall be drilled for fixing bolts within 7 days of concreting.
Holes for the bolts shall be drilled to the size and depth shown on the
Drawings.
(iv) Sections of the jointing making the completed joint shall follow a
straight line.
(v) The fixing bolts shall not be placed in a position until at least 28 days
after stressing is completed in post-tensioned box or beam and slab
structures. Prior to placing sections of jointing, contact surfaces shall
be cleaned to remove all grease, tar, paint, oil, mud or any other
foreign material that may affect adhesion of the sealant.
(vi) Sealant shall only be applied to dry contact surfaces. Sufficient
sealant shall be applied to the contact surfaces to cause extension of
sealant when the jointing is fixed in position.
(vii) Final sealing of the finished expansion joint shall be completed
immediately after completion of installation. All exposed ends, joints
between units and other areas of possible leakage shall be filled with
sealant. All voids between the sides of the jointing and concrete or
plates shall be filled with sealant.
(viii) Bolt cavities shall be cleaned and plugged with neoprene cavity plugs.
Prior to placing the plugs sufficient sealant shall be placed in the
cavities to cause extrusion of the sealant by the plugs.
(ix) All excess sealant shall be removed from the jointing and adjacent
areas.
(f) Acceptance Test
As per Clause 918.7 of IRC-83 (Part 3), necessary quality control certification
by manufacturer in regard to properties of Elastomer and steel shall be
furnished by the Contractor.

6
For severe environment, ozone resistance test as per Clause 915.2.3 of IRC:
83
(Part 2), shall be carried out for elastomer.
The properties of the elastomer shall conform to Table 1 of Clause 915.2 of

IRC:83 (Part 2). The acceptance testing for elastomer material shall conform
to Clause 918.4.1.2 of IRC:83 (Part 2) with additional criteria as stated in Sub-
clause 1902 (5).
The fabricated expansion joint shall be subjected to the following acceptance

tests:
(i) Routine test: Each expansion joint shall be tested for a least 100
cycles for a test movement, which shall be 10 per cent more than the
design expansion contraction movement.
(ii) In addition to routine test, one out of every 20-expansion joint shall be
subjected to the test movement for 4000 cycles.
(iii) The type test for abrasion resistance shall be carried to for one joint
out of every 20 nos. as per IS: 3400 (Part 3) and the standard
deviation shall be within ± 20 per cent.
N.B.: The Contractor’s manufacturer shall have in-house testing facility.
Alternatively, the testing shall be got done by him at his expense at
any testing establishment selected by the Engineer. A manufacturer
who cannot carry out the acceptance test shall not be entitled to
supply elastomeric slab seal joint.
(6) Strip Seal Joint
(a) Components
Strip seal expansion joint shall comprise the following items:
(i) Edge Beams: This special claw leg profiled member shall be extruded
rolled steel section combining good weldability with notch toughness.
(ii) Strip Seal: This shall be of chloroprene with high tear strength,
insensitive to oil, gasoline, and ozone. It shall have high resistance to
aging. This component, provided to ensure water tightness, shall
have bulbous shape of the part of the seal, which is inserted into the
groove, provided in the edge beam. The seal should be vulcanized in
single operation for minimum full length of joint.
(iii) Rigid Anchorage: This shall be made of weldable steel connecting the
rigid anchorage with deck reinforcement.
(b) Material
(i) The steel shall conform to steel grade Rst 37-2 of German Standard
or equivalent.
(ii) Chloroprene of strip seal shall conform to Clause 915.1 of IRC:83
(Part 2). The properties of chloroprene shall conform to Table 19.1.
(iii) Anchoarge steel shall conform to IS:2062
(iv) Anchor loop shall conform to IS:2062

7
Sealing element shall be made of chloroprene and shall be a extended

section. The working movement range of the sealing element shall be at least
80 mm with a maximum of 100 mm at right angles to the joint and + 40mm
parallel to the joint . The properties of strip seal element shall be as given in
the Table 19.1.
Table 19.1: Specifications for Strip Seal Element (Chloroprene)
Property Specified Value

Hardness 63 + 5 Shore A
Tensile Strength Min. 11 N/sq.mm
Elongation at fracture Min 350 per cent
Tear Propagation Strength
Longitudinal Min 10 N/mm
Transverse Min 10 N/mm
Shock Elasticity Min 25 per cent
Abrasion Min 220 mm3
Residual Compressive Strain Max 28 per cent
(22 h/700 C / 30 per cent strain)
Ageing in hot air

(14 days/10 0 C)
Change in hardness Max +5 Shore A

Change in tensile strength Max – 20 per cent
Change in elongation at fracture Max – 20 per cent
Ageing in ozone
(24 h/50 pphm/250 C/20 per cent strain) No cracks
Swelling behaviour in Oil
(116 h/25 per cent C) ASTM Oil No.
Volume change Max 5 per cent
Change in hardness (ASTM Oil No. 3) Max 10 Shore A
Volume Change Max. 25 percent
Change in hardness Max 20 shore A
Cold Hardening Point Min –350 C
(c) Fabrication (Pre-installation)
(i) Rolled steel profiles for edge beams shall be long enough to cater for
a 2-lane carriageway. These shall be cut to size of actual
requirements by means of a mitre box saw. Alignment of the cut-to-
size steel profiles shall then be made in accordance with the actual
bridge cross-section on worktables. For this purpose, the contour of
bridge cross-section shall be sketched onto these tables. After the
steel profiles are aligned, they shall be chucked to the tables by
means of screw clamps and tacked by arc welding.
(ii) Anchor plates shall be cut to the required size by gas cutting. These
shall be welded to the edge beams.

8
(iii) Anchor loops shall be bent to the required shape and welded to
anchor plates.
(iv) The finally assembled joints shall then be clamped and transported to
the work site.
(d) Handling and Storage

(i) For transportation and storage, auxiliary brackets shall be provided to
hold the joint assembly together.
(ii) Expansion joint material shall be handled with care. It shall be stored
under cover on suitable lumber padding to prevent damage. Any
damage occurring after delivery shall be made good by the Contractor
at his expense to the satisfaction of the Engineer.
(e) Installation
(i) The width of the gap to cater for movement due to thermal effect, pre-
stress, shrinkage and creep, superstructure deformations (if any) and
sub-structure deformations (if any) shall be determined and intimated
to the manufacturer. Depending upon the temperature at which the
joint is likely to be installed, the gap dimension shall be pre-set.
(ii) 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 Drawing 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.
(iii) The recess shall be shuttered in such a way that dimensions in the
joint is maintained. The formwork shall be tight.
(iv) Immediately prior to placing the joint, the pre-setting shall be
inspected. Should the actual temperature of the structure be different
from the temperature provided for pre-setting, correction of the pre-
setting shall be done. After adjustment, the brackets shall be tightened
again.
(v) The joint shall be lowered to the pre-determined position. Following
placement of the joint in the prepared recess, the joint shall be levelled
and finally aligned and the anchor loops on one side of the joint
welded to the exposed reinforcement bars of the structure. Upon
completion, the same procedure shall be followed for the other side of
the joint. With the expansion joint finally held at both sides, the
auxiliary brackets should be released, allowing the joint to take up the
movement of the structure.
(vi) Concrete shall then be filled into the recess. The packing concrete
shall feature low shrinkage and have the same strength as that of the
superstructure, but in any case not less than M 35/10 grade. After the
concrete has cured, the movable installation brackets still in place
shall be removed.
(vii) Rolled up neoprene strip seal shall be cut into the required length and
inserted between the edge beams by using a crow bar pushing the
bulb of the seal into the steel grooves of the edge beams. A landing to
a bead shall be formed in the thickened end of the edges of the seal,

9
which would force the thickened end against the steel beam due to
wedge effect when the strip seal is buttoned in place.
(viii) As soon as the concrete in the recess has become initially set, a study
ramp shall be placed over the joint to protect the exposed steel beams
and neoprene seals from traffic. Expansion joint shall not be exposed
to traffic loading before the carriageway surfacing is placed.
(ix) The carriageway surfacing shall be finished flush with the top of the
steel sections. The actual junction of the surfacing/wearing coat with
the steel edge section shall be formed by a wedge shaped joint with a
sealing compound. The horizontal leg of the edge beam shall be
cleaned beforehand. It shall be ensured that thorough compaction of
the surfacing in is made in order to prevent any premature depression
forming in it.
(f) Acceptance Test
(i) All steel elements shall be finished with corrosion protection system.
(ii) For neoprene seal, the acceptance test shall conform to the
requirements stipulated in Table 19.1. It shall also be stretch tested.
The Contractor shall produce test certificates conducted in a
recognized and approved laboratory.
(iii) Investigation of fatigue strength of the section with anchorage to
withstand 2 x 106 load change cycles without showing signs of
damage shall be required. The Contractor shall produce a test
certificate in this regard, conducted in a recognized and approved
laboratory.
(iv) The Contractor shall produce test certificates indicating that
anchorage system had been tested in a recognized and approved
laboratory to determine optimum configuration of anchorage assembly
under dynamic loading.
(v) The Contractor shall satisfy the Engineer that water tightness test for
the type of joint has been carried out in an approved laboratory to
check the water tightness under a water pressure of 4 bars.
(vi) The Contractor shall produce evidence of satisfactory performance of
this type of joint.
(7) Measurement
Expansion joint shall be shall be measured in linear meter inclusive of all axilliary and
incidental works. Measurement shall be made along the joint between the outside
faces of the deck.
(8) Payment
Expansion joint measured as provided above shall be paid at the contract unit rate
which shall be the full and the final compensation to the Contractor as per Clause 112
and for all incidental costs necessary to complete the works as per these
Specifications.
1902 BEARINGS

10
(1) Scope
The Clause covers the work in connection with the furnishing and fixing bearings in
position in accordance with the details shown on the Drawing to the requirements of
these Specifications or as directed by the Engineer.
(2) General
(a) Bearing plates, bars, rockers, assemblies and other expansion or fixed
devices shall be constructed in accordance with the details shown on the
Drawing.
(b) All bearings shall be capable of being replaced during the lifetime of the
structure and shall be robust, durable and proven type obtained from the
approved manufacturers, who can provide complete facilities for raw materials
and finished products.
(c) The Contractor shall exercise care in setting and fixing all bearings in their
correct positions and ensuring that uniformity is obtained on all bearing
surfaces
(d) Bearings shall be handled with care and stored under cover
(e) When bearing assemblies or plates are shown in the Drawing to be placed
(not embedded) directly on concrete, the concrete bearing area shall be
constructed slightly above grade (not exceeding 12 mm) and shall be finished
by grinding.
(f) It shall be ensured that the bearings are set truly level and in exact positions
as indicated on the Drawing so as to have full and even bearing on the seats.
Thin mortar pads (not exceeding 12 mm) may even be made to meet with this
requirement. The finished level plane shall not vary more than 4 mm from the
level shown on the Drawing.
(g) It shall be ensured that the bottoms of girders to be received on the bearings
are plane at the locations of these bearings and care shall be taken that the
bearings are not displaced while placing the girders.
(h) The anchor bolts, if shown on the Drawing, shall be installed to permit true
positioning of the bearing assemblies. The drilled holes for fixing the bolts shall
be completely filled with mortar consisting of 1 part of cement: 2 part of sand.
(3) Metallic (Steel) Bearings
(a) Materials
Materials for Steel Bearing shall comply to Section 2200 of these

Specifications.
Some additional requirements for materials for steel bearings are indicated
below:
(i) Railway axles (R 19) are also acceptable as forged steel for rollers.
(ii) For the purpose of checking the soundness of cast steel components,
castings shall be ultrasonically examined following procedure as per
IS: 7666 with acceptance standard as per IS: 9565. The castings may
also be checked by any other adopted method of non-destructive

11
testing as specified in IS: 1030. Quality level of castings shall be level

3 as per IS: 9565.
(iii) The Contractor shall submit manufacturer’s certificate regarding
composition of raw material. Confirmatory tests regarding composition
may be required by the Engineer. In such cases, the Contractor shall
arrange the facilities for such tests at his own expense.
(iv) Machining: Appropriate machining techniques like tuning, shaping,
planing, drilling, milling, grinding etc shall be adopted depending upon
the required tolerance, surface finish and the size of the item.
(v) Coating
 Mating surface shall be covered with fallow which shall be
removed after installation and grease shall be applied.
 Non mating surfaces shall be painted with red lead or epoxy
based painting.
 If specified, corrosion resistant coating like galvanizing, spray
coating with aluminium or zinc shall be applied.
The grease for bearings shall conform to requirements of IS: 506.
(b) Construction Operations
(i) All work shall conform strictly to the Drawing. Care shall be taken to
ensure that all parts of an assembly fit accurately together.
(ii) Knuckle pins, rolling surfaces of the rollers and bearing surface of the
bearing plates shall be machined and all bolt holes shall be drilled.
The whole bearings shall be fitted and finished as required for good
quality machined work to the satisfaction of the Engineer. However, in
case of bearings which are to be grouted or bedded on a suitable
yielding material on any surface which is to be in permanent contact
with the grout or the yielding material may be left unmahcined.
(iii) In pre-stressed concrete construction where launching of girders is
employed, adequate measures shall be taken to ensure that the roller
assembly is not disturbed in order to avoid slipping or jumping of
rollers due to vibration or jolts.
(iv) During concreting of girders, the bearings shall be held in position
securely by providing temporary connection between the top and
bottom plates in case of fixed bearings and between top plate, base
plate and saddle plate in case of roller cum rocker bearing or by any
other suitable arrangement which prevents the relative displacement
of the components.
(v) In pre-stressed pre-cast girders, where recesses are left on the
underside of girders to receive the anchor bolts, grout holes extending
to the beam sides or to the deck level shall be provided. The cement
sand grout shall have a mix of 1:1 ratio.
(c) Workmanship
(i) Fabrication shall be carried out by approved experienced and

qualified manufacturer to undertake precision engineering of this type.
(ii) Workmanship shall be of good quality, neatly finished and of good
appearance

12
(iii) Castings shall be true to the forms and dimensions shown on the
Drawing and shall be free from pouring faults, sponginess, cracks,
blowholes and other defects on position affecting their appearance or
strength. Warped or distorted castings shall not be accepted.
Exposed surfaces shall be smooth and dense.
(iv) All castings shall be cleaned by sand or shot blasting to remove sand
or scale and to present a clean uniform surface.
(v) All irregularities, fins or risers shall be ground off flush with the
adjacent surface. Castings with visible cracks, blow holes or similar
blemishes shall be rejected, if the imperfections are located in bearing
surfaces or cannot be remedied to the approval of the Engineer.
(vi) Imperfections, which are not located in, bearing surfaces shall be
cleaned out, filled with weld metal of the appropriate composition and
ground flush.
(vii) All surfaces of major components like top plates, saddle plates, base
plates, rollers of the bearings shall be machined all over for correct
alignment, interchangeability, proper fittings etc.
(d) Tolerances
Tolerances for its individual components or of the assembled bearings shall be

as shown on the Drawings or subject to the approval of the Engineer.
Unless otherwise specified, the following tolerances shall be maintained:
Diameter of Rollers, Knuckle Pins and Bores
Tolerances on diameter of rollers and all convex surfaces shall conform to IS:
919.
Tolerances on diameter of all concave surfaces shall conform to IS: 919.
Height of Bearings
Tolerances on height of any component casting shall not exceed +0.5 mm. No
minus tolerance shall be allowed. The edges of all ribs shall be parallel
throughout their length.
Base Plate
Tolerance on length and width of the base plate shall not exceed + 1.0 mm,
tolerance on the thickness of the plate shall not exceed + 0.5 mm. No minus
tolerance shall be allowed. All rocking, rolling and sliding surfaces shall have a
machine smooth finish to 20 micron maximum mean deviation as per IS:3073.
Castings
No minus tolerance shall be allowed in the thickness of any part of the

castings. The edges of all ribs shall be parallel throughout their length.
(e) Installation

13
General
(i) Bearings shall be placed in the positions as shown on the Drawing

with all bearings surfaces in full contact and to the tolerances as
specified.
(ii) Roller and rocker bearings shall be placed so that their axles of
rotations are horizontal and normal to the direction of movement of the
members they support. Upper and lower bearing plates shall be set
horizontal in both directions.
(iii) During installation, the bearings shall be pre-set with respect to the
bearing axis to account for the movement due to the followings:
 Temperature variation between the average temperature prevailing
at the time of installation and the mean design temperature.
 Shrinkage, creep and elastic shortening.
(iv) For girders in gradient, the bearing places shall be placed in a
horizontal plane.
Placing
(i) On supporting structures, pockets shall be provided to receive anchor

bolts; one side of the pocket shall project beyond the bearing plate.
The pocket shall be filled with cement sand mortar of mix 1:1 ratio and
the concrete bearing area shall also be finished level by a thin and stiff
cement sand mortar pad of mix 1:1 ratio (thickness not exceeding 12
mm) just before placing assemblies or bottom plate on the concrete
seat.
(ii) In case of pre-cast girders a recess of 6 mm shall be provided on the
underside with a level finish for housing the bearing plate. A thin and
stiff cement sand mortar pad of mix 1:1 ratio with thickness not
exceeding 3 mm shall be provided over the top plate before lowering
the pre-cast beam in position in order to ensure full and even pressure
on the plate surface.
(iii) It shall be ensured that while placing the girders, the bearings are in
their exact positions as indicated on the approved Drawing and not
displaced therefrom.
(iv) All concrete surfaces to be in contact with the mortar shall be
thoroughly cleaned and kept saturated with water for a period not less
than 24 hours before placing mortar and operations are to be carried
out when the surface temperature of the exposed bearings are the
minimum practical.
(v) No mortar that is more than 30 minutes old after completion of mixing
shall be used.
(vi) After placing and finishing the mortar the bearing shall be checked for
position and shims or other temporary supports removed and the
mortar made good. If the bearing has moved, bearing or the plate
shall be lifted, the mortar removed and the whole procedure repeated.
(vii) Exposed faces of the mortar shall be cured under damp Hessian for 7
days.

14
(viii) Placing of the bearing and mortar shall only be carried out in the
presence of the Engineer
Checking, cleaning and lubrication
Before erection, each bearing shall be uncrated, disassembled and checked.

Any damaged parts shall be made good to the satisfaction of the Engineer.
All bearings with sliding surfaces shall be cleaned and lightly lubricated with
an approved lubricant immediately before erection.
(f) Tests and Standard of Acceptance
(i) The materials to be used in the bearings shall conform to the

specifications laid down in these Specifications.
(ii) A suitable number of complete bearings as specified by the Engineer
shall be tested to 1.25 times the design load. Recovery should be 100
per cent. Contact surfaces shall be examined by illumination source
for any defects, cracks, etc. Segmental rollers shall be tested for
design movements.
(iii) For large lots (consisting of 12 sets or more), a quality control report
shall be submitted as detailed below:
 Unless otherwise agreed upon by the Engineer, the Contractor
shall furnish a complete report on the process of quality control.
The Engineer may appoint an authorized inspection agency for
inspection purpose on his behalf. Such an inspection agency shall
also submit reports to the Engineer regarding various tests
performed on the bearing or certify the acceptance of the bearings.
 Test certificates of all raw materials shall be submitted. If
manufacturer's test certificates are not available for the raw
materials, the bearing manufacturer shall perform the necessary
confirmatory tests as per relevant codes of practice and shall
furnish the test results.
 A detailed quality control system including stage by stage
inspection, starting from raw materials upto the finished bearing
shall be submitted by the Contractor.
 The Engineer shall reserve the right to witness such inspection at
manufacturer's work with or without prior permission of the
manufacturer. For this, the bearing manufacturer shall have in
plant testing facilities.
 In case there is a major discrepancy regarding material, the
Engineer shall reject the whole lot of bearings.
 In case minor defects in fabrication, like welding or machining is
found in the test bearings before destructive testing and if the test
bearing is found to be acceptable after destructive testing, the
minor defects in the test bearings shall not be a bar to the
acceptance of the entire lot.
(4) Special Bearings

15
(a) Spherical Bearing
The bearing shall consist of the following parts:
Bottom Plate
A bottom plate with concave surface shall be integrally cast on circular/square

plate. The bottom plate shall be connected to the sub-structure by means tight
fitted anchor bolts, which shall be embedded in concrete. The material of
bottom plate shall be cast steel.
Pure unfilled quality dimpled PTFE of specified thickness shall be provided on

top of concave surface of bottom plate in order to allow smooth rotation.
Saddle Plate
A saddle plate with square/circular/rectangular top and convex surface at

bottom shall be placed in the concave surface of bottom plate. The radius of
curvature of the convex bottom of the saddle plate shall be slightly less than
that of the concave top surface of the bottom plate to ensure sufficient contact
over a small area. Rotation along all axes shall be permitted along the contact
surface of the saddle plate and the bottom plate. Pure unfilled quality dimpled
PTFE sheet shall be recessed to specified depth of recess over the top of
saddle plate. Suitable elastomeric seal shall be provided on the saddle plate
to prevent ingress of dirt and moisture. The material of saddle plate shall be
cast steel.
Top Plate
The top plate shall have stainless steel plate welded to its bottom which shall
be slide over PTEF. The assembly shall be connected to the superstructure by
tight fitted anchor bolts. Translatory movements along longitudinal axis of
bridge shall be accommodated at the PTFE/Stainless steel-sliding surface.
The material of top plate shall be cast steel.
Guide Plate
Guide plates shall be welded to saddle plate so as to permit only longitudinal

movement. The material of guide plates should be cast steel.
(b) Pin Bearing
Pin bearing shall ensure fixity by arresting translatory movement. The pin
bearing shall not take any vertical load. It shall take care of the longitudinal
horizontal force of the entire superstructure unit as well as transverse
horizontal force developed at the fixed end.
A pin bearing shall consist of a short height structural built-up column

embedded in pier cap and the protruding length inside soffit of deck shall have
rocker plates on all four sides, which permit rotation.

16
Pin bearing shall resist horizontal force from any direction and will permit
rotation but shall not bear any vertical load. The material of pin bearing
including rocker plates shall be high tensile steel conforming to IS:961.
The sliding spherical and pin bearing shall conform to BS:5400, Parts 9.1 and
9.2 and all relevant clauses of this specification. Bearings shall be guaranteed
for design loads and movements. The term bearing shall include the entire
assembly covering all the accessories required for operation, erection and
dismantling for replacement. All bearings shall be of replaceable type. These
bearings shall be based on their design to the mentioned specifications.
(c) Materials
All materials shall be original, unused or non-re-cycled conforming to relevant

specifications:
(i) Cast Steel, Mild Steel, Stainless Steel shall conform to Clause 1902
3(a).
(ii) Copolymer Poly Tetra Fluora Ethylene (PTFE) unfilled quality shall
have required properties as per BS: 5400 and thickness shall be as
specified.
(d) Seating of Pin Bearing

(i) Backing plate with studs welded on the face opposite to the seating
shall be delivered by the Contractor.
(ii) This backing plate shall be accurately positioned on the reinforcement
grid of the pedestal and leveled.
(iii) Studs shall be tack welded/tied to the reinforcement to keep the
backing plate in proper location during casting.
(iv) Depth of embedment of the backing plate in the concrete shall be as
per relevant Drawing.
(v) The round base of the pot (bottom) of the pin bearing assembly shall
be connected to the backing plates by anchor screws after concreting
of pier cap/pedestal.
(vi) In order to ensure successful transfer of large horizontal forces to be
resisted by the Pin bearing, care shall be taken in detailing the
reinforcement in the sub-structure and the super-structure adjacent to
the studs in the backing plate.
(e) Acceptance Test on Spherical Bearings
(i) All bearings shall be checked for overall dimensions

(ii) All bearings shall be load tested to 1.25 times design vertical load
(iii) A pair of bearings selected at random shall undergo testing in order to
determine coefficient of friction, which shall be less than 0.05.
(iv) Two bearings selected at random shall be tested for permissible
rotation.
(f) Acceptance Test on Pin Bearings

17
(i) All bearings shall be checked for overall dimensions

(ii) All bearings shall be load tested.
(5) Elastomeric Bearings
The term "bearing" in this case refers to an elastomeric bearing consisting of one or
more internal layers of elastomer bonded to internal steel laminates by the process of
vulcanization. The bearing shall cater for translation and/or rotation of the
superstructure by elastic deformation.
(a) Raw Material
Chloroprene (CR) only shall be used in the manufacture of bearing.
Grades of raw elastomer of proven use in elastomeric bearings, with low

crystallization rates and adequate shelf life (e.g. Neoprene WRT, Bayprene
110, Skyprene B-5 and Denka S-40V) shall be used.
No reclaimed rubber or vulcanized wastes or natural rubber shall be used.
The raw elastomeric content of the compound shall not be lower than 60 per
cent by its weight. The ash content shall not exceed 5 per cent. (as per tests
conducted in accordance with ASTM D-297, sub-section 10).
EPDM and other similar candidate elastomers for bridge bearing use shall not
be permitted.
Properties
The elastomer shall conform to properties specified in Table 19.2.
Table 19.2: Properties of Elastomer
Property Unit Test Method, IS Specification Value of the

Reference Characteristic
Specified
1. Physical Properties
1.1 Hardness IRHD IS:3400 60±5
(Part 2)
1.2 Minimum Tensile Strength N/sq.mm. IS:3400 (Part 1) 17
1.3 Minimum Elongation at break Per cent IS:3400 400
(Part 1)
2. Maximum Compression Set Per cent IS:3400
(Part 10)
duration (h): +0 to 24.2,
temperature (0 C): 100 + 1
35
3. Accelerated Ageing IS:3400 (Part 4)
Duration (h): 70
Temperature (0 C): 100 + 1
3.1 Max change in hardness IRHD +15

18
3.2 Max change in Tensile Strength Per cent -15

3.3 Max change in Elongation Per cent -40
Shear modulus of the elastomer bearing shall neither be less than 0.80
N/sq.mm nor greater than 1.20 N/sq.mm.
The adhesion strength of elastomer to steel plates determined according to

IS:3400 (Part 14) method A shall not be less than 7 kN/m.
For elastomeric bearings (CR) used in adverse climatic conditions, the

following ozone resistance test shall be satisfied:
The ozone resistance of elastomer shall be proved satisfactory when

assessed by test according to IS: 3400 (Part 20). The strain, temperature,
duration and ozone concentration of the test shall be 20 per cent, 40 ± 1
degree Celsius, 96 h and 50 pphm by volume respectively.
No cracking detected by visual observation at the end of the test shall be

considered satisfactory. No specific tests for assessment of low temperature
resistance may be deemed necessary.
Note : For use of elastomer in extreme cold climates, the Engineer may
specify special grade of low temperature resistant elastomer in
conformity with operating ambient temperature resistant elastomer in
conformity with operating ambient temperature conditions. The
specifications of such special grade elastomer including the tests for
low temperature resistance shall be mutually agreed to by the
Engineer and the Contractor and are outside the purview of these
specifications.
Laminates of mild steel conforming to IS: 2062 shall only be permitted

to be used. Use of any other material like fiberglass or similar fabric,
as laminates shall not be permitted.
The Contractor’s manufacturers of elastomeric bearings shall satisfy

the Engineer that they have in-house facilities for testing the elastomer
for carrying out the following tests in accordance with the relevant
provisions of ASTM D-297.
(a) Identification of polymers: to confirm the usage of

Chloroprene (Appendix X-2)
(b) Ash content test : to determine the percentage
(sub-section 34)
(c) Specific gravity test : (sub section 15)
(d) Polymer content test : (sub-section 10)
The Engineer shall invariably get the test (a) performed in his
presence or in the presence of his authorized representative to satisfy
the requirement. In case of any disputes regarding interpretation of
results, the Engineer may carry out test as per ASTM S-3452-78

19
(Chromatography test) at the manufacturer's cost in a recognized

laboratory.
The elastomer specimen to conduct the test shall be obtained from the
bearings selected at random for destructive test. Remaining part of
the test bearing shall be preserved by the Engineer for any test to be
done in future if required.
(b) Fabrication
Bearing with steel laminates shall be cast as a single unit in a mould and
vulcanized under heat and pressure.
Casting of elements in separate units and subsequent bonding shall not be

permitted, nor shall cutting from large size cast be permitted.
Bearings of similar size to be used in bridge shall be produced by identical
process and in one lot as far as practicable. Phased production may only be
resorted to when the total number of bearings is large enough.
The moulds used shall have standard surface finish adequate to produce
bearings free from any surface blemishes.
Steel plates for laminates shall be sand blasted, clean of all mill scales and
shall be free form all contaminants prior to bonding by vulcanization. Rusted
plates with pitting shall not be used. All edges of plates shall be rounded.
Spaces used in mould to ensure cover and location of laminates shall be of

maximum size and number practicable. Any hole at surface or in edge cover
shall be filled in subsequently.
Care shall be taken to ensure uniform vulcanizing conditions and homogeneity

of elastomer through the surface and body of bearings.
The bearings shall be fabricated with the tolerances specified in Table 19.3.

S.No Item Tolerances
1. Overall plan dimensions 0,+6 mm
2. Total bearing thickness 0,+5 mm
3. Parallelism
a) Of top surface of bearing with respect to the bottom surface as 1 in 200
datum
b) Of one side surface with respect to the other as datum 1 in 100
4.
a) Thickness of individual internal layer of elastomer ± 20 percent (max of 2 mm)
b) Thickness of individual outer layer -0, + 1 mm
5.
a) Plan dimensions of laminates -3 mm +0

20
b) Thickness of laminates ± 10 per cent

c) Parallelism of laminate with respect to bearing base of datum 1 in 100
The vulcanizing equipment/press shall be such that between the plattens of

press, the pressure and temperature are uniform and capable of being
maintained at constant values as required for effecting a uniform vulcanization
of the bearing.
The moulding dies utilized for manufacturing the bearings shall be so set
inside the platen of the press so that the pressure developed during
vulcanization of the product is evenly distributed and the thickness maintained
at all places are within acceptable tolerances limits taking into consideration
the shrinkage allowance of vulcanizate.
Before any vulcanizate of any batch of production is used for producing
vulcanized bearings, test pieces in the form of standards slab and buttons
shall be prepared in accordance with prescribed standards and salient
properties tested and recorded regularly against each batch of production to
monitor the quality of the products.
(c) Acceptance Specifications
The acceptance specifications for elastomeric bearings shall conform to IRC:

83: Standard Specifications and Code of Practice for Road Bridges, Section 9,
and Part 2 Elastomeric Bearings.
(d) Certification and Marking
Bearings shall be transported to bridge site after final acceptance by Engineer

and shall be accompanied by an authenticated copy of the certificate to that
effect.
An information card giving following details for the bearings, duly certified by
the manufacturer shall also be appended:
Name of manufacturer
Date of manufacturer
Elastomer grade used
Bearing dimensions
Production batch no.
Acceptance lot no.
Date of testing
Explanation of markings used on the bearing
All bearings shall have suitable index markings identifying the information.
The markings shall be made in indelible ink or flexible paint and shall be
visible after installation. The top of the bearing and direction of installation
shall be indicated.
(e) Storage and Handling

21
Each elastomeric bearing shall be clearly labeled and marked. The bearing
shall be wrapped in a cover. They shall be packed in timber crates with
suitable arrangement to prevent movement and to protect corners and edges.
Care shall be taken to avoid mechanical damage, contamination with oil,
grease and dirt, undue exposure to sunlight and weather to the bearings
during transport and handling prior to and during installation.
(f) Installation
Installation of multiple bearings one behind the other on a single line of support
shall be identical dimensions.
Bearings shall be placed between true horizontal surfaces (maximum

tolerance 0.2 per cent perpendicular to the load) and at true plan position of
their control lines marked on receiving surfaces (maximum tolerance ± 3 mm).
Concrete surfaces shall be free from local irregularities (maximum tolerance ±

1 mm in height).
For cast-in-place concrete construction of superstructure, where bearings are

installed prior to its concreting, the forms around the bearings shall be soft
enough for easy removal. Forms shall also fit the bearings snugly and prevent
any leakage of mortar grout. Any mortar contaminating the bearings during
concreting shall be completely removed before setting.
For pre-cast concrete or steel superstructure elements, fixing of bearings to

them may be done by application of epoxy resin adhesive to interface, after
specified surface preparation. The specifications for adhesive material,
workmanship and control shall be approved by the Engineer. Care shall be
taken to guard against faulty application and consequent behaviour of the
adhesive layer as a lubricant. The bonding by the adhesive shall be deemed
effective only as a device for installation and shall not be deemed to secure
bearings against displacement for the purpose of design.
As a measure of ample safety against accidental displacement, the bearings

shall be placed in a recess as shown in Fig. 9 of IRC:83 (Part 2).
(g) Seatting of Elastomeric Bearings on a Non-Horizontal Plane
Installation of elastomeric bearings on a Non-Horizontal Plane shall be as

follows:
(i) Elastomeric bearings shall be delivered with MS backing plate

fastened to the bearing from the manufacturer.
(ii) Template of 6 mm M.S. plate and of size same as bearing holding
base plate with matching holes for the anchor screws shall be used.
Anchors shall be fitted to the templates with the anchor screws but
with MS washers in place of elastomer washers. The above template

22
assembly shall be fitted in the formwork at its proper location and in a

vertical plane.
(iii) After casting of the pedestal and removal of the formwork, the
template shall be removed.
Installation with face plate and without template in-situ casting
(i) The sub-assembly of elastomeric bearing with the MS backing plate

shall be fitted to the embedded anchors with anchor screws and
elastomeric washers replacing the steel washer.
(ii) A clearance shall be maintained between the stainless steel face of
the elastomeric bearing and that of the vertical face of the face plate
with stainless steel top installed on the projection below the soffit. This
shall be achieved by inserting removable steel sheeting of thickness
as per the Drawing, during preparation of the formwork before casting
of the superstructure.
Installation with face plate and with template in-situ-casting
(i) Template of 6 mm MS plate and of size same as face plate with

stainless steel top and matching holes for the anchor screws shall be
used. Anchors shall be fitted to the templates with the anchor screws
but with MS washers in place of elastomer washers. Separate screws
may be used in case of inconvenience of in the length of original
anchor screws. The above template assembly shall be fitted in the
formwork for the super-structure at its proper location and in a vertical
plane.
(ii) After removal of the super-structure formwork, the template shall be
removed.
(iii) The face plate with the required thickness of pack plate shall be
loosely fitted to the anchors embedded in the projection below the
superstructure, with elastomer washers and anchor screws.
(iv) The sub-assembly of elastomeric bearing with the MS backing plate
shall be fitted to the embedded anchors in the pedestal with anchor
screws and elastomeric washers replacing the steel washer this time.
(v) The required clearance between the stainless steel face of the
elastomeric bearings and that of the vertical face plate installed on the
projection below the soffit shall be checked. After adjustment of the
required working clearance the small gap between the vertical face of
the projection below the soffit and the back of the face (plate with pack
plates, if any) shall be grouted with epoxy grout.
(6) Pot Bearings
(a) General
Pot type bearings shall consist of a metal piston supported by a disc or

unreinforced elastomer confined within a metal cylinder to take care of
rotation. The pot bearings shall consist of cast steel assemblies or fabricated
structural steel assemblies.

23
Provisions of IRC-83 (Part I) shall be applicable for all metallic elements.

Provisions of IRC:83 (Part II) shall be applicable for all elastomer elements.
When any items are not covered by IRC:83 (Parts 1 and 2), the same shall be
as per guidelines given hereunder and BS:5400 (Sections 9.1 and 9.2), except
that no natural rubber shall be permitted. If there is any conflict between BS
and IRC, the provisions of IRC shall be guiding.
Combination bearings using any judicious combination and sliding element

shall be permitted. As for example:
Name Rotation Sliding Element Generally for

Element
Pot Pot None Vertical Load
Elastomer Elastomer None* Horizontal Buffer
Pot PTFE Pot PTFE-SS** Vertical Load and Horizontal Load
Spherical Spherical PTFE-SS** Vertical Load and Horizontal Load
Knuckle PTFE Knuckle PTFE-SS** Transverse Guide
Elastomer SS** Elastomer SS-SS Transverse Guide
* Elastomer shall permit movement by shear

** Stainless Steel
(b) Fabrication
(i) The surface mating with the PTFE in the sliding pair shall be corrosion
resistant stainless steel. The stainless steel shall overlap the PTFE
after full movement on all sides. If stainless steel sheet is used, it shall
be bonded by continuous welding along the edges. The surface shall
be prepared by thorough cleaning to remove grease, dust or any other
foreign substance.
(ii) PTFE modular sheets of the sliding pair shall be located by
confinement assisted by banding. Confined PTFE shall be recessed
into the metal backing plate. The shoulder of the recess shall be sharp
and square to restrict the flow of PTFE.
(iii) The thickness of the PTFE shall not be less than 4.5 mm with
projection above the recess not exceeding 2.0 mm. When the piston is
subjected to tilting, the seal shall slide along the wall and alter its
shape according to the angle of tilt. At the same time it shall be
sufficiently rigid to bridge the gap between the piston and the wall of
the pot. However, the percentage of plan area of the lubrication
activities to the gross area shall not exceed 25 percent. The depth of
the cavity shall not exceed 2.0 mm.
(iv) The diameter to thickness ratio of the confined elastomer shall not
exceed 15. The surface of the confined elastomer shall be smooth.
(v) A seal shall be provided to prevent extrusion of the confined elastomer
between the piston and the post wall. The seal shall stay functional
under the loads and rotations acting on it. Additional seal shall be
provided to prevent entry of dust into the pot. Sealing rings for pot
bearings shall be fabricated from stainless steel. When the piston is
subjected to tilting, the seal must slide along the wall and alter its

24
shape according to the angle of tilt. At the same time, it must be

sufficiently rigid to bridge the gap between the piston and the wall of
the pot.
(vi) The hardness of the piston and pot wall at their contact region shall be
minimum 350 BHN to reduce wear. The surface finish of the pot base
in contact with the confined elastomer shall be smooth.
(vii) All bearings shall be installed with anchor and anchor screws or some
similar device such that while replacing, the bearings can be removed
with minimum lifting of the superstructure.
(viii) The external surfaces of the assemblies shall be completely cleaned
by sand blasting. After sand blasting, dust shall be removed from the
surface using clean and dry compressed air of a clean brush after
which suitable coating shall be applied.
(ix) Pot bearings including all parts as shown on the Drawings shall be
fully shop assembled at the manufacturer's works to ensure proper
fitting of all parts.
(c) Materials
(i) Steel
 Structural steel shall confirm to IS:226 and IS:2062 as

applicable
 Cast steel shall conform to Gr 280-520W of IS: 1030. 0.3 to
0.5 percent copper may be added to increase the corrosion
resistance properties.
 Stainless steel shall conform to AISI: 304 or X04Cr 18NilO of
IS: 6911 for ordinary applications. For applications with
adverse/corrosive environment, the stainless steel shall
conform to AISI; 316L or O2Cr17Nil2Mo2 of IS: 6911.
(ii) PTFE
PTFE (poly tetra fluoro ethylene) shall be of unfilled pure virgin quality.
It shall be free sintered. The mechanical properties of unfilled PTFE
shall comply with Grade A of BS:3784.
(iii) Elastomer
The confined elastomer inside pot shall have the following properties:
 Hardness IRHD IS:3400 (Part 2)

50+5
 Min. tensile Strength Mpa IS:3400 (Part 1) 15.5
 Min. elongation at break, shall be as per Table 19.2 max
compression set and “Properties of Elastomer”
accelerated aging
Other details shall be as per Sub-clause1902 (5) (a).
(d) Workmanship
(i) Welding

25
All welding shall conform to IS: 9595 with electrodes of suitable grade
as per IS: 814. Preheating and post weld stress relieving shall be
done as per IS: 9595.
(ii) Cast Steel Assemblies
Cast steel for pot-bearing assemblies shall conform to requirements of

relevant IS. Castings shall be true to the forms and dimensions shown
on the Drawings, and shall be free from pouring faults, sponginess,
cracks, blow holes and other defects affecting their appearance or
their strength, warped or distorted castings shall not be accepted.
Exposed surfaces shall be smooth and dense.
All irregularities, fins or risers shall be ground off flush with the
adjacent surface. Castings with visible cracks, blow holes, or similar
blemishes shall be rejected if the imperfections are located on bearing
surfaces or cannot be remedied to the satisfaction of the Engineer.
Imperfections, which are not located on, bearing surfaces, shall be

cleaned out, filled with weld metal of the appropriate composition and
ground flush with adjacent surfaces.
(iii) Structural Steel Assemblies
Defects arising from the fabrication of the steel shall be inspected by

the Engineer, who shall decide whether the materials may be repaired
by the Contractor or will be rejected. The cost of repairs or
replacement shall be borne by the Contractor.
All plates shall be flat and rolled bars. Straightening shall be done by
methods, which shall not damage the material. Sharp kinks and bends
shall be the cause for rejection.
Steel may be flame cut to shape and length so that a regular surface,
free from excessive gouges and striations is obtained. Flame cutting
by hand shall be done only with the approval of the Engineer.
Exposed corners shall be machined or ground.
(e) Tolerances
(i) Plan dimensions : - 0 to +5 mm

(ii) Overall height : - 0 to +3 mm
(iii) Height of elastomer : ± 5 percent
(iv) Height of any steel
component
 Machined : - 0 to + 1 mm
 Unmachined : Class 2 of IS:4897
(v) Stainless steel sliding surface

26
 Flatness : 0.0004 H, where L is the length in direction of

measurement
 Surface Finish : Ra, < 0.25 pm s per IS:3073
(f) Painting
(i) All non-working surfaces shall be coated with two coats of epoxy
primer and one or more coat each of epoxy intermediate and finish,
total thickness < 0.150 pm or any other painting scheme as approved
by the Engineer.
(ii) Silicon grease shall be applied at the PTFE/SS interface after testing.
(iii) Anchor sleeves shall be cement coated at the manufacturer works.
(g) Test
(i) Raw Materials
Necessary test certificates for all raw materials shall be furnished by

manufacturers. Reference shall also be made to Sub-clause 1902(5)
a) for tests on elastomers.
(ii) Test on Casting
Tests specified in IS: 1030 shall be performed. Castings shall be

ultrasonically tested and certificates submitted. Quality level of
castings shall be level 3 as per IS: 9565.
(iii) Test on Welding
All welding shall be tested by Dye Penetration Method. Butt welding

shall be tested by Ultrasonic Method. The manufacturer shall certify
soundness of welding.
(iv) Acceptance Test on Bearing
 Bearings shall be checked for overall dimensions

 All bearings shall be load tested to 1.25 times maximum design
capacity including seismic force. Bearings tested at higher loads
shall not be used.
 A pair of bearings selected at random will undergo testing in order
to determine the coefficient of friction "u". The coefficient of friction
shall be < at 0.05 the design loads.
 Two bearings selected at random shall be tested for permissible
rotation.
(h) Installation of POT - cum - PTFE Bearings
(i) General

27
 Care shall be taken during installation of the bearings to permit their

correct functioning in accordance with the design scheme.
 To prevent contamination, dismantling of the bearings at site shall not
be done.
 The load shall be transferred onto the bearings only when the bedding
material has developed sufficient strength. The props for the formwork
shall only be removed after lapse of appropriate time. In special
cases, suitable devices like jacks, etc can ensure this.
 Temporary clamps and shims (introduced to maintain working
clearance) shall be removed at an appropriate time, before the
bearing is required to permit movement.
 Permitted installation tolerance of the bearing from plane of sliding
shall be maintained.
 Cement based non-shrink grout with air releasing additive and epoxy
based grout, whichever is specified shall be first tried at the site. For
the proprietary grout mixes, appropriate instructions from the
manufacturer shall be followed specially with regard to the following:
 Preparation: concrete cleaning, roughening, pre-soaking etc.
 Forms: sturdiness, leak proofing, shape, header tunnel vents
etc.
 Bearing Base: cleaning etc
 Placement: mixing, consistency, time period, finishing etc.
 Protection: curing, ambient temperature etc.
(ii) In-situ Casting of Superstructure
 Formwork around the bearing shall be carefully sealed to prevent

leakage.
 Sliding plates shall be fully supported and care taken to prevent
tilting, displacement or distortion of the bearings under the weight
of wet concrete.
 Bearings shall be protected during concreting operation. Any
mortar contaminating the bearing shall be completely removed
before it sets.
(i) Seating of Bearing
(i) Using Template
 Template with required rigidity and matching holes corresponding

to the base of the bearing shall be used.
 All the anchors shall be fitted to the lower face of the template
using the anchor screws but with steel washer replacing the
elastomer washers. Separate screws may be used in case of
inconvenience in the length of the original anchor screws.
 The template assembly shall be located with regard to level and
alignment. It shall be ensured that the top of the anchors lies in a
horizontal plane at the required elevation. The anchors shall be

28
tied/welded to reinforcements to avoid displacement during

concreting.
 Concreting of the pedestal/pier cap shall be done to a level leaving
a gap of 25-50 mm below the template.
 The template and steel washers shall be removed prior to
placement of the bearing assembly with temporary clamps. The
bearing assembly shall be fitted to the anchors with the help of
anchor screws and elastomer washers. Level at the bearing shall
be checked.
 The gap below the bearing assembly shall be grouted with cement
based grout.
(ii) Without Template with Gap
 Pockets commensurate with the sizes of the anchors shall be kept

in pedestals during concreting of the same. The pedestal shall be
cast approximately 25 mm short of the required finsihed level.
 Anchors shall be fitted to the bearing bottom with elastomer
washers and anchors screws. The bearing assembly shall be
seated in the location on steel chairs/packs. The anchors fitted
below the bearing shall go into pockets in the bed block. Level and
alignment of the bearing shall be checked. It shall be ensured that
the bearing sits in a horizontal plane.
 The gap below the bearing assembly including anchor pockets
shall be grouted with cement based grout.
(iii) Without Template without Gap
Elongated pockets commensurate with the sizes of the anchors shall

be kept in pedestals during concreting of the same. The geometry and
location of the anchor pockets (with tapered funnel extension, if
required) shall be such that after placement of the bearing the pockets
can be successfully grouted. The pedestal shall be cast 5mm - 15 mm
short of the required finished level. The required level shall be
achieved by chipping before placement of the bearing. Careful control
shall be exercised to cast at the exact finished level or 1mm - 3mm
down from the required finished level.
(iv) Seating of bearings shall be as per manufacture's instructions
Inspection and Testing

Where any patents are used, the manufacturer's certificate with test
proofs shall be submitted along with the design and got approved by
the Engineer before their use in work.
Tests and Standards of Acceptance

The materials shall be tested in accordance with these Specifications
and shall meet the prescribed criteria.

29
The work shall conform to these specifications and shall meet the
prescribed standards of acceptance.
(7) Measurement
Bearings shall be measured in number inclusive of all axilliary and incidental works.
(8) Payment
The bearing shall be paid at the contract unit rate which shall be the full and the final
compensation to the Contractor as per Clause 112 and for all costs required to
complete the work as per these Specifications.

30
SECTION 2000 – CONCRETE FOR STRUCTURES
Page No.
2001 SCOPE 20–1

2003 MATERIALS FOR CONCRETE 20–1
2004 THE DESIGN OF CONCRETE MIXES 20–7
2005 MIXING CONCRETE 20–13
2006 TRANSPORTATION OF CONCRETE 20–14
2007 PLACING OF CONCRETE 20–14
2008 COMPACTION OF CONCRETE 20–17
2009 CURING OF CONCRETE 20–18
2010 PROTECTION OF FRESH CONCRETE 20–19
2011 CONCRETING IN HOT WEATHER 20–19
2012 CONSTRUCTION JOINTS 20–20
2013 RECORDS OF CONCRETE PLACING 20–21
2014 REINFORCEMENT 20–21
2015 CONCRETE FOR SECONDARY PURPOSES 20–23
2016 EARLY LOADING 20–24
2018 PAYMENT 20–25
SECTION 2000 – CONCRETE FOR STRUCTURES
2001 SCOPE
This Section covers the materials, design of mixes, mixing, transport, placing, compaction and
curing of concrete and mortar required in the works. It also covers reinforcement for concrete.
2002 DEFINITIONS
Structural concrete is any class of concrete which is used in reinforced, pre-stressed or

unreinforced concrete construction which is subject to stress.
Non-structural concrete is composed of materials complying with the Specification but for
which no strength requirements are specified and which is used only for filling voids, blinding
foundations and similar purposes where it is not subjected to significant stress.
A pour refers to the operation of placing concrete into any mould, bay or formwork, etc. and
also to the volume which has to be filled. Pours in vertical succession are referred to as lifts.
2003 MATERIALS FOR CONCRETE
(1) General
The Contractor shall submit to the Engineer full details of all materials which he
proposes to use for making concrete. No concrete shall be placed in the works until the
Engineer has approved the materials of which it is composed. In accordance with
Clause 603, approved materials shall not thereafter be altered or substituted by other
materials without the consent of the Engineer.
(2) Cement
Cement shall comply with the requirements of Clause 614.
Cement shall be free flowing and free of lumps. It shall be supplied in the
manufacturer's sealed unbroken bags or in bulk. Bagged cement shall be transported
in vehicles provided with effective means of ensuring that it is protected from the
weather.
Bulk cement shall be transported in vehicles or in containers built and equipped for the
purpose.
Cement in bags shall be stored in a suitable weatherproof structure of which the

interior shall be dry and well ventilated at all times. The floor shall be raised above the
surrounding ground level not less than 30cm and shall be so constructed that no
moisture rises through it.
Each delivery of cement in bags shall be stacked together in one place. The bags shall
be closely stacked so as to reduce air circulation with min gap of 500mm from outside
SECTION 2000 CONCRETE FOR STRUCTURES

Page 201
wall. If pallets are used, they shall be constructed so that bags are not damaged during
handling and stacking. Stack of cement bags shall not exceed 8 bags in height.
Different types of cement in bags shall be clearly distinguished by visible markings and
shall be stored in separate stacks.
Cement from broken bags shall not be used in the works. Cement in bags shall be
used in the order in which it is delivered. Bulk cement shall be stored in weather proof
silos which shall bear a clear indication of the type of cement contained in them.
Different types of cement shall not be mixed in the same silo.
The Contractor shall provide sufficient storage capacity on site to ensure that his
anticipated programme of work is not interrupted due to lack of cement.
Cement which has become hardened or lumpy or fails to comply with the Specification
in any way shall be removed from the Site.
All cement for any one structure shall be from the same source as far as possible.
All cement used in the works shall be tested by the manufacturer. The manufacturer
shall provide the results of tests as given in Table 20.1 and 20.2 for each supply and for
the last six months of his production. The Contractor shall supply two copies of each
certificate to the Engineer.
Table 20.1: Test Results for Chemical Composition of Cement

Compounds % Mean Min Max. Standard
deviation
Lime CaO
Silica SiO2
Alumina Al2O3
Iron Oxide Fe2O3
Magnesia MgO
Sulphur Trioxide So3
Soda, Potash Na2O,K2O
Table 20.2: Test Results for Physical Properties of Cement

Characteristics Requirements Nominal Mean Min Max St.
Dev.
Fineness, M2/KG : (by Blaine's 225
Air Permeability Method)
Minimum Setting time (initial), 45
minutes
Maximum Setting time (final), 600
minutes 10
Soundness (by Le Chatelie
method) mm, maximum
Minimum Average Compressive
Strength of three mortar cubes,
(N/mm2) 16,27*
3 days 22,37*
7 days 33,53*
28 days
*denotes the requirements of High Strength Portland Cement.

Page 202
Each set of tests carried out by the manufacturer on samples taken from cement which
is subsequently delivered to site shall relate to no more than one day's output of each
cement plant.
The Contractor shall constitute, from each delivery and each type of cement and not
less than one samples for every 200 tonnes or part of it, representative samples to be
tested when instructed by the Engineer in a laboratory acceptable to him, in case of the
concrete mixes do not comply with the requirements of this Specification.
Cement which is stored on site for longer than one month shall be tested in such
laboratory for every 200 tonnes or part thereof and at monthly intervals thereafter.
The Contractor shall keep full records of all data relevant to the manufacture, delivery;
testing and the cement used in the works and shall provide the Engineer with two
copies thereof.
(3) Fine Aggregate
Fine aggregate shall be clean hard and durable and shall be natural sand, crushed
gravel sand or crushed rock sand complying with IS 383. All the material shall pass
through a 4.75 mm IS sieve and the grading shall be in accordance with IS 383. In
order to achieve an acceptable grading, it may be necessary to blend materials from
more than one source.
The deviation from the initial fineness modulus shall be no more than  0.30 for
ordinary concrete and  0.20 for high quality concrete.
However, in respect of the presence of deleterious materials the fine aggregate shall
not contain iron pyrites, iron oxides, mica, shale, coal or other laminar soft or porous
materials or organic matter unless the Contractor can show by comparative tests on
finished concrete as set out in Clause 617 and as per the direction of the Engineer, that
the presence of such materials does not affect the properties of the concrete.
(4) Coarse Aggregate
Coarse aggregate shall be clean hard and durable crushed rock, crushed gravel or
natural gravel corresponding to the following classes:
Class A : Aggregate shall consist of crushed igneous or quartzite rock from

an approved source.
Class B : Aggregate shall consist of crushed quarry rock other than Class
A from an approved source.
Class C : Aggregate shall consist of natural or partly crushed gravel
pebbles obtained from and approved gravel deposit. it may
contain a quantity of material obtained from crushing the oversize
stone in the deposit provided such material is uniformly mixed
with the natural uncrushed particles.
Class D : Aggregate shall consist entirely of crushed gravel. The crushed

Page 203
gravel shall be produce from material retained on a standard

sieve having an opening at least twice as large as the maximum
size of aggregate particle specified.
Class E : Aggregate shall consist of an artificial mixture of any of the above
classes of aggregate. The use of Class E aggregate and the
relative proportions of the constituent materials shall be approved
by the Engineer.
Coarse aggregate shall be supplied in the nominal size called for in the contract and
shall be of the grading as single sized aggregate or graded aggregate of nominal size
40 mm, 20 mm, 12.5 mm and 10 mm in accordance with IS 383.
Other properties shall be as set out below:
Flakiness Index : When tested in accordance with IS 2386 Part 1, the Flakiness Index
of the coarse aggregate shall be as set out hereunder:
For ordinary concrete : not more than 25
For high quality concrete : not more than 15
If the Flakiness Index of the coarse aggregate varies by more than five units from the
average value of the aggregate used in the approved trial mix, then a new set of trial
mixes shall be carried out if the workability of the mixes has been adversely affected by
such variation.
Water Absorption : The aggregate shall not have water absorption of more than 2 per
cent when tested as set out in IS 2386 Part 3.
Los Angeles Abrasion (LAA): The aggregate shall have LAA not more than 45% for
ordinary concrete, and not more than 35% for high quality concrete, when tested in
accordance with IS 2386 Part 4.
Aggregate Crushing Value (ACV): The aggregate shall have ACV not more than
30% for pavement structure and not more than 45% for other structure when tested in
accordance with IS 2386 Part 4.
Alkali Aggregate Reactivity: The aggregate shall comply with IS 383/3.2 notes when
tested in accordance with IS 2386 Part 7.
(5) Testing Aggregates
(a) Acceptance Testing
The Contractor shall deliver to the Engineer samples containing not less than
50 kg of any aggregate which he proposed to use in the works and shall
supply such further samples as the Engineer may require. Each sample shall
be clearly labelled to show its origin and shall be accompanied by all
information called for in IS 2386 Part 1 to 8.
Tests to determine compliance of the aggregates with the requirements of Sub-

clause 2003 (3) and (4) shall be carried out by the Contractor in a laboratory
acceptable to the Engineer. If the tested materials fail to comply with the

Page 204
Specification, further tests shall be made in the presence of the Contractor and
the Engineer. Acceptance of the material shall be based on the results of such
tests.
All the materials shall be accepted if the results of not less than three
consecutive sets of test executed in accordance with IS 2386 (Part 1-8) show
compliance with the
Sub-clauses 2003 (3) and (4).
(b) Compliance Testing/Process Control Testing
The Contractor shall carry out routine testing of aggregates for compliance
with the Specification during the period that concrete is being produced for the
works. The tests set out below shall be performed on aggregates from each
separate source on the basis of one set of tests for each day on which
aggregates are delivered to site provided that the set of tests shall represent
not more than 100 tonnes of fine aggregate and not more than 250 tonnes of
coarse aggregate, and provided also that the aggregates are of uniform quality.
Grading : IS 2386 Part 1
Silt, Clay Contents and Organic Impurities : IS 2386
Part 2
If the aggregate from any source is variable, the frequency of testing shall be
increased as instructed by the Engineer.
In addition to the above routine tests, the Contractor shall carry out the
following tests at the stated frequencies:
Chloride Content: As frequently as may be required to ensure that the

proportion of chlorides in the aggregates does not exceed the limit stated in
the Specification.
Sulphate Content and Alkali Aggregate Reactivity : As frequently as may be

required according to the variability of sulphate content and alkali reactivity
assessed from the laboratory tests carried out during the concrete mix design.
(6) Delivery and Storage of Aggregates
Aggregates shall be delivered to site in clean and suitable vehicles. Different type or
sizes of aggregates shall not be delivered in one vehicle.
Each type or size of aggregate shall be stored in a separate bin or compartment having
a base such that the contamination of aggregate is prevented. Dividing walls between
bins shall be substantial and continuous so that no mixing of types or sizes occurs.
The storage of aggregates shall be arranged in such a way that drying out in hot
weather is prevented in order to avoid sudden fluctuations in water content. Storage of
fine aggregates shall be arranged in such way that they can drain sufficiently before
use in order to prevent fluctuations in water content of the concrete.
(7) Water for Concrete and Mortar

Page 205
Water shall be clean and free from harmful matter and shall comply with the
requirements of IS 456.
Brackish water containing more than 1000 ppm chloride ion or 2000 ppm sulphate ion
shall not be used for mixing or curing concrete.
The Contractor shall carry out tests in compliance with IS 456 to establish compliance
with Specifications.
(8) Admixtures
(a) General
The use of admixtures in concrete may be required under the contract to
promote special properties in the finished concrete or may be proposed by the
Contractor to assist him in compliance with the Specification.
In all cases the Contractor shall submit to the Engineer full details of the
admixture he proposes to use and the manner in which he proposes to add it
in the mix. The information provided shall include:
(i) The typical dosage, the method of dosing, and the detrimental effects
of an excess or deficiency in the dosage.
(ii) The chemical names of the main active ingredients in the admixture.
(iii) Whether or not the admixture contains chlorides, and if so the chloride
ion content expressed as a percentage by weight of admixture.
(iv) Whether the admixture leads to the entrainment of air when used at
the manufacturer's recommended dosage, and if so the extent to
which it does so.
(v) Details of previous uses of the admixture in Nepal.
The chloride ion content of any admixture shall not exceed 1 per cent
by weight of the admixture nor 0.02 per cent by weight of the cement in
the mix.
Admixtures shall not be mixed together without the consent of the
Engineer.Calcium chloride or admixtures containing calcium chloride shall not
be used in prestressed concrete.
Admixtures may be supplied as liquid or as powder. They shall be stored in
sealed and undamaged containers in a dry, cool place. Admixtures shall be
dispensed in liquid form and dispensers shall be of sufficient capacity to
measure at one time the full quantity required for each batch.
(b) Workability Agents
Workability agents shall comply with BS 5075 and shall not have any adverse
effect on the properties of the concrete.
2004 THE DESIGN OF CONCRETE MIXES
(1) Classes of Concrete
The classes of structural concrete to be used in the works shall be as shown on the
Drawing and designated in Table 20.3, in which the class designation includes two
figures. The first figures indicates the characteristic strength f ck at 28 days expressed in
N/mm² and the second figure is the maximal nominal size of aggregate in the mix

Page 206
expressed in millimetres. Letter M in the class designation stands for Mix, letters SM
stand for Special Mix.
Consistence of the mix, assessed through the Slump Test where the slump is
measured in millimetres, is designated as follows:
S: Stiff consistence, for slump  40
P: Plastic consistence, for slump > 40 and  90
VP: Very Plastic consistence, for slump >90 and  150
F: Flowing consistence for slump > 150
Table 20.3: Concrete Classes and Strength

Characteristic Maximum Trial Early works
Strength Nominal mixes test cubes
Minimal
Classes of Consistence Type of uses fck Size of Target Any one Average of 3
concrete (N/mm²) Aggregate Strength result consecutive
mm fct=1.1 fck (aver. of 3 results
(N/mm²) cubes) (N/mm²)
(N/mm²)
M 10/75 S Ordinary 10 75 11 10 14
M 10/40 S Ordinary 10 40 11 10 14
M 15/20 S Ordinary 15 20 16.5 15 19
M 15/40 S Ordinary 15 40 16.5 15 19
M 20/20 S Ordinary 20 20 22 20 24
M 20/40 S Ordinary 20 40 22 20 24
M 25/20 S Ordinary 25 20 27.5 25 29
M 25/40 S Ordinary 25 40 27.5 25 29
M 30/40 S High Quality 30 40 33 30 34
M 30/20 P High Quality 30 20 33 30 34
M 30/12 P High Quality 30 12 33 30 34
M 35/40 P High Quality 35 40 38.5 35 39
M 35/20 P High Quality 35 20 38.5 35 39
M 40/20 P High Quality 40 20 44 40 44
M 45/20 P High Quality 45 20 49.5 45 49
M 50/20 P High Quality 50 20 55 50 54
SM 30/40 VP Underwater 30 40 33 30 34
SM 30/20 VP Underwater 30 20 33 30 34
SM 30/20 F Bored Piles 30 20 33 30 34
SM 40/20 S Precast Piles 40 20 44 40 44
SM 45/20 S Post- tensioned 45 20 49.5 45 49
Girders
(2) Design of Proposed Mixes
Concrete mixes shall comply with Clause 617.
The Contractor shall design all the concrete mixes called for in the Drawing using the
ingredients which have been approved by the Engineer in accordance with Clause
2003 and in compliance with the following requirements:

Page 207
(a) The aggregate portion shall be well graded from the nominal maximum size of
stone down to the 150 micron size.
(b) The cement content shall be such to achieve the strength called for in Table
20.3 but in any case not less than the minimum necessary as shown in Table
20.4
(c) The workability shall be consistent with ease of placing and proper compaction
having regard to the presence of reinforcement and other obstructions.
(d) The water/cement ratio shall be the minimum consistent with adequate
workability but in any case not greater than 0.5 for classes of concrete from
M20 to M50 taking due account of any water contained in the aggregates. The
Contractor shall take into account that this requirement may in certain cases
require the inclusion of a workability agent in the mix.
Table 20.4 Minimum Cement Content
Minimum cement content in kg per m3 of compacted

Classes concrete
of concrete
Moderate Intemadiate Severe
exposure exposure exposure
M10/75, M10/40 125 150 175
M15/40, M15/20 150 200 225
M20/40, M20/20 250 300 325
M25/20, M25/40 300 325 350
M30/40, M30/20, M30/12
M35/40, M35/20 325 350 375
M40/20, M45/20, M50/20 375 400 425
SM30/20, SM30/40 400 400 425
SM40/20, SM45/20 425 425 450
Note: The minimum cement contents shown in the above table are required in order
to achieve impermeability and durability. In order to meet the strength
requirements in the Specification higher contents may be required.
The categories applicable to the works are based on the factors listed hereunder:
Moderate exposure : Surface sheltered from severe rain, buried
concrete.
Intermediate exposure : Surface exposed to severe rain; alternate
wetting and drying; traffic; corrosive fumes;
heavy condensation.
Severe exposure : Surface exposed to water having a pH of 4.5
or less, groundwater containing sulphates.
(3) Laboratory Trial Mixes
For each mix of concrete for which the Contractor has proposed a design, he shall
prepare the number of concrete batches specified hereunder:

Page 208
Nominal composition: 3 separate batches

Modified compositions, the quantities of other constituents being unchanged:
Water : +10% 1 batch
7 Water : - 10% 1 batch
Cement : +15% 1 batch
Cement : - 15 % 1 batch
Samples shall be taken from each batch and the following action taken, all in
accordance with BS 1881:
(a) The slump of the concrete shall be determined.
(b) Six tests cubes shall be cast from each batch. In the case of concrete having a
maximum aggregate size of 20 mm, 150 mm cubes shall be used. In the case
of concrete containing lager aggregate, 200 mm cubes shall be used and in
addition any pieces of aggregate retained on a 50 mm IS sieve shall be
removed from the mixed concrete before casting the cubes.
(c) The density of all the cubes shall be determined before the strength tests are
carried out.
(d) All faces shall be perpendicular to each other.
(e) Three cubes from each batch shall be tested for compressive strength at
seven days and the remaining three at 28 days.
For "Smaller Contracts works", the following compositions are suggested as a starting
basis for the Laboratory trials:
Concrete Characteristic Cement Total Fine aggr./ Water

Class Strength (kg) aggregates (kg) Total Aggr. (max) Workability
N/mm² % 1
M 15/40 15 250 1900 35-45 160 Stiff-Plastic
M 15/20
M 20/20 20 300 1875 35-45 165 - 170 Stiff
M 30/40 30 350 1825 35-45 170 Stiff
M 30/20 30 350 1825 35-45 175 Plastic
M 35/20 35 350 1825 35-45 175 Plastic
A "result" being the average strength of the three cubes from one batch, the average of
the three results from tests at 28 days for the nominal composition shall not be less
than the Minimal Target Strength shown in Table 20.3.
One result from the modified compositions shall not be less than the nominal strength
as shown on Table 20.3.
(4) Site Trials
At least six weeks before commencing placement of concrete in the permanent works,
site trials shall be prepared for each class of concrete specified.
For each mix of concrete for which the Contractor has proposed a design and
successfully tested in Laboratory, he shall prepare three separate batches specified
hereunder using the materials which have been approved for use in the works and the
mixing plant which he proposes to use for the works. The volume of each batch shall
be the capacity of the concrete mixer proposed for full production.

Page 209
Samples shall be taken from each batch and the action taken similar to the above Sub-
clause 2004 (3) (a) to (e).
The average of the three results of tests at 28 days shall not be less than the Minimal
Target Strength shown in Table 20.3.
The Contractor shall also carry out tests to determine the drying shrinkage of the
concrete unless otherwise directed by the Engineer.
Based on the results of the tests on the Laboratory trial and site trial mixes, the
Contractor shall submit full details of his proposals for mix design to the Engineer,
including the type and source of each ingredient, and the results of the tests on the trial
mixes.
If the Engineer does not agree to a proposed concrete mix for any reason, the
Contractor shall amend his proposals and carry out further trial mixes. No mix shall be
used in the works without the written consent of the Engineer.
(5) Quality Control of Concrete Production
(a) Sampling
For each class of concrete in production at each plant for use in the works,
samples of concrete shall be taken at the point of mixing or of deposition as
instructed by the Engineer, all in accordance with the sampling procedures
described in BS 1881 and with the further requirements set out below.
Six 150 mm or 200 mm cubes as appropriate shall be made from each sample
and shall be cured and tested in accordance with BS 1881 three at seven days
and the other three at 28 days. Where information samples are required, such
as for post-tensioning operations, three additional cubes shall be made.
The minimum frequency of sampling of concrete of each grade shall be as

following:
For 1-5 m 3 quantity of work - 1 no. of sample

3
For 5-20 m quantity of work - 2 no. of sample
For 20 m 3 and more quantity of work - 3 no. of sample plus
one additional for each 20m 3 or part thereof.
At least one sample shall be taken from each shifts of work.
Until compliance with the Specification has been established the frequency of
sampling shall be three times that stated above and not less than 3
samples/day for each class of concrete in production at each plant or such
lower frequency as may be instructed by the Engineer.
(b) Testing
(i) The slump of the concrete shall be determined for each batch from
which samples are taken and in addition for other batches at the point

Page 2010
of production and deposition or at the frequency instructed by the

Engineer.
The slump of concrete in any batch shall not differ from the value
established by the trial mixes by more than 25 mm or one third of the
value whichever is the less.
(ii) The air content of air entrained concrete in any batch shall be within
1.5 times of the required value and the average value of four
consecutive measurements shall be within the required value
expressed as a percentage of the volume of freshly mixed concrete.
(iii) Early Works : Until such time as sufficient test results are available to
apply the method of control described in (iv) below, the compressive
strength of the concrete at 28 days shall be such that no single result
(average of 3 cubes) is less than the characteristic strength f ck as
shown in Table 20-3 under the heading "early works test cubes" and
also that the average of three consecutive results is not less than f ck +4
as shown in Table 20-3 under the same heading.
The 7-day cube result may be used as an early strength indicator, at

the discretion of the Engineer.
(iv) When at least 20 consecutive results on tested batches are available

for any class of concrete mixed in any one plant, no single result shall
be less than fck-4 (N/mm²) and also the average of any group of three
consecutive results shall not be less than fck+4 (N/mm²).
In addition the Coefficient of Variation shall be less than the figure

given below:
Number of batches Maximum coefficient of variation

Ordinary concrete High quality concrete
After 20 tested batches 18% 15%
After 50 tested batches 15% 12%
Standard Deviation of the results

Where the Coefficient of Variation 
Average Value of the results
(v) Failure to comply with Requirements
If any one result in a group of three consecutive results is less than f ck-
4 (N/mm²), but the other results of group satisfy the strength
requirement, then only the batch from which the failed result was
obtained shall be deemed not to comply with the Specification.
If the average strength of the group is less than the strength

requirement then all the batches between those represented by the
first and the last result shall be deemed not to comply with the
Specification, and the Contractor shall immediately adjust the
production procedure or the mix design subject to the agreement of

Page 2011
the Engineer to restore compliance with the Specification. If adjustment

of the mix design is agreed, the Contractor shall again be required to
comply with Sub-clauses 2004 (3) and 2004 (4).
The Contractor shall take necessary action to remedy concrete which

does not comply with this Specification. Such action may include but
not necessarily confined to the following:
 Increasing the frequency of sampling until control is again

established.
 Carrying out non destructive testing such as ultrasonic
measurements, load tests or other appropriate methods,
 Cutting test cores from the concrete and testing in
accordance with BS 1881
 Carrying out strengthening or other remedial work to the
concrete where possible or appropriate.
 Removing the concrete.
 Accepting as sub standard work.
2005 MIXING CONCRETE
Before any batching, mixing, transporting, placing, compacting and finishing and curing the
concrete ordered or delivered to site, the Contractor shall submit to the Engineer full details
including Drawing of all the plant which he proposes to use and the arrangements he proposes
to make.
Concrete for the works shall be batched and mixed in one or more plants or concrete mixer
unless the Engineer agrees to some other arrangement. If concrete mixers are used, there
shall be sufficient number of mixtures including stand by mixers.
Batching and mixing plants shall be complying with the requirements of IS 1791 and capable of
producing a uniform distribution of the ingredients throughout the mass. Truck mixers shall
comply with the requirements of IS 4925 and shall only be used with the prior approval of the
Engineer. If the plant proposed by the Contractor does not fall within the scope of IS 1791 it
shall have been tested in accordance with IS 4634 and shall have a mixing performance within
the limits of IS 1791.
All mixing operations shall be under the control of an experienced supervisor.
The aggregate storage bins shall be provided with drainage facilities arranged so that the
drainage water is not discharged to the weigh hoppers. Each bin shall be drawn down at least
once per week and any accumulations of mud or silt shall be removed.
If bulk cement is used, the scale and weight hopper for cement shall be distinct from the scale
and weight hopper for aggregates.
Cement and aggregates shall be batched by weight. Water may be measured by weight or
volume.

Page 2012
The weighing and water dispensing mechanisms shall be maintained in good order. Their
accuracy shall be maintained within the tolerances described in IS 1791 and not more than
plus or minus one percent, and checked against accurate weights and volumes when required
by the Engineer.
The weights of cement and of each size of aggregate and the weight or volume of water as
indicated by the mechanism employed shall be within a tolerance of plus or minus three per
cent of the respective weight per batch agreed by the Engineer.
The Contractor shall provide standard test weights at least equivalent to the maximum working
load used on the most heavily loaded scale and other auxiliary equipment required for
checking the satisfactory operation of each scale or measuring device. Tests shall be made by
the Contractor in the presence of the Engineer during the site trials described in Sub-clause
2004 (4) and then at intervals to be determined by the Engineer but not less than once per
three months. The Contractor shall furnish the Engineer with copies of the complete results of
all check tests and shall make any adjustments, repairs or replacements necessary to ensure
satisfactory performance.
The nominal drum or pan capacity of the mixer shall not be exceeded. The turning speed and
the mixing time shall be as recommended by the manufacturer, but in addition, when water is
the last ingredient to be added, mixing shall continue for at least one minute after all the water
has been added to the drum or the pan.
The blades of pan mixers shall be maintained within the tolerances specified by the
manufacturer of the mixer and the blades shall be replaced when it is no longer possible to
maintain the tolerances by adjustment.
Mixers shall be fitted with an automatic recorder registering the number of batches discharged.
The water to be added to the mix shall be reduced by the amount of free water contained in the
coarse and fine aggregates. This amount shall be determined by the Contractor by a method
agreed by the Engineer immediately before mixing begins each day and thereafter at least
once per hour and for each delivery of aggregates during concreting. When the correct quantity
of water, determined as set out in the Specification, has been added to the mix, no further water
shall be added, either during mixing or subsequently.
Mixers which have been out of use for more than 30 minutes shall be thoroughly cleaned
before any fresh concrete is mixed. Mixers shall be cleaned out before changing to another
type of cement.
2006 TRANSPORTATION OF CONCRETE
The concrete shall be discharged from the mixer and transported to the works by means which
shall prevent adulteration, segregation or loss of ingredients, and shall ensure that the concrete
is of the required workability at the point and time of placing. The loss of slump between
discharge from the mixer and placing shall be within the tolerances specified in Sub-clause
2004 (5) (b) (i).
The capacity of the means of transport shall not be less than the full volume of a batch.

Page 2013
The time elapsing between mixing transporting placing and compaction altogether of a batch of
concrete shall not be longer than the initial setting time of the concrete. If the placing of any
batch of concrete is delayed beyond this period, the concrete shall not be placed in the works.
2007 PLACING OF CONCRETE
(1) Consent for Placing
Concrete shall not be placed until the Engineer's consent has been given in writing.
The Contractor shall give the Engineer at least two full working day notice of his
intention to place concrete.
If concrete placing is not commenced within 24 hours of the Engineer's consent the
Contractor shall again request consent as specified above.
(2) Preparation of Surface to Receive Concrete
Excavated surfaces on which concrete is to be deposited shall be prepared as set out

in Section 900.
Existing concrete surfaces shall be prepared as set out in Clause 2012. Before
deposition of further concrete they shall be clean, hard and sound and shall be wet but
without any free-standing water.
Any flow of water into an excavation shall be diverted through proper side drains to a
sump or be removed by other suitable method which will prevent washing away the
freshly deposited concrete or any of its constituents. Any underdrain constructed for
this purpose shall be completely grouted up when they are no longer required by a
method agreed by the Engineer.
Unless otherwise instructed by the Engineer surfaces against which concrete is to be

placed shall receive prior coating of cement slurry or mortar mixed in the proportions
similar to those of the fines portion in the concrete to be placed. The mortar shall be
kept ahead of the concrete. The mortar shall be placed into all parts of the excavated
surface and shall not be less than 5 mm thick.
If any fissures have been cleaned out they shall be filled with mortar or with concrete
as instructed by the Engineer.
The amount of mortar placed at one time shall be limited so that it does not dry out or
set before being covered with concrete.
(3) Placing Procedures
The concrete shall be deposited as nearly as possible in its final position. It shall be
placed so as to avoid segregation of the concrete and displacement of the
reinforcement, other embedded items or formwork. It shall be brought up in layers
approximately parallel to the construction joint planes and not exceeding 300 mm in
compacted thickness unless otherwise permitted or directed by the Engineer, but the
layers shall not be thinner than four times the maximum nominal size of aggregate.

Page 2014
When placing on a nearly horizontal surface, placing shall start at the lower end of the
surface to avoid decompaction of concrete.
Layers shall not be placed so that they form feather edges nor shall they be placed on
a previous layer which has taken its initial set. In order to comply with this requirement,
another layer may be started before initial set of the preceding layer.
All the concrete in a single bay or pour shall be placed as a continuos operation. It shall
be carefully worked round all obstructions, irregularities in the foundations and the like
so that all parts are completely full of compacted concrete with no segregation or
honey combing. It shall also be carefully worked round and between waterstops,
reinforcement, embedded steelwork and similar items which protrude above the
surface of the completed pour.
All work shall be completed on each batch of concrete before its initial set commences
and thereafter the concrete shall not be disturbed before it has set hard. No concrete
that has partially hardened during transit shall be used in the works and the transport
of concrete from the mixer to the point of placing shall be such that this requirement
can be complied with.
Concrete shall not be placed during rain which is sufficiently heavy or prolonged to
wash mortar from coarse aggregate on the exposed faces of fresh concrete. Means
shall be provided to remove any water accumulating on the surface of the placed
concrete. Concrete shall not be deposited into such accumulations of water.
In dry weather, covers shall be provided for all fresh concrete surfaces which are not
being worked on. Water shall not be added to concrete for any reason.
When concrete is discharged from the place above its final deposition, segregation
shall be prevented by the use of chutes, down pipes, trunking, baffles or other
appropriate devices.
Forms for walls shall be provided with openings or other devices that will permit the
concrete to be placed in a manner that will prevent segregation and accumulations of
hardened concrete on the formwork or reinforcement above the level of the placed
concrete.
When it is necessary to place concrete under water the Contractor shall submit to the
Engineer his proposals for the method and equipment to be employed. The concrete
shall be deposited either by bottom-discharging watertight containers or through
funnel-shaped tremies which are kept continuously full with concrete in order to reduce
to a minimum the contact of the concrete with the water. Special care shall be taken to
avoid segregation.
If the level of concrete in a tremie pipe is allowed to fall to such extent that the water
enters the pipe, the latter shall be removed from the pour and filled with concrete
before being again lowered into the placing position. During and after concreting under
water, pumping or de-watering in the immediate vicinity shall be suspended if there is
any danger that such work will disturb the freshly placed concrete.
(4) Interruptions to Placing

Page 2015
If the concrete placing is interrupted for any reason and the duration of the interruption
cannot be forecast or is likely to be prolonged, the Contractor shall immediately take
the necessary action to form a construction joint so as to eliminate as far as possible
feather edges and sloping top surfaces and shall thoroughly compact the concrete in
accordance with Clause 2008. All work on the concrete shall be completed before
elapse of initial setting time and it shall not thereafter be disturbed until it is hard
enough to resist damage. Plant and materials to comply with this requirement shall be
readily available at all time during concrete placing.
Before concreting is resumed after such an interruption the Contractor shall cut out and
remedy all damaged or uncompacted concrete, feather edges or any undesirable
features and shall leave a clean sound surface against which the fresh concrete may
be placed.
If it becomes possible to resume concrete placing without contravening the

Specification and the Engineer consents to resumption, the new concrete shall be
thoroughly worked in and compacted against the existing concrete so as to eliminate
any cold joints.
In case of long interruption concrete shall be resumed as directed by Engineer .
(5) Dimensions of Pours
Unless otherwise agreed by the Engineer, pours shall not be more than two meters
high and shall as far as possible have a uniform thickness over the plan area of the
pour. Concrete shall be placed to the full planned height of all pours except in the
circumstances described in Sub-clause 2007 (4).
The Contractor shall plan the dimensions and sequence of pours in such a way that
cracking of the concrete does not take place due to thermal or shrinkage stresses.
(6) Placing Sequence
The Contractor shall arrange that the intervals between successive lifts of concrete in
one Section of the works are of equal duration. This duration shall not be less than
three days or not more than seven days under temperate weather conditions unless
otherwise agreed by the Engineer.
Where required by the Engineer to limit the opening of construction joints due to
shrinkage, concrete shall not be placed against adjacent concrete which is less than
21 days old.
Contraction gaps in concrete shall be of the widths and in the locations as shown on
the Drawing and they shall not be filled until the full time interval shown on the Drawing
has elapsed.
2008 COMPACTION OF CONCRETE

Page 2016
Concrete shall be fully compacted throughout the full extent of the placed layer. It shall be
thoroughly worked against the formwork and around any reinforcement and other embedded
item, without displacing them. Care shall be taken at arises or other confined spaces.
Successive layers of the same pour shall be thoroughly worked together.
Concrete shall be compacted with the assistance of mechanical immersion vibrators, unless
the Engineer agrees another method.
Immersion and surface vibrators shall operate at a frequency of between 70 and 200 hertz. The
Contractor shall ensure that vibrators are operated at pressures and voltages not less than
those recommended by the manufacturer in order that the compactive effort is not reduced.
A sufficient number of vibrators shall be operated to enable the entire quantity of concrete
being placed to be vibrated for the necessary period and, in addition, stand-by vibrators shall
be available for instant use at each place where concrete is being placed.
Vibration shall be continued at each point until the concrete ceases to contract, air bubbles
have ceased to appear, and a thin layer of mortar has appeared on the surface. Vibrators shall
not be used to move concrete laterally and shall be withdrawn slowly to prevent the formation
of voids.
The vibrators shall be inserted vertically into the concrete to penetrate the layer underneath at
regular spacing which shall not exceed the distance from the vibrator over which vibration is
visibly effective and some extent of vibration is overlapped.
Vibration shall not be applied by way of reinforcement nor shall the vibrators be allowed to
touch reinforcement, sheathing ducts or other embedded items.
2009 CURING OF CONCRETE
(1) General
Concrete shall be protected during the first stage of hardening from loss of moisture
and from the development of temperatures differentials within the concrete sufficient to
cause cracking. The methods used for curing shall not cause damage of any kind to
the concrete.
Curing shall be continued for as long as may be necessary to achieve the above
objectives but not less than seven days or until the concrete is covered by successive
construction whichever is the shorter period.
The above objectives shall be dealt with in Sub-clauses 2009 (2) and 2009 (3) but
nothing shall prevent both objectives being achieved by a single method where
circumstances permit.
The curing process shall commence as soon as the concrete is hard enough to resist
damage from the process. In the case of large areas or continuous pours, it shall
commence on the completed Section of the pour before the rest of the pour is finished.
(2) Loss of Moisture

Page 2017
Exposed concrete surfaces shall be closely covered with impermeable sheeting,

properly secured to prevent its removal by wind and the development of air spaces
beneath it. Joints in the sheeting shall be lapped by at least 300 mm.
If it is not possible to use impermeable sheeting, the Contractor shall keep the exposed
surfaces continuously wet by means of water spray or by covering with a water
absorbent material which shall be kept wet, unless this method conflicts with Sub-
clause 2009 (3).
Water used for curing shall be of the same quality as that used for mixing.
Formed surfaces may be cured by retaining the formwork in place for the required
curing period.
If instructed by the Engineer, the Contractor shall, in addition to the curing provisions
set out above provide a suitable form of shading to prevent the direct rays of the sun
reaching the concrete surfaces for at least the first four days of the curing period.
(3) Limitation of Temperature Differentials
The Contractor shall limit the development of temperature differentials in concrete after
placing by any means appropriate to the circumstances including the following:
(a) limiting concrete temperatures at placing as set out in Sub-clause 2011 (2);
(b) use of low heat cement for mass concreting, subject to the agreement of the
Engineer;
(c) leaving formwork in place during the curing period. Steel forms shall be
suitably
insulated on the outside;
(d) preventing rapid dissipation of heat from surfaces by shielding from wind.
2010 PROTECTION OF FRESH CONCRETE
Freshly placed concrete shall be protected from rainfall and from water running over the
surface until it is sufficiently hard to resist damage from these causes.
Concrete placed in the works shall not be subjected to any loading including traffic until it has
attained at least its characteristic strength as defined in Clause 2004.
2011 CONCRETING IN HOT WEATHER
(1) General
The Contractor shall prevent damage to concrete arising from exposure to extreme
temperatures, and shall maintain in good working order all plant and equipment
required for this purpose.
In the event that conditions become such that even with the use of equipment the
requirements cannot be met, concrete placing shall immediately cease until such time
as the requirements can again be met.

Page 2018
(2) Concrete Placing in Hot Weather
During hot weather the Contractor shall take all measures necessary to ensure that the
temperature of concrete at the time of placing in the works does not exceed 30°C and
that the concrete does not lose any moisture during transporting and placing.
Such measures may include but are not necessarily limited to the following:-
(a) Shielding aggregates from direct sunshine.

(b) Use of a mist water spray on aggregates.
(c) Sun shields on mixing plants and transporting equipment.
Surfaces in which concrete is to be placed shall be shielded from direct sunshine and
surfaces shall be thoroughly wetted to reduce absorption of water from the concrete
placed on or against them.
After concrete has been placed, the selected curing process shall be commenced as
soon as possible. If any interval occurs between completion of placing and start of
curing, the concrete shall be closely covered during the interval with polythene sheet to
prevent loss of moisture.
2012 CONSTRUCTION JOINTS
Whenever concrete is to be bonded to other concrete which has hardened, the surface of
contact between the Sections shall be deemed a construction joint.
Where construction joints are shown in the Drawing, the Contractor shall form such joints in
such positions. The location of joints which the Contractor requires to make for the purpose of
construction shall be subject to the approval of the Engineer. Construction joints shall be in
vertical or horizontal planes except in sloping slabs where they shall be normal to the exposed
surface or elsewhere where the Drawing requires a different arrangement.
Construction joints shall be arranged as to reduce to a minimum the effects of shrinkage in the
concrete after placing, and shall be placed in the most advantageous positions with regard to
stresses in the structures and the desirability of staggering joints.
Feather edges of concrete at joints shall be avoided. Any feather edges which may have
formed where reinforcing bars project through a joint shall be cut back until sound concrete has
been reached.
The intersections of horizontal and near horizontal joints and exposed faces of concrete shall
appear as straight lines produced by use of a guide strip fixed to the formwork at the top of the
concrete lift, or by other means acceptable to the Engineer.
Construction joints formed as free surfaces shall not exceed a slope of 20 per cent from the
horizontal.
The surface of the fresh concrete in horizontal or near horizontal joints shall be thoroughly
cleaned and roughened by means of high pressure water, and air jets or wire brush, when the
concrete is hard enough to withstand the treatment without the leaching of cement. The surface
of vertical or near vertical joints shall be similarly treated if circumstances permit the removal of
formwork at a suitable time.

Page 2019
Where concrete has become too hard for the above treatment to be successful, the surface
whether formed or free shall be thoroughly scabbled by mechanical means, manually or wet
sand blasted and then washed with clean water. The indentations produced by scabbling shall
not be less than 10 mm deep and shall be away from the finished face by 40mm.
If instructed by the Engineer the surface of the concrete shall be thoroughly brushed with a thin
layer of mortar composed of one part of cement to two parts of sand by weight and complying
with Sub-clause 2502 (2) immediately prior to the deposition of fresh concrete. The mortar shall
be kept just ahead of the fresh concrete being placed and the fresh layer of concrete shall be
thoroughly and systematically vibrated to full depth to ensure complete bond with the adjacent
layer.
No mortar or concrete shall be placed until the joint has been inspected and approved by the
Engineer.
2013 RECORDS OF CONCRETE PLACING
Records of the details of every pour of concrete placed in the works shall be kept by the
Contractor in a form agreed by the Engineer. These records shall include class of concrete,
location of pour, date and duration of pour, ambient temperature and concrete temperature at
time of placing and all relevant meteorological information such as rain, wind etc., moisture
contents of the aggregates, details of mixes, batch numbers, cement batch number, results of
all tests undertaken, part of the structure and place where test cube samples are taken from.
The Contractor shall supply to the Engineer four copies of these records each week covering
work carried out the preceding week. In addition he shall supply to the Engineer monthly
histograms of all 28 day cubes strength results together with cumulative and monthly standard
deviations, Coefficient of Variation, and any other information which the Engineer may require
concerning the concrete placed in the works.
2014 REINFORCEMENT
(1) General
Reinforcement as plain bars and deformed bars and steel fabric shall comply with the
following Indian Standards.
IS 1786 for high strength deformed steel bars and wires.

IS 1566 for steel mesh fabric.
IS 432 mild steel and medium tensile steel bars.
All reinforcement shall be from an approved manufacturer and, if required by the
Engineer, the Contractor shall submit the ISI certification mark or other test certificate
from the manufacturer acceptable to the Engineer.
The sampling and frequency of testing shall be as set out in the NS 84-2042 and NS
191-2045.
All reinforcement not complying with the Specification shall be removed from site.
(2) Storage of Reinforcement

Page 2020
All reinforcement shall be delivered to site either in straight lengths or cut and bent. No
reinforcement shall be accepted in long lengths which have been transported bent over
double.
Any reinforcement which is likely to remain in storage for a long period shall be
protected from the weather so as to avoid corrosion and pitting. All reinforcement which
has become corroded or pitted to an extent which, in the opinion of the Engineer, will
affect its properties shall either be removed from site or may be tested for compliance
with the appropriate Indian Standard in accordance with Sub-clause 2014 (1) at the
Contractor expense.
Reinforcement shall be stored at least 150mm above the ground on a clean area free
of mud and dirt and sorted out according to category, quality and diameter.
(3) Bending Reinforcement
Unless otherwise shown on the Drawing, bending and cutting shall comply with IS
2502.
The Contractor shall satisfy himself as to the accuracy of any bar bending schedules
supplied and shall be responsible for cutting, bending, and fixing the reinforcement in
accordance with the Drawing.
Bars shall be bent mechanically using appropriate bar benders. Bars shall be bent cold
by the application of slow steady pressure. At temperatures below 5°C the rate of
bending shall be reduced if necessary to prevent fracture in the steel.
Bending reinforcement inside the forms shall not be permitted except for mild steel
bars of diameter less or equal to 12 mm, when it is absolutely necessary.
After bending, bars shall be securely tied together in bundles or groups and legibly
labelled as set out in IS 2502.
(4) Fixing Reinforcement
Reinforcement shall be thoroughly cleaned. All dirt, scale, loose rust, oil and other
contaminants shall be removed before placing it in position. If the reinforcement is
contaminated with concrete from previous operations, it shall be cleaned before
concreting in that Section.
Reinforcement shall be securely placed and fixed in position as shown in the drawing
or directed by the Engineer.
Unless otherwise agreed by the Engineer, all intersecting bars shall be either tied
together with not less than 1.6 mm diameter soft annealed iron wire and the end of the
wire turned into the body of the concrete, or shall be secured with a wire clip of a type
agreed by the Engineer.
Spacer blocks shall be used for ensuring that the correct cover is maintained on the
reinforcement. Blocks shall be as small as practicable and of a shape agreed by the
Engineer. They shall be made of mortar mixed in the proportions of one part of cement
to two parts of sand by weight. Wires cast into the block for tying in to the

Page 2021
reinforcement shall have not less than 1.6 mm diameter and shall be soft annealed
iron.
Alternatively another type of spacer block may be used subject to the Engineer's
approval.
All reinforcement shall be checked of shape, size, diameter and number where
necessary. Reinforcement shall be rigidly fixed so that it remains intact during placing
of concrete. Any fixers made to the formwork shall not remain within the space to be
occupied by the concrete being placed.
No splices shall be made in the reinforcement except where shown on the Drawing or
agreed by the Engineer. Splice lengths shall be as shown on the Drawing or directed
by the Engineer.
Reinforcement shall not be welded except where required by the contract or agreed by
the Engineer. If welding is employed, all welded splices shall be full penetration butt
welds complying with the procedures set out in IS 2751 or IS 9417 as applicable.
Mechanical splices shall not be used unless the Engineer agrees otherwise.
Acceptance for welded or mechanical splices of approved design shall be based on
qualification tests to be carried out by the Contractor prior to start of the work.
Construction control testing as instructed by the Engineer shall be also carried out.
The Contractor shall ensure that reinforcement left exposed in the works shall not
suffer distortion, displacement or other damage. When it is necessary to bend
protruding reinforcement aside temporarily, the radius of the bend shall not be less
than four times the bar diameter for mild steel bars or six times the bar diameter for
high yield bars. Such bends shall be carefully straightened without leaving residual
kinks or damaging the concrete round them before concrete placing. In no
circumstances heating and bending of high yield bars shall be permitted.
Bars complying with IS 1786 or other high tensile bars shall not be bent after placing in
the works.
2015 CONCRETE FOR SECONDARY PURPOSES
(1) Non–structural Concrete
Non-structural concrete (NS concrete) shall be used only for non structural purposes
where shown on the Drawing.
NS concrete shall be compound of ordinary Portland cement and aggregates

complying with this Specification.
The weight of cement mixed with 0.3 cubic metres of combined aggregate shall not be
less than 50 kg. The mix shall be proportioned by weight or by volume. The maximum
aggregate size shall be 40 mm nominal.
The concrete shall be mixed by machine or by hand in accordance with Sub-clause

2015 (3) to a uniform colour and consistency before placing. The quantity of water

Page 2022
used shall not exceed that required to produce a concrete with sufficient workability to
be placed and compacted where required.
The concrete shall be compacted by hand towels or rammers or by mechanical

vibration.
(2) No Fines Concrete
No Fines concrete (NF concrete) is intended for use where a porous concrete is
required and shall only be used where shown on the Drawing or instructed by the
Engineer.
The mix shall consist of Ordinary Portland cement and aggregate complying with this
Specification. The aggregate size shall be 40 mm to 10 mm only. The weight of cement
mixed with 0.3 cubic metres of aggregate shall not be less than 50 kg. The quantity of
water shall not exceed that required to produce a smooth cement paste which will coat
evenly the whole of the aggregate.
(3) Hand Mixed Concrete
Concrete for structural purposes shall not be mixed by hand. Where non structural
concrete is required, hand mixing may be carried out subject to approval of the
Engineer.
For making hand mixed concrete, cement, sand and aggregate shall be batched
separately by volume or by weight as applicable. Then cement and sand shall be
mixed dry to uniform colour. The aggregate shall be stacked in a proper shape upon
which cement sand mix shall be spread and whole mix shall be turned up and down to
have uniform mix of all ingredients. Then water shall be added as specified in Sub-
clause 2015 (1) and shall be mixed to uniform consistency.
For hand mixed concrete the specified quantities of cement shall be increased by 10%
and not more than 0.25 cubic meter shall be mixed at one time. During windy weather
precautions shall be taken to prevent cement from being blown away in the process of
gauging and mixing.
2016 EARLY LOADING
No load shall be applied to any part of a structure until the specified curing period has expired,
and thereafter loading shall be allowed after approval by the Engineer. The Engineer’s decision
shall be based on the type of load to be applied, the age of concrete, the magnitude of stress
induced and the propping of the structure.
No structure shall be opened to traffic until test cubes have attained the specified minimum 28
days strength as defined in Clause 2004.
2017 MEASUREMENT

Page 2023
(1) Concrete
Concrete laid in place as specified in the Drawing or directed by the Engineer shall be
measured in cubic metre separately for each class. No deduction shall be made in the
measurement for:
(a) bolt holes, pockets, box outs an cast in components provided that the volume
of each is less than 0.15 cubic metres;
(b) mortar beds, fillets, drips, rebates, recesses, grooves, chamfers and the like of
100 mm total width or less;
(c) reinforcement
(2) Blinding Concrete/Non Structural Concrete
Blinding concrete laid in place shall be measured in cubic metre. No deduction shall be
made for openings provided that the area of each is less than 0.5 square metres.
Blinding concrete over hard material shall be measured as the volume used provided
that the maximum thickness of 150 mm allowed for overbreak is not exceeded.
(3) Admixtures, Workability and Hardening Agents
Measurement of these items shall be carried out as specified in the contract.

(4) Reinforcement
All types of reinforcement shall be measured in metric tone in the ranges as given
below:
 Diameter equal to or less than 8mm
 Diameter above 8mm upto 16mm
 Diameter above 16mm
Only that reinforcement which is required and placed in work as per Drawing or as
directed by the Engineer shall be measured. Other reinforcement not shown on the
Drawing or directed by the Engineer such as splices, chairs, cap lengths hangers and
the like and the reinforcements not conforming to shape, size and length as shown on
the Drawing or as directed by the Engineer shall not be measured.
Rolling margin or cutting waste shall not be measured. Length along centre line of the
individual reinforcement of each type placed as described above shall be measured
including their hooks, and bents, if any. An average weight of at least 5 samples each
one metre length shall be determined by the laboratory approved by the Engineer. The
weight of each type of the reinforcement shall be determined by multiplying average
weight of the respective reinforcement by its length.
(5) Fabric Reinforcement
Fabric reinforcement laid as per Drawing or as directed by the Engineer shall be

measured in square meter. No allowance shall be made for laps and wastage.
2018 PAYMENT

Page 2024
(1) Concrete
Every class of concrete shall be paid as per respective contract unit rate. In addition to
those specified in Clause 112 the respective rate shall also include the cost of:
(a) admixtures and workability agents including submission of details unless
specified.
(b) class of UF1, 2 or 3 surface finish.
(c) laying to sloping surfaces not exceeding 15° from the horizontal and to falls.
(d) formwork to lean concrete.
(e) placing and compacting against excavated surfaces where required including
any additional concrete to fill overbreak and working space.
(f) complying with the requirements of Clauses 2001 to 2013, 1806 and 1807.
(2) Admixtures, Workability and Hardening Agents
Payment shall be made at contract unit rate which shall be the full and the final
compensation to the Contractor as per Clause 112 and for all specified in the contract.
(3) Reinforcement
The reinforcement shall be paid at contract unit rate. In addition to those specified in
Clause 112 the rate shall also include compensation for the cost of providing , cutting to
length, splice lengths additional to those shown on the Drawing, laps, bending,
hooking, waste incurred by cutting, cleaning, spacer blocks, provision and fixing of
chairs or other types of supports, welding, fixing the reinforcement in position including
the provision of wire or other material for supporting and tying the reinforcement in
place, bending reinforcement aside temporarily, and straightening, placing and
compacting concrete around reinforcement and for complying with Clause 2014.
(4) Fabric Reinforcement
The fabric reinforcement shall be paid at contract unit rate which shall be also inclusive
of compensation for wastage and laps.
(5) Payment for Sub-standard Works
Concrete not meeting the requirements of the relevant Specifications (termed as

substandard concrete) shall be paid as substandard work provided it is accepted by
the Engineer as substandard work. For the acceptance of such work the Engineer may
require further investigation and/or tests which the Contractor shall conduct at his own
cost. Acceptance or rejection of such work is the sole responsibility of the Engineer
and his decision in this respect shall be the final and binding upon the Contractor.
If accepted as substandard work the payment for such work shall be made at the
contract unit rate reduced by the formula given below
Design strength - Observed strength

Percent of reduction, P = X 100
Design strength
The reinforcement, admixtures, workability and hardening agents, if any, contained in
the substandard concrete shall be also paid at their respective contract unit rates of the
same concerned item reduced by the same percent P.

Page 2025
The reduced contract unit rates of substandard concrete and other items contained
shall be the full and the final compensation to the Contractor.

Page 2026
8 SECTION 2100 - PRESTRESSED CONCRETE
Page No.
2101 SCOPE 21–1

2102 GENERAL 21–1
2103 CEMENT AND CONCRETE CLASSES FOR PRESTRESSED
CONCRETE STRUCTURES 21–1
2104 TENDON SHEATHS 21–1
2105 ANCHORAGES 21–2
2106 PRESTRESSING TENDONS 21–2
2107 INSTALLATION OF PRESTRESSING TENDONS 21–2
2108 JACKS FOR PRESTRESSING 21–3
2109 TENSIONING OPERATIONS 21–4
2110 BONDING AND GROUTING 21–5
2111 REJECTION OF PRESTRESSED WORK 21–6
2112 TESTING PRESTRESSED WORK 21–7
2114 PAYMENT 21–7
SECTION 2100 - PRESTRESSED CONCRETE
2101 SCOPE
This Section covers the materials, equipment and methods required for carrying out
prestressing operations on in-situ concrete. This Section also covers the classes of concrete
appropriate to prestressed concrete. The production of in-situ concrete is covered by Section
2000.
2102 GENERAL
Prestressed concrete work shall be carried out in accordance with IRC 18, 1985 and BSCP
110, `The Structural Use of Concrete, Part I, Design, Materials and Workmanship’, except that
where the requirements of the Codes differ from this Specification, this Specification shall take
precedence.
The Contractor shall submit to the Engineer full details of the plant he proposes to use for the
installation of prestressing tendons, the materials he proposes to use and the arrangements he
proposes to make. He shall also submit evidence of his competence to undertake the
installation.
All prestressing components, sheathing ducts, anchorages, prestressing tendons, jacks, etc.
shall be stored in clean dry conditions. They shall be clean and free from rust at the time of
fixing in position and subsequent concreting.
2103 CEMENT AND CONCRETE CLASSES FOR PRESTRESSED CONCRETE

STRUCTURES
Cement for prestressed concrete shall be exclusively Ordinary Portland Cement (OPC) or High
Strength Portland Cement (HSPC) complying with Clause 614.
Concrete classes for prestressed concrete shall be not less than M45/20 high quality concrete
and shall comply with Section 2000.
2104 TENDON SHEATHS

Tendon sheaths shall conform the recommendations of IRC Code 18. Tendon sheaths shall be
tested at the manufacture in accordance with Appendix 1 of IRC code 18 and the Contractor
shall provide test certificates in accordance with Clause 605.
All tendon sheaths or ducting shall be sufficiently strong to withstand without damage the
stresses to which it may be subjected during handling and after being fixed in position. The
ducting shall completely protect the wires or cables from contact with concrete and the
Contractor shall ensure that the wires or cables are completely free in the duct before
tensioning. Any ducting which has been damaged during transportation to the site or which in
the opinion of the Engineer is inadequate for its purpose shall not be used in the works.
Ducting shall be free from loose material, oil coatings, or other contaminants which may affect
the bond with the concrete.
SECTION 2100 PRESTRESSED CONCRETE

Page 21  1
The stools, saddles or supports for the ducts shall be of rigid construction and of such form that
they remain securely in position and maintain the correct profile of the cables without strain on
the sheath until the concrete placed round them has hardened. The supports shall be not more
than one metre apart.
Vents shall be incorporated into each duct at high and low points, at each end and at
intermediate points not more than five metres apart or in accordance with the Drawing.
Blocking of vents during concreting operations shall be prevented.
2105 ANCHORAGES
Anchorages shall be the correct type for the prestressing system and must have been used in
similar other works. The procured anchorages shall conform to BS 4447. They shall be rigidly
fixed true to alignment in the formwork so that they cannot move during concreting operations.
The anchorages shall be provided with means for injecting grout into the ducts.
Anchorages shall be delivered on site in protecting packing against corrosion with adequate
information of identifying the articles and with the manufacturer's detailed instructions for their
use.
If the anchorage is fixed after the main body of the concrete has been placed, it shall be
carefully bedded so that it is bearing evenly and is in intimate contact with the concrete.
2106 PRESTRESSING TENDONS
Tendons and wires used in prestressed concrete shall comply with the standards indicated on
the Drawing. The Standards include the following:
IS 1785 Part 1 for Plain hard-drawn steel wire

ASTM A 416 for high tensile strength strand.
All wires, bars and/or strands shall be assigned the lot number and shall have suitable tags for
their identification. All samples shall be truly representative of the lot to be furnished and in the
case of wire or strand. The contractor shall furnish samples of at least 5m length selected from
each lot for testing.
Tendons shall be stored on site under cover and protected from the weather. The storage area
shall have a hard impermeable floor. Tendons shall be stored either straight or in the coils in
which they left the factory.
Tendons shall not be allowed to become affected by excessive rusting or by pitting of the
surface by corrosion. If pitting is present the Contractor shall replace the affected tendons by
new ones. Tendons shall be supplied in coils of sufficiently large diameter such that tendons
shall retain their physical properties and shall be straight as it unwinds from the coil.
2107 INSTALLATION OF PRESTRESSING TENDONS
(1) Fabrication Procedures
Fabrication shall be carried out clear of the ground and under cover or where this is
impractical, and agreed by the Engineer, in the open with suitable precautions.

Page 21  2
The fabrication procedures shall not cause any mechanical damage to the tendons.
Any tendon material found to be bent or kinked at fabrication shall be rejected unless
tests are made to the satisfaction of the Engineer which shows that the damage is not
detrimental.
Prestressing steel shall be cut by rotating disc or blade cutters or by such method as is
recommended by the manufacturer.
Where required for the particular system, the ends of the tendon shall be prepared at
fabrication for subsequent stressing and anchoring.
(2) Installation and Fixing
Before being installed, prestressing tendons shall be thoroughly cleaned of mill scale,
mortar, oil, paint, dust, grease, or any other deleterious matter whatsoever.
The prestressing steel (or where the tendons are accommodated in ducts, the sheaths,
ducting or formers) shall be accurately placed in the positions shown on the Drawing
and shall be firmly secured in position. They shall not deviate from the positions shown
on the Drawing by more than 5 mm in all directions.
Wooden supports shall not be used nor shall the sheaths, ducting or formers be placed
on previous layers of fresh concrete or be adjusted during the placing of concrete.
The prestressing steel, sheaths, ducting or formers shall be so placed and secured
that twisting, kinking or excessive deformation during and subsequent to concreting is
eliminated and the prestressing tendons when finally stressed shall conform accurately
to the profiles shown on the Drawing. Ducts and formers shall not be placed with small
radius bends which would induce excessive frictional restraint on the wires or strands.
Where many individual wires or strands are placed in a duct, adequate provision shall
be made to keep the wires separated by means of suitable spacers of approved
design, construction and spacing.
2108 JACKS FOR PRESTRESSING
Jacks for tensioning tendons shall be hydraulically operated and capable of providing a slow
uniform increase of load.
Each jack shall be equipped with an appropriate pressure gauge capable of indicating the
hydraulic fluid pressure at all times during the stressing operation with an accuracy of 1N/mm².
A certified calibration chart showing the relationship between gauge readings and force on the
ram for both ascending and descending ram movements shall be made available on the site by
the Contractor.
The Contractor shall maintain tensioning jacks in good working order and shall ensure true and
accurate readings by regular testing, calibration and servicing.
2109 TENSIONING OPERATIONS

Page 21  3
(1) General
Prestressing force, whether partial or full, shall not be transferred to the concrete until
cube crushing tests have indicated that the concrete has attained the strength
specified on the Drawing. The test cubes shall have been cured in conditions similar to
the concrete to be prestressed.
Stressing of the tendons shall be carried out with due care by experienced workmen
under competent supervision approved by the Engineer. Adequate steps shall be taken
to safeguard against injury. Special precautions shall be taken when working with and
near tendons which have been tensioned or are in the process of being tensioned.
The Contractor shall ensure that he has been supplied all required instructions by the
Engineer and that he has the necessary information to carry out the works. The
instructions controlling the stressing operations are based on the design of the
structure and may be modified by the Engineer as a result of the information obtained
from site tensioning records.
Full and accurate records shall be kept of all stressing operations and two copies of
the records, which shall include wedging-device slip measurements during anchoring,
loads and extensions, shall be submitted to the Engineer on the day following each
stressing operation. The accuracy of the measurement of cable extensions, shall be
plus or minus two per cent (2%). The Engineer may order the Contractor to cease
any or all stressing operations where proper records are not being kept or where the
operations are not being properly or safely carried out. The Contractor shall take
immediate steps to ensure that the work is carried out to the satisfaction of the
Engineer.
Where the required tensions or extensions are not obtained the tendons shall be re-
tensioned as directed by the Engineer. If on re-stressing, the extensions are not
achieved, the Engineer may at his discretion reject the tendons involved.
The tendons shall be maintained in such condition that they can be restressed until the
Engineer has given final approval after inspecting the tensioning log.
(2) Post-tensioning
When a post-tensioning system is employed, all cable ducts, excluding extractable

formers shall be thoroughly flushed with water immediately after concreting and before
the concrete has hardened.
Ducts produced by extractable formers shall be flushed out as soon as the concrete
has hardened. Where anchorage of the prestressing tendons is by friction grips or
wedges and where no other slipping limitation is specified, the slip of each individual
prestressing steel element, both during tensioning and after anchoring shall not
exceed seven millimetres. Tendons failing to satisfy these limitations shall be re-
stressed.
The sequence of stressing shall be as shown on the Drawing and shall be such that
lateral eccentricity of stress on any member is reduced to a minimum.

Page 21  4
After stressing and anchoring, no tendon shall be cut, bent or in any way deformed
until the Engineer has given his final approval.
Where tendons are cut back, the exposed ends of the tendons and anchorages shall
be heavily coated with an approved bituminous compound or epoxy resin to prevent
corrosion of the prestressing steel.
2110 BONDING AND GROUTING
After stressing and anchoring post-tensioned tendons shall be intimately bonded to the
adjacent concrete by means of concrete or in the case of internal cables, by colloidal cement
grout.
The properties of grout, the equipment and the grouting procedure shall be as follows:-
(1) Grout Type
The grout shall be a colloidal mix of water and ordinary Portland Cement with a
Water/Cement ratio of between 0.40 and 0.45 by weight.
Admixtures of an approved type may be authorised by the Engineer for incorporation in

the grout if tests have shown that their use improves the properties of the grout, for
example by increasing the workability, by reducing bleeding, or by expanding grout.
Admixtures shall not contain chlorides or nitrates. When an expanding agent is used
the total unrestrained expansion shall not exceed 10 per cent.
(2) Mixing Equipment and Procedures

The mixing equipment shall be of a type capable of producing grout of uniform
consistency with fully dispersed cement particles and shall be incorporated with
suitable sieves for retaining lumps or other solid ingredients. After water has been
added to the mixer, the cement shall be added. Admixtures if used, shall be added
during the latter half of the mixing time. High speed mixing shall be carried out
continuously for between two and four minutes in a close clearance high speed
centrifugal mixer.
Subsequent to mixing and prior to injection the grout shall be continuously agitated by
slow machine mixing. Any grout that has been left standing for more than 30 minutes
shall be discarded and the container thoroughly washed before further mixing is
carried out.
(3) Injection Equipment and Procedures
A positive displacement pump shall be used for injecting the grout, capable of
developing a pressure of at least 1 N/mm². The pump shall be fitted with a pressure
gauge and an effective control against build-up of excessive pressure. The pump
suction intake shall be kept below the surface level of the grout at all times during
grouting operations.
All tendons shall be grouted in their ducts as soon as practicable after the stressing
operation. Each duct shall be cleaned by blowing through compressed air, flushing with

Page 21  5
clean water and surplus water shall be removed by compressed air or other approved
means. Openings at the anchorages other than grout injection nozzle openings shall
be plugged with mortar or other suitable material. Subsequent to the hardening of the
plugging material the nozzle of the injection pipe shall be firmly connected to the duct in
such a way that air cannot be sucked in. Injection shall be commenced from one end
only and its progress monitored by the appearance of grout at successive vent holes.
When the consistency of the grout emerging from a vent is equal to that of the grout
being injected, that vent shall be plugged.
Injection shall continue until grout of a consistency equal to that being injected appears
at the far end of the duct. The injection nozzle shall then be withdrawn and all holes
and vents plugged to prevent loss of grout.
As far as possible all ducts in any one member shall be grouted in immediate
succession commencing with the lowest duct.
Grouting shall not be carried out when the air temperature is 2° C or lower.
The temperature of newly grouted cable ducts shall be prevented from falling below 2°
C for a minimum period of seven days.
(4) Quality Control
The grout shall be tested in accordance with the Standards and Codes and its fluidity,
bleeding, setting and compressive strength shall comply with the following
requirements:
 Fluidity measured with a 10 mm funnel output Marsh cone shall be less than
25 seconds.
 Bleeding shall be less than 2% by volume 3 hours after mixing, with a final
maximum value of 4%. Separated water shall be re-absorbed within 24 hours.
 The compressive strength of the hardened grout shall not be less than 17
N/mm² at seven days.
To demonstrate that the grout type and equipment are meeting the requirements of this
Specification, the Contractor shall carry out a site trial in accordance with Section 500
at least 24 hours before the intended date to commence the work.
2111 REJECTION OF PRESTRESSED WORK
Any prestressing tendons, anchorages, or any part whatsoever of prestressing component

which has been damaged during the tensioning operation shall be rejected.
In cases where excessive loss of prestress has occurred or in which the grouting has not been
satisfactorily carried out, or which is deficient in any other manner, the Contractor shall propose
corrective measures to the Engineer's agreement. The Contractor shall not rectify any
deficiency prior to the Engineer's agreement or instructions. Corrective measures shall be
carried out to the satisfaction of the Engineer and at the Contractor's expense failing which the
element shall be replaced by the Contractor at his cost.

Page 21  6
2112 TESTING PRESTRESSED WORK
If instructed by the Engineer, load testing of structures containing prestressed units shall be
carried out generally as set out in BSCP 110.
Details of all testing procedures shall be agreed between the Engineer and the Contractor
before testing is commenced.
2113 MEASUREMENT
Prestressed concrete shall be measured in cubic metre.
Tendons for prestressing shall be measured in tonne computed on the basis of their total length
and weight per unit length.
Provisions of ducts/seaths shall be measured in number which shall be inclusive of removal of

extractable formers and then grouting in ducts.
Anchorage assembly shall be measured in numbers fixed in place with all accessories.
Formwork, staging scaffolding shall be measured and paid as per Section 1800.
2114 PAYMENT
Prestressed concrete, tendons, ducts/seaths anchorage assembly shall be paid as per their
respective contract unit rates which shall be the full and the final compensation to the
Contractor as per Clause 112 and also for the cost of load tests if specified, and other ancillary
and incidental works necessary to complete the item as per this Specification.

Page 21  7
SECTION 2200 - STRUCTURAL STEELWORK
Page No.
2201 GENERAL 22–1

2203 FABRICATION: GENERAL REQUIREMENTS 22–1
2204 FABRICATION OF BOLTED STRUCTURES 22–11
2205 CASTINGS AND HEAT TREATMENT 22–16
2206 WELDED CONSTRUCTION 22–17
2207 FIELD ERECTION REQUIREMENTS 22–23
2208 ASSEMBLING AND BOLTING 22– 24
2209 PROTECTION AGAINST CORROSION 22–26
2211 PAYMENT 22–32
SECTION 2200 - STRUCTURAL STEELWORK
2201 GENERAL
(1) Scope
This Section covers fabrication, storage, handling and erection of steel structures
excluding those covered by Sections 1600 and 1900.
(2) Codes of Practice
The fabrication, storage, handling and erection of structural steelworks shall comply with
the relevant Sections of the IS and IRC, if otherwise not specified in the contract.
Should there be any disagreement between IS and IRC, the provision in the IRC shall
prevail to the extent of the disagreement.
2202 MATERIALS
(1) Materials for use in connection with the protection of the steel work against corrosion are
specified in Clause 2209. Other materials used in connection with steel structures such
as concrete, bearing pads, etc., shall be governed by the appropriate Sections of these
Specifications. Unless otherwise specified or described in the contract, structural steel
materials shall comply with the appropriate standards listed below.
IRC 24-1967 : Standard Specifications and Code of

Practice for Road Bridges.
IS 2062-1992 : Steel for General Structural Purposes
IS 9550-1980 : Specification for Bright bars.
IS 3757-1985 : Specification for High Strength Structural Bolts.
IS 6623-1985 : Specification for High Strength Structural Nuts.
IS 6649-1985 : Specification for Hardened and Tempered Washers

for High Strength Structural Bolts and Nuts.
2203 FABRICATION: GENERAL REQUIREMENTS
(1) General
This Clause shall apply to all operations undertaken in the fabrication in the workshop or
elsewhere whether on or off the site. The requirements contained herein shall not be
waived, nor shall be modified to conform to any set of rules that any shop adopted as its
standard unless so authorised in writing by the Engineer.
SECTION 2200 STRUCTURAL STEELWORK

Substitution of structural Sections of different dimensions, weight or strength from those

specified in the contract may be made only when approved in writing by the Engineer.
No payment shall be made for increased weight or strength/properties resulting from
approved substitution, but any decrease in weight shall be deducted from the final pay
quantity.
The various components/elements of the steel structure shall be fabricated in

accordance with the approved shop Drawing. Any errors or omissions in them shall be
reported to the Engineer, and his decision for their correction shall be final.
(2) Shop Detail Drawing
The Contractor shall furnish shop detail Drawing for the complete fabrication of all
components/elements required by the contract. When it is specified in the contract that
the employer shall furnish prints of standard shop detail Drawing, the Contractor shall be
required to make any additions or revisions to the detail Drawing as may be necessary to
produce a finished structure in accordance with the contract. Shop detail Drawing shall
consist of detailed Drawing showing the dimensions and sizes of the
components/elements, bolt lists for field erection, a match marking diagram, complete
field erection Drawing and such other details and information as may be necessary for
fabrication.
Shop detail Drawing of widening or reconstruction work shall contain sufficient field
dimensions, so that the shop Drawing may be checked. The Drawing shall also contain a
note to the effect that these are field measurements which the Contractor has furnished
and for which he is responsible. Such detail Drawing shall also show a portion of the
existing work, using light dotted lines or coloured ink for this purpose.
Shop detail Drawing shall be prepared in a neat and legible form, on the dull side of
tracing cloth, with India ink, or by other methods approved by the Engineer. Each sheet
shall have a title in the lower right hand corner giving the fabricator’s name, the
fabricator’s contract number and brief description of the details shown on the sheet.
Bills of material and bolt lists may be furnished on the fabricator’s own standard sheets.
The Contractor shall submit blueprints of shop Drawing to the Engineer for approval. No
work shall be done in the shop until such Drawing has been finally approved. In general,
2 sets of preliminary prints shall be required, but the Contractor shall furnish additional
prints free of charge upon request. Only checked Drawing in complete sets shall be
submitted for approval. The details of anchorages, bearing plates, castings, etc., shall be
submitted in advance, in order to avoid delay in construction.
When changes on the submitted Drawing are requested by the Engineer, or when the
Contractor makes additional changes, other than those requested, attention shall be
called to the changes on the blueprints submitted for approval by encircling or
underscoring all change with contrasting coloured ink or rayon.
After the Drawing has been finally approved, the Contractor shall, without direct
compensation thereof, furnish to the Engineer 4 sets of prints of the corrected Drawing,
and such additional prints as may be required. The shop Drawing as approved by the
Engineer shall become a part of the contract.

The ordering of material or the performance of shop work prior to the Engineer’s
approval of shop Drawing shall be at the Contractor’s risk and cost. No changes shall be
made in any approved Drawing without the written authorisation of the Engineer. The
Engineer’s approval of shop Drawing shall not relieve the Contractor of responsibility for
the accurate assembly and fitting of all structural members. After the shop work has
been completed, the Contractor shall deliver to the Engineer all of the original tracings of
the shop details, or photo positives thereof, on cloth.
(3) General Shop Practice
(a) Storage
Before and after fabrication, all materials shall be so stored that they are not
deformed or damaged, and shall be protected against the accumulation of water,
dirt, oil or other foreign matter. Material that has become pitted from exposure or
other causes shall not be acceptable for any use. Material that has been
damaged during storage shall be replaced with equivalent or better material.
(b) Identification
Structural alloy steel shapes and Sections shall, in addition to standard mill
practice identification, be further identified during all operations, from the mill to
the completely fabricated structure, by the use of, and continued maintenance of,
colour coding in accordance with IS 2049.
Alloy steel and non-ferrous alloy bolts shall be identified by coded markings
embossed or impressed on the head or tip during manufacture. Pieces on which
identification has been lost shall be rejected.
(c) Workmanship and finish
All metals shall be neatly and accurately cut to required size with proper
allowance as may be necessary or required for finishing operations.
All fins, ragged or distorted edges resulting from shearing, speed sawing, or
flame cutting shall be removed by milling, chipping, or grinding.
Shearing shall not be used for the purpose of cutting non-ferrous metals where
the thickness is greater than 13mm.
(d) Flame cutting
The gas cutting torch may be employed in the operation of cutting metals or
preparing joints provided that the metal is not carrying stress during the
operation. Carbon steel above 0.30 carbon alloy steels, heat treated steel or
aluminium, wrought non-ferrous metals and plated metals shall not be flame cut
unless subsequent corrective treatment is provided which shall be subject to the
approval of the Engineer.

When the cutting torch is used, the burned edges shall be trimmed smooth to
exact lines by milling, chipping or grinding. Maximum deviation for “free hand”
cutting shall be 1.5mm from true lines. A mechanical guide shall be used for the
flame cutting torch on all work requiring precision cutting on which the maximum
deviation permitted shall not be greater than 0.8mm. All “notch effects” shall be
completely removed from the portions of members where the extreme fibre is
subject to flexure, tension or perpendicular shear.
Where the ends of members which are to take bearing, are cut with a torch, a
suitable allowance in their length shall be made to permit proper milling or
planning.
Joints for welding may be prepared by “flame cutting” or “flame gouging”

provided all slag and oxidised metal are removed.
(e) Re-entrants
Interior and re-entrant corners shall be filleted to a 25 mm radius unless a

shorter radius is indicated in the plan. Fillets less than 25 mm in radius shall be
formed by drilling.
(f) Bending
All bending or crimping shall be done at the bend lines shown, by a mechanical
operated press, without unnecessary loss of Section in the metal being bent. The
bends shall conform to wood or metal templates. All low carbon steel and other
wrought metals shall be bent cold when the required bending will not produce
cracks or fractures. When heating is necessary to accomplish bending of
ferrous metals, the material shall be carefully heated to and bent at or above a
temperature evidenced by a dark red colour, but in no case at a lower
temperature. All material bent below such temperature shall be rejected and
annealing shall not be considered a corrective measure. Heated material shall
be slowly cooled after the bending operation. Heat treated metals shall be
shaped before heat treatment. Material having fractures or other defects caused
by bending shall be rejected.
Cold-bent load-carrying rolled steel plates shall conform the following:
(i) They shall be so taken from the stock plates that the bent-line is at right
angles to the direction of rolling.
(ii) The radius of bends, measured to the concave face of the metal shall be
more than specified below.
Angle through which plate is bent Radius

61o to 90o 1.0 T
91o to 120o 1.5 T
121o to 150o 2.0 T
Where T is the thickness of the plate undergoing bend.

(iii) Before bending, the corners of the plate shall be rounded to a radius of
1.5 mm throughout that portion of the plate at which the bending is to
occur. If a shorter radius is essential, the plates shall be bent hot.
(g) Straightening Material
All wrought and extruded Sections must be made straight or cambered as

shown in the plan before being marked, punched or otherwise worked on in the
shop. If straightening is necessary, it shall be done by methods which will not
change the physical properties, reduce the Section, or otherwise damage the
metal. Material which develops kinks, fractures or evidence of embrittlement
shall be rejected. Materials that are warped by cutting, punching or welding shall
be straightened to correct lines and dimensions before being assembled.
Sections that are distorted during assembly and/or welding shall be straightened
by methods that will not shear, fracture, or pre-stress the welds or connecting
members. If, in the opinion of the Engineer, Sections can not be properly
straightened after assembly, the bent material shall be taken out, straightened
and reassembled in the unit. Any material damaged during such operations
shall be replaced with equivalent or better material.
Unless otherwise specified in the contract, structural steel Sections which

deformations do not exceed normal rolling tolerances will be acceptable without
straightening. When the plans so indicate, beams shall have unwrapped webs
with flanges at true right angles thereto. Such beams shall, if necessary, be
straightened cold by an approved method of web pressing.
(h) Layouts and Templates
Full scale layouts will be required for intricate portions of structures that present
problems of fabrication or erection. When requested by the Engineer, such
layouts shall be made available to him for checking purposes. Duplicate work
shall be fabricated with the aid of templates or jigs. Wood or metal templates
shall be used for all mitre joints except when an approved jig is used. Reaming
or drilling templates shall be made of metal, using hardened steel bushings 25
mm thick.
Sweeps for laying out and checking curved surfaces shall be made of wood or
metal and shall be of sufficient length to produce accurate results.
Working points and working lines shall be clearly marked on all templates and
sweeps.
All templates shall be made available for the Engineer's use.
(i) Built-up Members
A built-up member shall be true to detailed dimensions and it shall be free of

twists, bends, open joints, or other defects resulting from faulty fabrication or
workmanship. The assembly shall be such that all field joints will have the
planned clearance. The joints shall be smooth, and free from all burrs or other
obstructions.

Closed Sections or pockets which might harbour moisture or dust and which
cannot be readily cleaned and painted shall be filled with plates or closed by
caulking or welding. Filler plates shall be full size and fitted sufficiently tight to
exclude all moisture and dust after being painted. Tack welding may be
employed to hold fillers in place.
(j) Incidental Items
The following items shall be furnished by the Contractor without additional

payment unless otherwise provided for in the contract:
(i) Pilot Points and Driving Nuts:
One new pilot point and one driving nut for each size of shouldered pin.
(ii) Erection Pins, Bolts and Washers:
All erection pins, bolts and washers necessary for field erection.
(iii) Field Rivets:
Extra rivets of each size and length, in the amount of 10 rivets plus 10
per cent of the number actually required for field erection, to
compensate for losses due to misuse, improper driving or other
contingencies.
(iv) Field Shims:
Shims 3 mm or more in thickness shall be made of structural steel and

those thinner than 3 mm shall be made of sheet brass.
"Field shims" shall be constructed to mean all metal plates which are
required, because of inequalities or inaccuracies in fabrication or
erection or because of the substitution of Sections by the fabricator, to
bring metal surfaces of members into contact or to bring the structure to
the required grade and alignment. "Fillers" shall be constructed to mean
metal plates which are required by the design to bring metal surfaces of
members into contact or to bring the structure to the required grade and
alignment, and shall be included in the quantities for which payment
shall be made.
(v) Sections:
Increase of Sections over net size required in the contract, and other
Sections, metals, parts, or equipment added for the purpose of erection
only which may or may not subsequently remain a part of the finished
structure.
(4) Machining
(a) Definition of Terms

(i) Rough Finish:
The surface shall be true but may show very slight grooves.
(ii) Finish:
The surface shall be true and smooth and shall show no visual evidence
of grooves.
(iii) Smooth Finish:
The surface shall be true and perfectly smooth to the touch.
(iv) Polished Finish:
The surface shall be true, smooth and polished.
(v) Milled Finish:
The surface shall be the same as the defined for rough finish.
(vi) Bored Finish:
The surface shall be the same as that defined for smooth finish.
(b) Machine Lubricant
Soap water solution shall be used as a lubricant on all structural material

requiring machine work. The use of oil or grease shall not be permitted for this
purpose. Cutting oil shall be used on machinery parts and bolt stock.
(c) Edge Planning
Structural steel plates with sheared edges having a thickness of more than 16
mm and structural alloy plates having a thickness of 13mm or more, except web
plates for built-up girders, sole or base plates, and fillers, shall be planed to
correct size with square edges by removing not less than 6 mm of metal. The
use of mechanically guided needle torch may be permitted in lieu of specified
edge planning of expansion plates when used for the purpose of making bevel
cuts.
(d) Bearing Surfaces
After a column has been otherwise completely welded and before the cap or
base plates are attached, the bearing surfaces shall be milled true to the angle
shown in the plan.
End connection angles shall be welded to the main member before milling.
Cap and base plates of columns shall have full contact with the milled surface
after assembly. Sole plates of beams and girders shall have full contact with the
flanges. Warped or deformed plates shall be machine finished or otherwise
straightened by an approved method to secure an accurate and uniform contact.

Countersunk river heads or extruding weld metal shall be chipped smooth and
flush with the surrounding surface.
Castings shall be machined as indicated in the plan.
Bronze bearing plates shall have a “Polished Finish”.
(e) Abutting Joints
The ends of members shall not be milled until such members have been
completely welded. Members whose ends are improperly milled shall be
rejected.
The ends of members forming a compression joint or splice shall be accurately

milled to proper length, alignment and bearing, using a wood or steel template as
a guide. Gusset plates connecting milled ends of members shall conform to the
same wood or metal templates from which the milled ends were formed. The use
of bevel square shall not be permitted.
Joints in main chord tension members shall be close and neat, and in no case
shall the opening be more than 3 mm.
(f) Boring Pin Holes
Pin holes shall be accurately located as detailed, and bored true to exact
dimensions. They shall be bored smooth, straight, and at right angles to the axis
of member. A finishing cut, which shall be a complete and separate operation,
will be required.
Unless otherwise indicated in the plans, the difference in diameters of the pins
and the pin holes shall be 0.8 mm exact.
(g) Pins and Rollers
Pins and rollers shall be accurately turned to the detailed dimensions. The final
surface shall be smooth, straight, and free from flaws. The final surface shall be
machined to a smooth finish.
All bridge pins and rollers 150mm in diameter and smaller shall be made of
Bright steel bars complying with IS 9550.
All segmental rollers and all pins whose nominal diameter is to be greater than
150mm shall be made from annealed forging. A hole 50mm in diameter shall be
bored longitudinally through the centre of each pin or roller having a diameter
greater than 230mm. Pins or rollers showing defective interiors shall be rejected.
Pins shall be held in place by recessed nuts. The nuts shall be hexagonal in
sharp and shall be made of malleable iron, pressed or cast steel. The grip face of
the nut shall be machined square to the axis of the pin. Pins and nuts shall be
accurately made so that the recessed face of the nut will bear uniformly against
the end face of the pin when the nut is turned up tight. The threaded portion of

the pin shall project at least 6mm through the nut after assembly. Where a
recessed cut is made between the threads and the shoulder of the pin, it shall
not be wider than 6 mm nor deeper than the base of the thread.
(5) Marking and Dispatching
All material shall be accurately and legibly marked according to the field erection plan,
prior to dispatch. Such markings shall be made with contrasting paint on previously
painted surfaces. The omission of marks on duplicate pieces shall not be permitted
unless otherwise authorised by the Engineer.
When practicable, loose connection plates for a member shall be bolted in position
thereon for shipment. All rivets, bolts, nuts and washers shall be parcelled separately as
to size. They shall be shipped in suitable containers, but the gross weight of any single
container shall not exceed 100 kg. A list and description of the included material shall be
plainly marked on the outside of each container.
Pins, roller nets, name plates, sheet lead, and small parts shall be boxed or crated for
shipment. Pins shall be shipped with the nuts in place.
When the Engineer directs, finished work shall be weighed in the presence of the
Inspector. The fabricator shall supply satisfactory scales and shall do the handling and
weighing. When requested by the Engineer, members weighing more than 300 kg shall
be marked to show their scale weight.
The loading, unloading, handling, transportation and storing of structural material shall be
carefully conducted so that the metal will be kept clean and free from damage. All
girders, partly assembled trusses, and large I beams shall be transported in an upright
position. Cambered members shall be securely blocked to prevent any loss of camber.
All sheets land copper waterstops shall be crated for transport.
Anchor bolts, pier nose angles, and other anchorage or grillage materials shall be
dispatched in advance of other material to suit the requirements of the construction work.
(6) Shop Painting
All ferrous metals which have not been plated, galvanised or enamelled shall be given
one shop coat of paint of the kind specified in the contract. Non-ferrous metals shall not
be painted or otherwise surface treated unless so specified in the contract. All cleaning
and painting shall conform to Clause 2209.
(7) Inspection and Testing
(a) General Requirements
The Contractor shall advise the Engineer as to the actual date and place of
preparation of materials so that sufficient time may be had, prior to such
preparation, to arrange for inspection. This inspection will be dependent upon
the character and importance of the work and may involve inspection in the mill,
the foundry, the fabricating shop and the field, as may be considered necessary
by the Engineer. Information relative to the time of beginning various operations,
such as mill rolling, foundry casting, heat treating, shop layout, punching,

riveting, welding, milling, assembling, painting and shipping, shall be furnished to

the Engineer in sufficient time so that he may provide for the proper supervision
and inspection of the work. In general 28 days shall be considered as the
required time of advance notice. Failure to furnish such information shall result in
the rejection of the material involved.
The Employer may depute structural-metals-inspectors for the inspection of all

metals at the plant or in the field. When such inspection service can be
furnished in the usual routine manner without any additional expenditure, no
charge shall be made against the Contractor. When such inspection service
entails additional costs, the Contractor shall be charged for the expense incurred
but such charges shall not be greater than the amount specified in the contract
per person per ton, based on the total metal tonnage of the contract.
As soon as the progress of the work permits, the Contractor shall furnish to the
Engineer 2 copies, or more, if required, of each of the following:
Mill or purchase orders, certified reports of physical characteristics and chemical

analysis of all materials involved, and the fabricator's shipping statements
showing the net scale weight of each shipment. When requested, the scale
weights of individual member or Sections shall be furnished.
All materials and workmanship shall be subject to inspection and Engineer's

agreement. The inspection of materials and fabrication shall as far as possible
be carried out at the place of manufacture.
Except as provided for above no fabricated steelwork shall be dispatched to the

Site before it has been inspected and agreed. All inspected and agreed
steelwork shall be marked in accordance with the agreed procedures.
(b) Inspector's Authority
The Inspector shall reject the materials and/or the workmanship which do not
fulfil the requirements of the contract. However, in cases of dispute, the
Contractor may appeal to the Engineer, whose decision shall be the final.
Inspection at the mill and shop is provided for the purpose of facilitating
fabrication work and to avoid errors, but such inspection shall not relieve the
Contractor of his responsibility for the correction of errors and faulty
workmanship or for the replacement of imperfect materials.
(c) Facilities for Inspection
The Contractor shall furnish all facilities, tools, and such assistance as the
Inspector may require for the inspection of material and workmanship in the mill,
foundry or shop. The inspector shall be granted free access to the plant
premises for the required inspection service. All fabricated parts shall be piled
separately in such a manner as to facilitate inspection.
The Contractor shall furnish office space at the fabrication plant for the
Inspector's use during the period of fabrication, assembly and paintings.

(d) Testing
Unless otherwise provided, the Contractor shall furnish test specimens as

specified, and all labour, testing machines and tools necessary to prepare the
specimens and to make the prescribed tests. Where check tests are required by
the Engineer to determine the suitability of any materials, the Contractor shall
furnish representative samples for further testing by the Engineer before such
material is finally approved for use.
Where no specific tests are provided for in the contract, tests for metals shall be
conducted in accordance with the Engineer's directions.
(e) Rejection
Rejected materials and workmanship shall be promptly replaced with

satisfactory material and workmanship. Any shipment of materials that has been
damaged in transit shall not be unloaded until an agreement as to its disposition
has been reached with the Engineer.
2204 FABRICATION OF BOLTED STRUCTURES
(1) End Connection Angles
End connection angles of floor beams, stringers and diaphragms shall be accurately
assembled to the dimensions shown in the plan, and the length, back to back of angles,
shall be exact. Unless otherwise specified, the finishing of end connection angles shall
not be required except as a correction to a faulty assembly. When finishing is necessary
for such correction, the thickness of the angle shall not be reduced by more than 3mm
but in no case shall the final thickness of the angle be less than 9 mm. Portions of
members extending beyond the face of the connection angles shall be chipped or ground
flush. No portion of a web or a connecting member shall be recessed more than 9mm
from the face of the connection angles.
(2) Stringers
Stringers shall be straight and their bearing surfaces shall be true and free from all burrs
and distorted edges. The fixed ends of stringers supported on brackets or on the top
flanges of floor beams shall be secured by means of bolts having hexagonal heads and
nuts.
The maximum clearance between abutting ends of stringers shall be 13mm unless
otherwise specified. Stringers supported on brackets shall have a maximum clearance
of 13mm between the end of the stringer and the web of the floor beam.
(3) Expansion Devices
Expansion and deflection devices shall be fabricated to exact dimensions, and no

tolerance in materials or dimensions shall be allowed. Unless otherwise indicated in the
plan these devices shall be secured to stringers or floor beam by means of bolts having
hexagonal heads, hexagonal nuts and lock washers.

(4) Bolted Plate Girders
The web plate of a finished girder shall in no case project beyond the face of the flange
angles or end stiffener angles. In girders with full-length cover plates, the edges of the
web shall not be more than 6 mm inside the face of the flange angles except that, in
cases of cambered beams, the width of the web may be 13 mm less than the distance
(back to back) between the flange angles provided the web is centred. In girders without
cover plates, the edges of the web shall not be more than 3 mm below the face of the top
flange angles. In girders with partial length cover plates, the above requirements shall
apply together with the additional requirement that, unless the edges of the webs are
flush with the faces of the flange angles at the ends of the cover plates, any space
between them shall be plugged with a weld at least 13 mm long. In no case shall the
ends of the webs be more than 9 mm inside the face of the end stiffener angles.
Holes in all girder web splices shall be subpunched or subdrilled. After assembly these
holes shall be reamed to specified size.
Splicing of flange angles shall not be permitted, unless required by the contract, except
when girders are to be constructed with curved ends, in which case the flange angles
shall be spliced near the curved portion to facilitate bending and assembly. Curved and
flange angles shall be bent in pairs. After bending, the curved angles shall be true to the
plan radius and free of all wrinkles or waves. After assembly, these curved end angles
shall be butt welded to the flange angles, and the weld shall then be ground smooth.
When splices in flange angles are required by the contact, the abutting ends of the
angles shall be milled to a close fit. All holes in such splices shall be subpunched and
reamed, or drilled from the solid. Smoothly ground butt welds will be acceptable for joints
in flange angles in lieu of milling. Such welds shall not be considered as a substitute for
the splice plates or angles as detailed.
Unless otherwise indicated in the plan, end stiffeners and intermediate stiffeners intended
for supports for concentrated loads shall be milled or ground smooth to secure a uniform,
even bearing against the top and bottom flange angles. When welding is indicated or
permitted in lieu of milling or grinding, the welds shall be of sufficient size to develop fully
the stiffener in bearing and they shall be so placed as to completely seal the stiffener
ends against entrapment of moisture. Welding transversely across the tension flanges of
beams or girders which have a flange stress of more than 75 per cent of their designed
capacity, shall not be permitted. At locations of higher stress, wedge fillers shall be
incorporated in conjunction with longitudinal welds.
Intermediate stiffeners shall fit sufficiently tight to exclude moisture after being painted.
Fillers under stiffeners shall fit within 1.5mm at each end. Crimped stiffeners angles or
tees shall be properly bent to a steel template, and they shall have full contact bearing
against the flange and the web plates.
(5) Holes for Unfinished Bolts
(a) General

All holes shall be true to the shape and size specified, clean-cut, perpendicular
to the axis of the member and free from all burrs and distorted, torn or ragged
edges.
The minimum distance from the centre of a hole to a sheared edge shall be
38mm, and the minimum distance to a planed or rolled edge shall be 1.5 times
the diameter of the bolt specified for such hole, except as hereinafter provided or
otherwise indicated in the plan. The edge distance for lace bars shall be not less
than 1.6 times the diameter of the rivet or bolt.
(b) Type
When reaming or drilling is not specified in the contract, full size punched holes
in low carbon and low alloy steels may be acceptable, provided the thickness of
the metal does not exceed the diameter of the hole to be punched, and provided
no more than 5 thickness of metal are to be connected. When there are more
than 5 thicknesses of metal or when any of the material is thicker than the
diameter of the hole, all of the holes in the material composing such connections
shall be formed by subpunching (or subdrilling) and reaming or by drilling from
the solid, as hereinafter specified. Stress-carrying high-carbon steels, non-
ferrous metals and alloys 13mm in thickness or less shall be subpunched (or
sub-drilled) and reamed. Where such metals are of greater thickness the holes
shall be drilled from the solid with all parts assembled. Railing Sections may be
jig drilled full size.
When general reaming is specified in the contract for low carbon and low alloy
steels, all bolt holes, including connection holes to main members, shall be
subpunched (or subdrilled) and reamed, or drilled from the solid; except for the
following, which may be full punched:
 Holes for unfinished bolts, or plug welds.

 Holes in expansion and deflection devices, stringer diaphragms and
railings.
 Holes in laterals and lateral plates; away frames other than in towers or
bents; brackets; sole, bearing or anchor plates; and grillages.
(c) Punched Holes
The diameter of full-sized punched holes shall be 1.5mm larger than the nominal
diameter of the rivet or bolt. The diameter of the die shall not exceed the
diameter of the punch by more than 1.5mm.
All holes shall be so accurately punched that, after the assembly of the
component parts of a member, and before any reaming is done, a cylindrical pin
whose diameter is 3mm less than the nominal diameter of the punched hole
shall pass freely through at least 75 per cent of the holes in any group.
Correspondingly, a pin whose diameter is 5mm less than the nominal diameter of
the punched holes shall pass freely through all holes in any group. Material
failing to meet either of the above requirements shall be rejected. Reaming shall
not be permitted as a corrective measure.

(6) Holes for Turned Bolts
The diameter of holes for turned bolts shall be 0.4 mm larger than the diameter of the
bolt. If the bolts are to be inserted in the shop, the holes may be either drilled from the
solid, or subpunched and reamed. If the bolts are to be inserted in the field, the holes
shall be subpunched or subdrilled in the shop and reamed in the field. All drilling or
reaming for turned bolts shall be done after the parts to be connected are assembled and
securely fastened together. No offsets shall be permitted in holes for turned bolts.
(7) Slotted Holes
Slotted holes shall be securely located, true to planned dimensions. Where full size slot
punches are not used for this purpose, the holes shall be made under size and
subsequently finished to true size and shape by chipping grinding or filing.
(8) Bolts
(a) Unfinished Bolts
Unless otherwise specified, all bolts for steel construction shall be unfinished
and shall have hexagonal heads, hexagonal nuts and lock washers. The length
of the bolt shall be such that, after placement, it will project through the nut not
less than 3mm nor more than 9mm. The material for and the manufacture of
bolts shall conform to the equipments of IS 1364 or IS 3757 as appropriate.
(b) Turned Bolts
The heads and the nuts shall be hexagonal. The bolt shall be machined from a
hexagonal bar, the size of which shall be the same as the bolt head. The shank
of the bolt shall be turned and given a smooth finish to exact diameter. The
length of the unthreaded portion of the bolt under the head shall be 3mm greater
than the thickness of material it is to pass through. The diameter of the
unthreaded portion of the bolt shall have a diameter at least 2.4 mm less than
the diameter of the unthreaded portion of the bolt, and it shall be the nearest
standard bolt size. The threads shall extend from the end of the bolt to within 1
thread distance from the shoulder. Washers 6mm in thickness shall be used
under all nuts, and the hole in the washer shall be the same size as the reamed
or drilled hole.
(c) Anchor Bolts
Anchor bolts shall be of the swage type and shall have hexagonal nuts. Bolts for
expansion joints shall be provided with 2 nuts. Those portions of bolts which
extend above masonry or concrete shall be painted 1 shop coat of paint.
(d) High Strength Friction Grip Bolts
High Strength friction grip bolts shall comply with IS 3757.
All load indicators shall be suitably marked for identification purposes and shall
be of standard black, lightly oiled, finish and shall be packed prior to dispatch, by

the manufacturer, in waterproof containers and shall be stored in those

containers under cover until required for use in the works.
Only general grade load indicators shall be used with general grade high
strength friction grip bolts.
Each high strength friction grip bolt when installed in the works shall be complete
with one washer placed under the nut and one load indicator placed under the
bolt head and each bolt shall be tightened at all stages by rotating the nut only,
the bolt head being completely restrained against rotational movement.
Alternatively, in joints where accessibility is limited to the extent that bolts must
be tightened by rotating the bolt heads, then washers shall be laced under the
bolt heads and both load indicators and nut face washer shall be placed under
the nuts. In these cases each bolt shall be tightened at all stages by rotating the
bolt head only, the nut being completely restrained against rotational movement.
All high strength friction grip bolts shall first be tightened sufficiently to secure the
structural steelwork during its erection or assembly. Following the completion of
the erection or assembly of each portion of the structural steelwork those bolts
shall be finally tightened until the gaps between the load indicators and either the
bolt heads or the nut face washers have been reduced to:
(i) 0.400mm where load indicators are fitted under the bolt heads.
(ii) 0.250 mm where load indicators are fitted under the nuts and beneath
nut face washers.
The bolts may be tightened by a part-torque part-turn method. The part-torque
tightening for bedding down shall be in accordance with BS 4604: Part 1 except
that it shall be carried out by a calibrated tightening device such as a torque-
controlled manual wrench or power operated wrench. The bedding torque to be
applied to the bolts shall be as given in Table 22.1.
Table 22.1: Preliminary Tightening of Nuts
Nominal dia of bolt Bedding torque ± 10 percent

mm Nm
16 80
20 160
22 210
24 270
27 340
30 460
After bedding down of the joints, each nut and the protruding threads of the bolt
shall be permanently marked to record their relative positions. The nuts shall
then be tightened to the approval of the Engineer by the part-turn of the nut
method in accordance with BS 4604: Part 1.
2205 CASTINGS AND HEAT TREATMENT

(1) Foundry Practice
Patterns for casting shall be furnished by the Contractor. They shall be constructed to
produce a finished casting in true conformity to the dimensions and details shown in the
plan. All sharp angles shall be boldly filleted. Fillets shall be of such size that there is no
reduction in planned clearances due to their addition. External corners on all castings,
except ornamental type, shall be rounded to a 5 mm radius. Proper allowance for
shrinkage shall be made in all patterns. Sufficient materials shall be provided on all
surfaces which are to receive a finish so that, after finishing, the castings will be the
planned size, and the finished surfaces will be true, free from pockets, sand intrusions, or
other defects. Draft provided shall allow the plan dimensions and shall not reduce the
thickness of metal specified. All patterns shall be painted, indicating in different colours,
the metal, cores and finished surfaces.
Split cores shall not be permitted between unfinished surfaces of restricted clearance.
The number and spacing of chaplets shall be such that the strength of the casting is not
impaired by their use.
The casting shall be accomplished by a method that will ensure the complete filling of all
corners, arises and edges. Castings requiring undercut surfaces shall be cast by the
“lost wax process” or equivalent. Where practicable, castings having one machined
surface shall be cast with the surface down. Metal from different melts shall not be
permitted in the same casting.
Castings shall not be withdrawn from the mould until they have properly cooled.
Quenching of casting to speed up the cooling shall not be permitted.
All castings shall be thoroughly cleaned of moulding and core sand by sand blasting or
by other approved methods. All high spots and rough edges resulting from pouring
connections shall be ground smooth.
All castings shall ring true when suspended and struck with a hammer. When ordered by
the Engineer, the soundness of the casting shall be further tested by drilling, planing,
magnetic particle test or X-ray.
Any structural defect in a casting such as blow holes, pipes, sand holes, cracks, checks,
slag inclusions, cold shuts, unfilled arises, warped surfaces, or deformation from core or
flask movement shall be cause for rejection.
Castings with minor defects shall not be repaired until the Engineer has given his
permission. The method employed in such repair work shall be approved by the
Engineer.
(2) Heat Treatment
The term “heat treatment” shall mean any method of intentionally and systematically
applying heat, at a temperature below the melting point, to any casting after it has cooled.
This heat may be applied one or more times irrespective of cooling the procedure.
The term “annealing” shall mean either normalising (air cooling) a casting or full
annealing (furnace cooling) a casting.

Full annealing shall consist of a heat treatment in which the casting is heated slowly to
the proper temperature above the critical range, maintained in such temperature for the
required time, and allowed to cool slowly in the furnace until the temperature has fallen to
260 degrees F or less. The casting may then be withdrawn from the furnace and air
cooled. The furnace temperature shall be controlled by pyrometers.
All other castings shall be annealed when so specified in the contract.
All forgings, and such other steel Sections as may be required by the contract, shall be
full annealed. Other steel members, except primped web stiffeners, that have been
partially-heated shall be full annealed unless otherwise authorised by the Engineer.
2206 WELDED CONSTRUCTION
(1) General
Welding shall be generally in accordance with IS 1024 and relevant British Standards as
further amplified in the following Sub-clauses.
(2) Materials
Welding materials unless specified in the contract or agreed by the Engineer shall
comply with the appropriate Indian Standard listed below:
(a) IS 814 - 1991 covered electrodes for manual metal arc welding of carbon and
carbon manganese steel (fifth revision).
(b) IS 1278-1972 filler rods and wires for gas welding (second revision)
Classification and colour coding of electrodes shall be in accordance with IS 814-1991.
(3) Welding Equipment
Welding equipment shall comply with the appropriate Indian Standard listed below unless
otherwise stipulated in the contract or agreed by the Engineer.
 IS 2635 - 1975 : DC electric welding generators (second revision).
 IS 4804 (Part 1) - 1968: Single-phase transformers.
 IS 4804 (Part 2) - 1968 : Single-phase rocker arm spot welding machines.
 IS 4804 (Part 3) - 1969 : Single-phase spot and projection welding machines.
 IS 4559 - 1993 : Single operator rectifier type DC arc welding power source (second
revision).
 IS 2641 - 1989 : Electrical welding accessories (first revision).

The welding plant and equipment employed on the works shall be of sufficient capacity to
carry out the agreed procedures and suitable for the types of electrodes in use. All
necessary stagings and screens shall be provided for the welders, supervisors and
inspectors and all plant and equipment shall be maintained in an efficient condition.
Suitable tong test ammeters shall be provided for measuring the current, except only,
when efficient means of so doing are incorporated as part of the welding plant.
The strength of the welding current shall be within the range recommended by the
manufacturer of the particular electrode being used and shall be towards the upper limit
of the range rather than the lower.
Welding shall wherever possible be carried out in covered workshops and under the
specified conditions of temperature, where continuous supervision is exercised.
Machine welding may be allowed where approved machines are in use correctly
controlled by qualified operators.
Site welding shall not be carried out unless prior written agreement from the Engineer
has been obtained. All such welding shall be subject to 100% non-destructive testing.
(4) Qualification of Welders
All welding operators shall be qualified persons in accordance with Clause 23 of BS 5135
and the names of all operators and details of their qualifications shall be submitted to the
Engineer for agreement. Any operator whose standard of workmanship is unsatisfactory
shall be immediately suspended. The operators shall be produced by the Contractor for
re-testing and verification of his qualification once he has received further instruction in
this respect. Routine testing of all operators shall be required in every six months.
(5) Workmanship
(a) Assembly
Material that is to be welded shall be free form loose mill scale, rust, or other
foreign matter on the surface to be welded and for a distance of at least 50 mm
on each side of the weld. The preparation of edges for welding may be made by
milling, chipping or cutting with a torch. All traces of overheated metal caused by
torch cutting shall be removed. For this chipping to expose clean metal may be
required. Grinding shall not be permitted on any surface or edge which is to be
welded, unless the surface is subsequently thoroughly cleaned of carborundum
and metal particles.
Members or parts which have been painted shall have all of the paint removed
from the area which will be affected by the heat of the arc. This shall be
accomplished by burning with a blow torch or blow pipe and brushing with a wire
brush.
(b) Welding

Welding shall not be done in rain, snow or wind, or when the temperature of the
metal is below 4oC, unless satisfactory protection such as shelters, wind-breaks
and heat is provided.
During moderately cold weather the use of small movable shelters and
preheating the metal by means of blow torches will be in general satisfactory.
When the temperature is below - 10oC, the span or portion of structure
undergoing welding shall be entirely housed in and heated to a minimum of 5 oC.
The use of open salamanders for such heating shall not be permitted.
Welding procedures shall be such that distortion is reduced to the minimum

practicable and local distortion is rendered negligible in the final structure.
All welding procedures including those items listed in Clause 20 of BS 5135 shall
be submitted to the Engineer in advance for agreement. All welding procedures
submitted for agreement shall have previously been approved by an
Independent Inspector, from authentic documented experience gained with
welding of joints similar to that for which the welding procedure applies. Where
no such approval is available, then the welding procedure shall be subject to
approval after testing in accordance with the requirement of BS 4870.
All welds shall be of the specified size and shape, and they shall be placed at the
locations designated. Welds which are not in conformity with those required or
welds which are defective shall be chipped out and redone in an approved
manner. Weld protrusions which interfere with later work or which present an
uneven or unworkmanlike appearance shall be finished smooth by chipping and
grinding. Deposited weld metal must be completely fused to all metal with which
it is in contact. The weld shall be free of all pits, porous Sections, cold shuts, or
slag inclusions. All pits and craters shall be filled and all ends shall be boxed.
An electrode of the proper size shall be selected for the weld desired. The
electric current shall be adjusted for the electrode so that full fusion will be
obtained without undercutting. Undercut welds shall be chipped back to bright
metal and rewelded. The arc shall be kept uniform and steady and shall be
applied in a manner which will fuse the metal without boiling, running or
unnecessary spatter.
The placement of welds shall be such as to minimise shrinkage or distortion of

the members. Members in which there is distortion caused by welding must be
straightened to the satisfaction of the Engineer without structural damage to the
member or to the welds.
Peening for welds shall not be permitted.
(c) Final Finish of Welds
The final finished surface of the weld shall be smooth and regular and shall
conform as closely as practicable to the design requirements. All slag shall be
removed from the finished weld. All flux deposit which may cause paint to rot
shall be entirely removed. The entire surface shall be thoroughly wire-brushed

before painting. If required by the Engineer, the final surface shall be finished
smooth by chipping and grinding the weld deposit.
(d) Weld Inspection
Inspection shall be made during the welding process and after the weld is
completed and cooled in accordance with IS 3600. All defects shall be entirely
removed or repaired to the satisfaction of the Engineer. The Engineer shall
designate at least 25 mm of every 2500 mm of welding for removal, to determine
the penetration, fusion and porosity of the weld.
Plug borings shall be furnished when requested with the use of “X-ray” or
magnetic-particle examinations may be made where the proper testing
equipment is available. In such cases the inspection practice shall be in
accordance with IS 1182 or IS 5334 as appropriate.
(6) Safety Precaution
Suitable shoes, helmets, hand shields, glasses, gloves, aprons, screens, canvas, wind
shields and all other equipment necessary for the protection of the work, the welders, the
helpers and the Engineer’s Inspector shall be provided by the Contractor at his own
expense. The provisions of IS 818 - 1968 Code of Practice of Safety and health
requirements in electric and gas welding and cutting operations (first revision) shall be
observed.
(7) Procedure Trials
When directed by the Engineer and before fabrication is commenced, welding and flame
cutting procedure trials shall be carried out using representative samples of materials to
be used in the work.
The samples of material shall be selected and marked by the Engineer when the
materials for the work are inspected at the mills. Trials on material 20mm thick shall be
taken to include all material up to but not exceeding 20mm thick. Trials on material 38mm
thick shall be taken to include material over 20mm and up to but not exceeding 38mm
thick. Material over 38mm thick shall be tested for every thickness increment of 6mm.
The welding and flame cutting trials shall demonstrate to the satisfaction of the Engineer
the procedures to be adopted in the fabrication of the work which shall include:
(a) Welding procedure in accordance with BS 5135-1984.
(b) The heat control techniques required to ensure that the flame cut surfaces of
steel are free from cracks, local hardness, and any other defects which would be
detrimental to the finished work.
The trials shall include specimen weld details representative of the actual construction
which shall be welded in a manner simulating the most unfavourable conditions liable to
occur in the particular fabrication. Where primers are to be applied to the work prior to
fabrication, they shall be applied to the sample material before the procedure trials are

made. After welding the specimens shall be held at a temperature not less than 10o for a
period of not less than 72 hours and shall then be sectioned and examined for cracks
and other defects.
The following groups of tests as per BS 709 shall be carried out in accordance with
Clause 621.
(i) Butt Welds
 Transverse tensile test

 Transverse and longitudinal bend tests
 Separate tests shall be performed in each case with the root of the weld
in tension and compression respectively.
 Charpy V-notch impact tests BS 4360
 Macro examination test
(ii) Fillet Welds
 Fillet weld fracture test

 Macro examination test
(8) Use of Electrodes
Electrodes and fluxes shall be used in accordance with the manufacturers' instructions.
(9) Butt Welds
Unless otherwise described in the contract, all butt welds shall be complete penetration
welds made between prepared fusion faces.
In the fabrication of built-up assemblies, all butt welds in each component part shall be
completed, whenever possible, before the final assembly. The position of welds required
for temporary attachments shall be agreed by the Engineer before the work commences.
Where automatic or semi-automatic processes are used back gouging of deposited weld
shall not be required where the Engineer is satisfied that the root run is free from
imperfection.
Where butt welds are to be ground flush, there shall be no loss of parent metal. The final
grinding shall be in the direction described in the contract.
Strud shear connector shall be welded in accordance with the manufacturer's

instructions.
In butt joints the root edges or root faces shall not be out of alignment by more than 0.125
times the thickness of the thinner material for material up to 12mm thick or by more than
2mm for thicker material.
Requirements for "run-on" and run-off" plates shall be as follows:

(a) One pair of run-on plates and one pair of run-off plates all prepared to the same
thickness and profile as the parent metal shall be attached by clamps to the start
and finish respectively of all butt welds. Unless otherwise required by the
Engineer, approximately 1 in 5 pairs of run-off plates, for butt welds in tension
flanges and 1 in 10 pairs for other butt welds, shall be production test plates. The
combined size of each pair of production test plates shall be either 225mm,
300mm or 375mm wide X 200mm long as shown in Table 22.2 the length being
measured in the rolling direction of the metal and at right angles to the weld.
Table 22.2: Sizes of Run-off Production Test Plates
Combined size (per pair) of run-off production test plates

Material Plates up to Plates from 30mm to Plates over 75mm thick
30mm thick 75mm thick
IS-1915 300 x 200 375 x 200 Sizes to be agreed by the Engineer
(b) Butt welds shall run the full length of the joint and extend at full weld profile for a
minimum distance of 25mm into the run-off plates, and for a minimum distance of
200mm, 275mm, and 350mm respectively into the 225mm X 200mm X 200 mm
run-off production test plates.
(c) On completion of the welds the run-off production test plates shall not be
removed until they have been marked in a manner agreed by the Engineer to
identify them with the joints to which they are attached.
(d) When removing the run-on and run-off plates by flame cutting the cuts shall not
be nearer than 5mm to the sides of the parent metal and the remaining metal
shall be removed by grinding or other method agreed by the Engineer.
(e) Specimens for the following tests to be carried out in accordance with Clause
621 shall be selected from the run-off production test plates by the Engineer:
(i) Transverse tensile test(s): The number of test shall be sufficient to cover
the full thickness of plate.
(ii) Transverse bend test
(10) Camber
Main girders shall be fabricated to the cambers shown on the Drawing. Plates shall be
prepared to produce a profile which approximates to a parabolic curve, from the supports
to the midspan point of the girder.
2207 FIELD ERECTION REQUIREMENTS
(1) Handling and Storage of Materials
Structural metals shall be carefully unloaded manually or by means of suitable

equipment so as to avoid damage to the materials or their painted surfaces. Under no
circumstances shall structural steel be dropped or skidded off cars or vehicles, nor shall
it be dragged over the ground. Beams and girders shall be transported and handled in
upright position. Pin holes, or other field connection holes, shall not be used as places for
"hook-on".

Material not to be placed directly in the structure shall be stored above probable high
water, on skids or platforms in a manner that will prevent distortion in the members or the
accumulation of water or dirt on such members. Beams and girders shall be stored in an
upright position and securely stored. Provision shall be made to protect all metals
against corrosion.
All damaged metals shall be rejected.
(2) Preparation for Bearing Area
Before placing column bases, bed plates or shoes and the bearing shall be prepared to
proper elevation.
(3) Falsework
(a) Design
The requirements of Section 1800 shall apply insofar as they are applicable
together with the following modifications and additions: Steel shall be assumed
to weigh 8000 kg per cubic meter. In addition to the superimposed dead load the
falsework shall be designed so as to carry safely the weight of any equipment
which it may be required to support.
(b) Plans for Falsework
The Contractor shall prepare plans and design of the falsework. When so
requested, these plans shall be submitted to the Engineer for his approval,
before the construction of the falsework is started. The Engineer's approval of
such plans or his acquiescence in the work shall not relieve the Contractor of
responsibility for satisfactory results.
(c) Construction
Falsework construction shall conform to the requirements of Section 1800

insofar as they are applicable, together with the following modifications and
additions. Falsework bends shall be so constructed as to provide a minimum
clearance of 600 mm between the falsework caps and the lower members of the
structure which are to be supported thereon to provide ample space for the
jacking and riveting of such members.
(d) Removal
The requirements for the removal of falsework shall be as provided in Section

1800 insofar as they are applicable.
(4) Straightening Bent Metal
Straightening of bends in main structural members shall not be permitted in the field.
Such members shall be returned to the fabricator for proper repair or replacement.

Bent material shall be straightened, to the satisfaction of the Engineer and under his
direct supervision, before such material is incorporated into the structure.
The straightening of bends shall be done by methods that will not produce embrittlement,
fracture or damage. All material shall be straightened cold when practicable. No plated,
galvanised, enamelled, heat treated aluminium and similar metals shall be heated.
When metals of these types can not be satisfactorily straightened cold, they shall be
returned to the fabricator for repair or replacement.
Mild steel and structural grade steel may be heated when necessary to accomplish
straightening. Other carbon steel and low alloy steels shall not be heated unless specific
approval is granted by the Engineer. Heating and straightening shall conform to the
requirements of Sub-clause 2203 (3) (g).
2208 ASSEMBLING AND BOLTING
(1) General
All field contact surfaces, including shims, which have not been given a shop coat of
paint, shall be thoroughly cleaned and given a coat of the specified "shop coat" paint,
except when such surfaces are to be completely sealed by welding. Assembly of
Sections shall be made while the contact paint is still plastic. All surfaces of metal which
will be inaccessible after erection shall be thoroughly cleaned of all foreign matter, spot
coated and field painted in accordance with the provisions of Clause 2209.
Immediately before assembly, all pins shall be thoroughly cleaned and given a coat of
red lead. The pins shall be inserted into the holes before the red lead is dry and the pin
nuts are drawn tight. The exposed threads shall be effectively burred or checked at the
face of the nut.
Fabricated Sections which have been assembled reamed, and matchmarked in the shop
shall be erected in exact conformity with such match marks. The interchanging of parts
shall not be permitted.
Steel structures shall be assembled to correct line and elevation before any welding is
undertaken.
(2) Trusses
Truss spans, except those portions erected by the cantilever method, shall be erected on
blocks so placed as to provide required camber. The camber shall be secured by
adjusting all panel points to the elevations as shown in the plan or as directed by the
Engineer.
Care shall be taken that trusses are in perfect alignment and that all milled ends of
compression members are in full contact. The spans must be fully erected, including all
portals, laterals, struts and sways, and all field connections, except connection for
stringers, rails and expansion devices, shall be securely driftpinned and bolted before
any of these is permitted. In case of cantilever spans, the Engineer may permit welding
portions of the anchor spans before the cantilever arms are completely erected.

(3) Simple Girders
Simple girder and beam spans shall be accurately set to square or skew as required in
the Drawing, with all diaphragms driftpinned and bolted in place before field welding is
permitted. Truss, girder or beam spans designed continuous over supports shall be
completely erected before any welding is permitted.
Unless otherwise provided in the contract, suspended spans shall not be erected until
the adjoining spans are completely erected. No welding shall be permitted until the
erection is complete.
For continuous or cantilever spans, the number of fitting-up bolts and driftpins required
shall be determined by the Engineer for the stresses developed in the various joints
during erection. Driftpins and bolts shall be used in equal proportions and shall be
located as to hold effectively the joint members in close contact and in correct position
during all welding operations.
Erection washers not less than 5 mm in thickness and not less than 50 mm in diameter
shall be used with all erection bolts.
(4) Welding
Connections to be welded shall be held in tight contact by means of bolts and clamps
before welding and the welding shall conform to the requirements of Clause 2206.
(5) Bolted Connections
Contact surfaces shall be thoroughly cleaned of rust, mill scale, dirt, grease, paint
lacquer, or other foreign material before assembly. All bolts shall be installed with a
hardened washer under nut or bolt head whichever is the element turned in tightening.
Bolts may be tightened by any method to the required tension. The torque value needed
to develop the required bolt tension shall be determined by the Engineer. Bolt tension
shall be checked at locations determined by the Engineer in the presence of the
Contractor and in such manner that the Engineer can read the torque gauge. Other
methods of determining bolt tension may be used, provided the prior approval of the
Engineer is obtained in writing. Nuts shall be positioned whenever practicable on the
side of the member who will not be visible from the travelled way. Nuts for bolt which can
be partially bedded in concrete shall be positioned on the side of the member that will be
encased in concrete. Bolts up to 6mm larger in diameter of those shown in the Drawing
may be used provided that the required clearance and edge distances are not reduced
below those required for the larger bolt.
2209 PROTECTION AGAINST CORROSION
(1) Preparation of Surfaces to Receive Paint
Before paint is applied to any surface other than metal-coated surfaces the appropriate
surface preparations as described in the contract shall be carried out in accordance
with the following:
(a) Bare Metal Surfaces

Blast cleaning shall be carried out in accordance with BS4232 to the quality of
surface finish as described in the contract. The maximum grade of abrasive
permitted shall be as specified in Table 2 of BS4232. Non-metallic abrasives
shall not be permitted. The abrasive used for blasting shall be free from
contamination and any recovered material shall be cleaned to the satisfaction
of the Engineer before re-use. The maximum amplitude (peak to trough) of the
blast-cleaned surface shall not exceed 0.10 mm. Surfaces shall be protected
within the following time of having been blast cleaned:
 2 hours if humidity in air is  85%
A sample blast-cleaned steel panel measuring not less than 150 mm x 150 mm
x 6 mm adequately protected by sealed clean polythene wrapping shall be
submitted to the Engineer for approval before any work is put in hand. The
approved sample shall then be retained by the Engineer’s inspectors for
comparison with the prepared steelwork.
(b) Mechanical Cleaning.
Mechanical cleaning shall be carried out by power-driven tools, such as
carborundum grinding discs, chipping hammers and needle guns, followed by
steel-wire brushing and dusting to remove all loosened material. Excessive
brushing of the metal through prolonged application of rotary wire brushes
shall be avoided. Surfaces shall be protected within the time as specified
above in Sub-clause 2209 (1) (a) after they are mechanically cleaned.
(c) Welds and Areas Affected by Welding

Unless otherwise described in the contract, welds and surfaces which have
been affected by welding shall be prepared for painting by the same process
as described in the contract for the adjoining metal.
(d) Painted Surfaces
Painted surfaces shall be cleaned of all dust immediately prior to the

application of further paint. Any loose paint and rust shall be removed. Areas
contaminated by oil and grease shall be cleaned with white spirit. Where
required by the Engineer, the whole surface shall then be cleaned by washing
down with a solution of an approved liquid detergent followed by rinsing with
clean fresh water and allowed to dry thoroughly before paint is applied.
(2) Treatment of Surfaces
(a) High Strength Friction Grip Bolt Interfaces
The treatment of interfaces to be jointed by high strength friction grip bolts shall
be as described in the contract. Paint work shall be stopped off at a distance of
75 mm from the joints and all interfaces shall be cleaned by wire brushing
before assembly.

(b) Untreated Surfaces
Steel work surfaces which will have concrete cast against them shall be left
unpainted. The surfaces shall be thoroughly wire brushed to remove loose
rust, mill scale and surface contamination.
(3) Storage of Paint
Paint shall be stored in sealed containers in a lock-up store in accordance with the
manufacturer's instructions. Paint which has not been used within the "shelf life" period
specified on the containers or within 12 months of the date of manufacture, whichever
is the lesser, shall not be used.
Paint from painter's kettles shall be returned to store at the end of each working period
where it shall be kept in a sealed container. Before it is re-issued for use it shall be
thoroughly mixed and no fresh paint or thinners shall be added.
(4) Application of paint
All paint shall be supplied from the store to the painters ready for application. The
addition of thinners or of any other material shall be thereafter prohibited. Any
instructions given by the paint manufacturer shall be strictly followed.
All painting shall be carried out by skilled painters under competent supervision. Paint
shall be applied to dry surfaces which have been prepared in accordance with Sub-
clause 2209 (1). The interval between preparation of the metal surface and the
application of the first priming coat of paint shall be in accordance with the relevant
requirements of Sub-clause 2209 (1).
Paint shall not be applied under the following conditions:

(a) When the ambient temperature falls below 4°C or the relative humidity rises
above 90°, except if otherwise stated in the manufacturer's instructions.
(b) During rain or mist.
(c) When condensation has occurred or is likely to occur on the steel.
Each coat of paint shall be applied by the method instructed by the manufacturer to
produce a continuous film paint of uniform and even thickness. As soon as the first
priming coat has dried, an extra stripe coat of paint shall be applied by brush to edges,
corners, crevices, bolt heads and welds, using paint of similar composition to the
subsequent undercoat, but in a contrasting shade. Successive coats shall have
different shades for identification and each coat shall be thoroughly dry before the
application of a further coat.
The total dry paint film thickness of the paint system on bare steel surfaces and on
metal coated surfaces shall be as described in the contract. The dry paint film shall be
measured by Elcometer or other instrument approved by the Engineer.
In order to obtain the dry film thickness specified, the Contractor shall ensure that the
coverage rate given by the paint manufacturer shall enable this thickness to be
attained.

Wet film thickness gauges may be used for checking but shall not be permitted as a
means of predicting the dry film thickness.
Unless otherwise agreed by the Engineer the paint system applied at the works shall
be applied under cover, in controlled conditions, at the fabricator's works. One
undercoat plus one finishing coat shall be applied at Site within the time limit stipulated
by the paint manufacturer.
No paint shall be used after the expiration of the "pot-life" stipulated by the
manufacturer. The paints of expired "pot life" shall not be mixed with fresh paint or have
thinners added to them.
(5) Storage of Painted Steelwork
Painted steel work which is to be stored prior to erection shall be kept clear of the
ground and shall be laid or stacked in an orderly manner that will ensure that no water
or dirt can accumulate on the surfaces. Suitable packing shall be laid between the
layers of stacked materials. Where cover is provided, it shall be ventilated.
Prime painted steelwork which is to be stored out-doors or transported prior to
fabrication shall not be exposed for periods longer than the following, before being
overcoated:
Blast primers - 1 coat Maximum 8 weeks, including 2 weeks of this

time out-doors.
(6) Repairs to damaged Surfaces.
Areas of paint which have been damaged during handling, storing, loading and off-
loading, transportation, erection and construction shall be cleaned to bare metal, and
the edges of the undamaged paint levelled with sandpaper. The full specified painting
system shall then be re-applied and the new paint shall overlap the existing paint by at
least 50 mm all round the affected area.
(7) Painting of Joints
As soon as possible after joints have been made and passed by the Engineer the
parent and joint material, exposed parts of bolts, nuts and washers, weld and weld
affected areas shall be prepared as stated in the contract and brought up to the same
state of painting as the adjoining surfaces.
(8) Painting Methods
Coat of paint in a system of painting shall be applied each by one of the following
methods:
(a) Brush
(b) Roller (for shop painting only), supplemented by brush where necessary
(c) Air pressure spraying
(d) Airless spraying
(9) Protective systems

The Contractor shall furnish the Engineer with duplicate copies of the manufacturer's
data sheets for the paints he proposes to use. Following the Engineer's written
instruction the requirements of the paint manufacturer's data sheets shall be adopted
for the Works.
Where called for by the Engineer the Contractor shall carry out paint application
procedure trials, either at the fabricator's works or at Site as appropriate, with the
equipment and labour to be used in the works. The Contractor shall supply suitable
blast cleaned steel and sufficient paint for the trials and must demonstrate his ability to
apply each coat of paint of a designated paint system in accordance with the
Specification and the paint manufacturer's data sheet. No painting of the contract
steelwork shall be permitted until the procedure trials have been completed to the
satisfaction of the Engineer. Any adjustment to the registered paint formulation shown
to be required by the trials, other than an increase in the amount of thinners, must be
agreed by the Engineer and made at the paint manufacturer's works before the final
stage of a paint procedure trial and before delivery of the first batch of paint.
All requirements of the paint manufacturer's data sheets shall be complied with. Paint
shall be supplied from the Contractor's paint store to the painters ready for application,
the only adjustment of formulation being as provided in paragraph 2 above. Any
addition of thinners must be made in the store under the supervision of the Engineer
and only as allowed under the manufacturer data.
(a) Superstructure Steelwork
(i) Steelwork Members
Surface preparation at works: Blast clean to I st quality (including joint

areas) BS7079.
Painting: as shown on the following Table:
Painting Coat Paint Method of

at works application
Ist Zinc Chromate/Red Airless Spray
Oxide Blast Primer
(Stripe to edges etc.) Zinc Phosphate epoxy Brush (Airless
ester undercoat Spray grade paint)
2nd As Stripe Coat
Excluding Airless Spray
joints 3rd As Stripe Coat
Airless Spray
4th As Stripe Coat
Airless Spray
Micaceous Iron Oxide
5th Phenolic/tung oil undercoat Brush
At site Micaceous Iron Oxide
6th Phenolic/tung oil Brush
Finish Dark Grey
(ii) High Strength Friction Grip Bolted Joints

a. Cover Plates
Surfaces preparation at works: Blast clean to 1st quality BS7079.
Painting at works (excluding : One coat, Zinc Chromate/Red Oxide

contact surfaces) Blast primer applied by Airless Spray.
Surface Preparation at site : Before assembly, wire brush contact

surfaces by hand.
After assembly, wire brush works coat

of blast primer.
Painting at site (after bolting) : Coats 1, Stripe and 2 to 6 as (i) above

but all applied by brush and coat within
4 hours of wire brushing works blast
primer.
Minimum total dry film thickness at

stripe coated areas: 250 micron.
b. Contact Surfaces of Steelwork Members
Surface preparation Before assembly, mask around contact

at site : surface apply paint stripper and scrape off
works coat of blast primer. Wash off stripper
and wire brush by hand when dry.
c. Bolts, Nuts and Washers
At site : Remove oil than prepare surfaces and paint

as for cover plates above.
(iii) Painting System for Repairs to Damaged Surfaces
Coats 1, Stripe (if relevant) and 2 to 6 as above but all applied by

brush
(b) Parapets and Guard-rails
Surface Preparation : Pickling

Metal Coating : Hot-dip galvanising Minimum weight of galvanising 1610
g/m² or minimum thickness 85 micron.
(10) Metal Coatings
Unless otherwise specified by the Engineer procedures for applying metal coatings
shall be in accordance with the following:-
(a) BS729 Part 1 : Hot-dip Galvanised Coatings

Part 2 : Sherardised Coatings
Metal coatings to BS 729 shall only be applied to components of a tensile strength up

to and including that of General Grade HSFG bolts unless specified by the Engineer.
(b) BS2569 Part 1 Sprayed metal Coatings

(Zinc and Aluminium). The nominal thickness of coatings to be 100 micron.
(c) BS3382 : Part 1 and 2. Electroplated Coatings on Threaded

Components( Cadmium and zinc). This British Standard shall be deemed to
cover the electroplating of components up to and including 36mm diameter.
The minimum thickness of coating to be 5 micron.
Where a metal coating is required only on part of an assembled Section it shall be

applied before the rest of the Section receives its priming cot.
(11) Etch Primers and Blast Primers
Etch primers and blast primers shall be suitable for continuous spray application. They
shall not be used on phosphated steel nor shall they be overcoated with zinc rich
primers.
2210 MEASUREMENT
The structural steel shall be measured in tonne and shall be based on the net weight of metal in
the fabricated/erected structure computed on the basis of nominal weight of the elements. While
computing the weight, the specific gravity of steel shall be adopted 7.85 tonne per cubic metre.
The weight shall be determined from the dimensions shown on the Drawing. The weight so
measured shall be inclusive of weld fillets and weight of protective coatings, if any.
All operations like cutting, bendings, straightening, heat and cold treatments, machining,
temporary and permanent erections, connections, bolts, nuts and washers, welding, painting and
protection against corrosion and other ancillary and incidental operations shall be deemed
included in the weight of the steel structure as measured above.
2211 PAYMENT
The structural steel as measured shall be paid at the contract unit rate which shall be the full and
the final compensation to the Contractor as per Clause 112 and also for the cost of all operations
required for fabrication, connections, oiling, painting, temporary erection, inspection, tests and
final erection including all other ancillary and incidental works needed to complete the work as
per these Specifications and/or directed by the Engineer.

9 SECTION 2300 - TIMBER CONSTRUCTION
Page No.
2301 SCOPE 23–1

2302 MATERIAL 23–1
2304 TESTS AND STANDARDS OF ACCEPTANCE 23–2
10 2305 MEASUREMENT
23–3
11 2306 PAYMENT 23–
3
2300 - TIMBER CONSTRUCTION
2301 SCOPE
This Section covers timber construction of permanent works at locations as shown in the
Drawing. The work specified herein may not be relevant not for the temporary facilities and
formwork (centering and shuttering).
2302 MATERIAL
(1) Timber
Timber shall be straight and free from twist, sapwood, shakes, dead and loose knots,
worm holes, other holes, signs of decay and other defects, and seasoned and shall
comply with the requirements of IS 883-1994 The Engineer shall inspect and stamp
each timber to be used as structural members. The natural moisture content of any
untreated timber delivered to site shall not exceed those as recommended by IS 287-
1993. When timber is specified as unsawn it shall be cut above the ground swell and
shall taper from butt to tip. A straight line drawn from the centre of the tip to the centre
of the butt shall not fall outside the centre line of the piece at any point more than 1%
of the length of the piece. When the timber is specified as sawn it shall be sawn true
and square to the full dimensions. When timber is specified as wrot it shall be finished
with a plane, smooth and true to dimensions on the faces so specified.
(2) Hardware
Hardware shall consist of bolts, with the necessary nuts and washers, timber
connectors, drift pins, dowels, nails, screw nails, coach bolts, spikes and other metal
fasteners. They shall be galvanised or ungalvanised as specified. Bolts, nuts and
washers shall be mild steel and comply with IS 1363-1992. Timber connectors shall
be of the type shown on the Drawing. Drift Pins and dowels shall be mild steel. Nails
shall comply with IS 723-1972. Screw nails and screws shall comply with IS 451-
1972/IS 2585-1968. Coach bolts shall comply with IS 2609-1972. Spikes and other
metal fastenings shall be mild steel.
(3) Timber Preservation
When described in the contract or shown on the Drawing timber shall be treated with
preservative in accordance with the Indian Standard Code of Practice for the
preservation of timber IS 401-1982.
(4) Galvanising
When described in the contract or shown on the Drawing, all hardware shall be
galvanised in accordance with the Indian Standard Recommended Practice for Hot-
Dip Galvanising of Iron and Steel: IS 2629-1985 and IS 1367 Part 13-1983: Hot Dip
Galvanised Coating on threaded Fasteners. The Engineer may require galvanised
hardware to be tested in accordance with IS 2633-1986.
SECTION 2300 TIMBER CONSTRUCTION

(5) Flashing
Flashing shall be galvanised sheet of the gauge shown on the Drawing or described in
the contract. It shall comply with the requirements of IS 277-1992: Galvanised Steel
Sheets (Plain and Corrugated). The coating shall be of 750 Grade as specified in IS:
277-1992.
2303 CONSTRUCTION
(1) Handling and Storage of Materials
Timber shall be stored in piles at the site unless it is to be immediately incorporated in

the structure. It shall be stacked so as to allow free air circulation and inspection on
skids above the ground and standing water. It shall be protected from the sun to
prevent warping. It shall be handled in a manner that will avoid injury or breakage.
Treated timber shall be handled with rope slings. Cant hooks or other sharp
instruments shall not be used. Undue injury during handling will be cause for rejection.
Flashing, hardware, preservatives and other material shall be stored under cover in
such a manner as to obviate deterioration.
(2) Framing
All timber shall be accurately cut and framed to a close fit and shall have even bearing
over the entire contact surfaces. No shimming shall be permitted in making joints.
Holes for drift pins and dowels in untreated timber shall be bored with a bit 1.5 mm less
in diameter than the pin or dowel. Holes for drift pins and dowels in treated timber
shall be bored to the same diameter as the pin or dowel. Holes in small timbers for
spikes may be bored with a bit with the same diameter as the smaller end of the spike,
when necessary to prevent splitting. All bolts shall be fitted with washers. Groundsills
shall be firmly and evenly bedded in solid material. Posts shall be framed true and
have full even bearing on the sills, caps shall be framed true and have full bearing on
the posts or piles. Bents shall be properly aligned before bracing is placed. The
minimum distance between the outside bolt and the end of any brace shall be 200 mm.
In placing beams and/or stringers for bridge decks the better edge shall be placed
downwards. The tops of beams and stringers after placing shall not vary from a plane
more than that will permit bearing of the superstructure timber on all the beams and/or
stringers. Kerbs and railings shall be accurately framed and aligned so that on
completion they present a smooth visual line vertically and horizontally. Floor planks
shall be laid such that no joints will occur over any one stringer or beam closer than
every third plank. No planks other than required to fill out skews, shall be less than 2
metres in length and at least 50% of the planks shall be 5 metres or more in length.
Close boarded floor planks shall be laid longitudinally breaking joint by at least 600
mm. They shall be secured in place by barbed nails, screws or coach bolts as shown
on the Drawing, or described in the contract. These fastenings shall be spaced at not
more than 250 mm and be staggered. Two fasteners shall be placed at each end of
each plank.
2304 TESTS AND STANDARDS OF ACCEPTANCE

The materials shall be tested in accordance with the relevant standards specified and shall
meet the prescribed criteria. The Contractor shall furnish necessary test certificates as required
by the Engineer.
2305 MEASUREMENT
Depending upon the nature of work, the quantities shall be measured in numbers, in the units
of volume, area, or length as specified in the contract.
2306 PAYMENT
The quantities measured as provided above shall be paid at the contract unit rate applicable for
the particular type of work. The contract unit rate shall be the full and the final payment to the
Contractor as per Clause 112 to complete the work as per these Specifications.

SECTION 2400 - MISCELLANEOUS STRUCTURES
Page No.
2401 GABIONS 24–1

2402 CRIB WALLS 24–6
2403 SLOPE STABILISATION AND SURFACE EROSION PROTECTION 24–9
2404 SUB-SURFACE DRAINS 24–16
2405 DRILLED SUB-SURFACE DRAINS 24–19
2406 SCOUR PROTECTION AND RIVER TRAINING WORKS 24–20
SECTION 2400 - MISCELLANEOUS STRUCTURES
2401 GABIONS
(1) Scope
This Clause covers the furnishing of materials and construction of gabion works that
may be required to act as buttresses, retaining walls, catch walls, stream or river
training structures, check dams within gullies, or where placed as mattresses, to
prevent stream or gully erosion.
(2) Materials
(a) Stones
Stones used for filling the gabion boxes or mattresses shall be clean, hard,
sound, unweathered and angular rock fragments or boulders. The specific
gravity of the stone shall be not less than 2.50 and the stones shall not absorb
water more than 5 percent when tested as per IS:1124. The length of any
stone shall not exceed three times its thickness. The smallest dimension of
any stone shall be at least twice that of the longer dimension of the mesh of
the crate. However smaller size of stones as spalls shall be allowed for filling
voids and its volume including voids shall not be more than 20 percent of the
total volume of the stones. Before filling any gabion boxes and mattresses the
Contractor shall submit representative samples of the rock he proposes to use
in the gabions for approval by the Engineer. Further representative samples
shall be submitted for approval each time when there is a change in the type
and strength of the rock.
(b) Gabions
Gabions shall consist of steel wire mesh crates. The steel wire shall be mild
steel wire complying with NS 169-2045. All wires used in the manufacturing
crates and diaphragms, binding and connecting lids and boxes shall be
galvanised with an heavy coating of zinc by an electrolytic or hit dip
galvanising process. The weight of deposition of zinc shall be in accordance
with NS 163-2045. Zinc coating shall be uniform and be able to withstand
minimum number of dips and adhesion test specified as per NS 163-2045.
Tolerance on diameter of wire shall be + 2.5 percent. The tensile strength shall
be between 300 to 550 N/mm2.
The wire shall be woven into an hexagonal mesh with a minimum of 3 twists.
All edges of the crates shall be finished with a selvedge wire at least 3 gauges
heavier than the mesh wire. Gabions shall be manufactured in the standard
sizes shown in Table 24.1 with mesh and wire sizes as shown in Table 24.2.
Diaphragms shall be manufactured of the same materials as the parent gabion

box and shall have selvedge wire throughout their perimeter. The number and
SECTION 2400 MISCELLANEOUS STRUCTURES

size of diaphragms to be provided with each crate shall be as in Table 24.1. All
crates shall be supplied with binding and connecting wire of the gauges shown
in Table 24.2 of sufficient quantity to bind all diaphragms and closing edges.
Table 24.1: Standard Size of Wire Mesh Gabions
Dimensions in Number of Dimensions of Volume of crate in

metres diaphragms diaphragms in cubic metres
(Prior to fill) metres
1x 1x1 - - 1
1.5 x 1 x 1 1 1x1 1.5
2x1x1 1 1x1 2
3x1x1 2 1x1 3
1 x 1 x 0.75 - - 0.75
2 x 1 x 0.75 1 1 x 0.75 1.5
3 x 1 x 0.75 2 1 x 0.75 2.25
1 x 1 x 0.5 - - 0.5
2 x 1 x 0.5 1 1 x 0.5 1
3 x 1 x 0.5 2 1 x 0.5 1.5
1 x 1 x 0.3 - - 0.3
2 x 1 x 0.3 1 1 x 0.3 0.6
3 x 1 x 0.3 2 1 x 0.3 0.9
Table 24.2: Standard Sizes of Mesh and Wire in Gabions
Mesh opening Mesh type Thickness of Thickness of Thickness of

mm mesh wire binding and selvedge
connecting wire
wire
(DxH) S.W.G. S.W.G. S.W.G.
64x83 60x80* 11,12 13,14 8,9
83x114 80x100 9,10,11 11,12,13 6,7,8
114x128 100x120 10,9 12,11 7,6
* To be used in special cases subject to approval by the Engineer where

stones of larger size are not available.
Note: Equivalent diameter in mm as per NS 163-2045
SWG 6 7 8 9 10 11 12 13 14
mm 4.88 4.47 4.06 3.66 3.25 2.95 2.64 2.34 2.03
(3) Construction of Gabions
(a) General Requirements
Before filling any gabion boxes and mattresses, the Contractor shall submit
samples of gabion boxes and/or gabion mattresses assembled, erected and
filled with stones for approval which, when approved, shall be retained for

reference and comparison with the gabions built as part of the permanent
works. The size, type and location of the samples shall be as directed by the
Engineer.
Gabion boxes and gabion mattresses shall be assembled, erected and filled
with stones in the dry on prepared surfaces except as may be otherwise
approved. Approval for assembling and erecting gabions in water shall be
given only, if in the Engineer's opinion such a method will produce work which
is otherwise in accordance with the Specification.
(b) Preparation of Foundation and Surface for Bedding
The bed on which the gabion boxes or mattresses are to be laid shall be even
and conform to the levels shown on the Drawing. If necessary cavities
between rock protrusions shall be filled with material similar to that specified
for gabion filling.
(c) Arrangement of Joints
(i) Walls
In walls, gabion boxes shall be placed such that vertical joints are not
continuous, but staggered. Aprons shall be formed of headers. If more
than one unit is required to obtain the necessary width, units of
unequal length shall be used and the joints between them should be
staggered.
(ii) Channel linings
In channel linings, gabion box and mattress units shall be laid so that
the movement of stone inside the mesh due to gravity or flow of water
is avoided. Hence, on side slopes, units shall be placed with their
internal diaphragms at right angles to the direction of the slope and,
on inverts, as far as possible, at right angles to the direction of flow.
(d) Assembly
Gabion boxes and gabion mattresses shall be assembled on a hard flat

surface. After fabrication, unpacking or unfolding, they shall be stretched out
and any kinks shall be removed. Creases shall be in the correct position for
forming the boxes or mattress compartments. The side and end panels shall
be folded into an upright position to form rectangular boxes or compartments.
The top corners shall be joined together with the thick selvedge wires sticking
out of the corners of each panel. The tops of all sides and partitions shall be
levelled except as may be appropriate to special units. The sides and end
panels shall be tied together using binding wire of the thickness given in Table
24.2, starting at the top of the panel by looping the wire through the corner and
twisting the wire together. Binding shall continue by looping the wire through
each mesh and around both selvedges with three rounds which shall be joined
tightly together by twisting and the end shall be poked inside the unit. The

diaphragms shall be secured in their correct positions by binding in the same

way. The bindings wire shall be fixed using 250mm long nose fencing pliers or
equivalent approved tools.
The gabion boxes and gabion mattresses shall be laid in such a manner that
the hinges of the lid will be on the lower side on slopes and on the outerside in
walls.
Where mattresses are laid horizontally hinges shall not be placed on the
downstream side as much as practicable.
(e) Filling
Except in the case of sack gabions, the crates shall be placed in their final
position before filling commences. They shall be stretched to their full
dimension and securely pegged to the ground or wired to adjacent gabions
before filling. The vertical corners shall be kept square and to full dimension by
inserting a steel bar of at least 20 mm diameter at each vertical corner,
maintaining it in the correct final position throughout the filling process, and
removing it when the crate is full. Before filling commences, the selvedges of
the crate shall be bound to the selvedges of adjacent crates with binding wire.
Where crates are being assembled in position in a wall the binding of the
edges of each crate in the assembly process and the binding together of
adjacent crates shall be carried out in the same operation.
Before filling with stone, gabions shall be anchored at one end or side and
stretched from the opposite end or side by inserting temporary bars and
levering them forward, The top and bottom shall be kept stretched by
tensioning with tie wires attached to an anchorage or equivalent approved
method until the gabion has been filled. The gabions shall be inspected at this
stage but before filling with stone to ensure that the tie/wiring has been
properly carried out and the gabion boxes or gabion mattresses are not pulling
apart. Gabion boxes or gabion mattresses may be tensioned either singly or in
the case of a long straight structure by straining a number of units together
using an approved tensioning system.
The filling shall be carried out by placing individual stones into the gabion by
hand in courses in such a manner that the stones are bedded on each other
and bonded as in dry random rubble masonry as per Clause 2608. No loose
stones shall be tipped into the crate and the practice of coursing and bonding
the outer layer and filling the interior with unlaid stones shall not be permitted.
All 1m deep gabions shall be filled in three equal layers and 0.5m deep
gabions in two equal layers. Horizontal bracing wires made with the same
bindings wire as used for tying shall be fixed directly above each layer of the
stone in the compartments, the wires being looped round two adjoining
meshes in each side of the compartment and joined together to form a double
tie which shall be tensioned by wind lassing together to keep the face of the
gabions even and free from bulges. Bracing wires shall be spaced horizontally
along and across the gabions at distances not greater than 0.33m. Where the
upper faces of gabion boxes are not covered with further gabions vertical

bracing wires shall be fitted between the top and bottom mesh using two tie
wires per square metre of surface.
The ties shall be fixed to the bottom of the units prior to filling and tied down to
the lid on completion. Where a double layer of gabion boxes is used to form an
apron both upper and lower layers shall have vertical tie wires.
(f) Securing Lids
The gabion boxes and mattress compartments shall be over filled by 50mm
above their tops to allow for subsequent settlement. The lids shall then be tied
down with binding wire to the tops of all partition panels. The lids shall be
stretched to fit the sides exactly by means of a suitable tool but due care shall
be taken to ensure that the gabions are not so full that the lids are
overstretched. The corners shall be temporarily secured first.
(g) Tolerance
On completion, the crates shall be completely and tightly filled, square, true to
dimensions and the line and level shown on the Drawing. However the
tolerance limit permitted in the length, height and width of the gabion boxes
and mattresses as manufactured shall be  3 percent from the ordered size
prior to filling. The tolerances on the wire mesh opening shall be  10% on the
nominal dimension 'D' values as follows:
Mesh type Nominal dimension 'D' values

60x80 64
80x100 83
100x120 114
However, the number of opening per gabion box/mattress shall not be less
than the nominal length divided 'D' on horizontal direction and nominal height
divided by 'H' in vertical direction where D and H are as per Table 24.2.
(4) Test and Standard of Acceptance
(a) The gabion wire shall be tested for mass, uniformity and adhesion of zinc
coating and tensile strength of the wire itsef. Failure of test results to comply
with the specifications shall lead to the rejection of gabion wires. The test on
the samples taken as per Table 24.3 from each lot of the G.I. wire received at
the side of the work shall be carried out in accordance with NS 169-2045 and
NS 163-2045.
Table 24.3: Scale of Sampling and Permissible Number of Defective
no. of coils in a lot no. of coils randomly Permissible no. of

selected for sampling* defective coil

Upto 25 2 0
26-50 3 0
51-150 5 0
151-300 8 1
300 and above 13 1
* One sample per coil shall be tested in all respect.
(b) The stones shall be tested for specific gravity and water absorption. At least 3
set of tests shall be made for every source of material. The test results shall
meet the specified criteria.
(c) In each hundred cu.m or part thereof one representative sample of completed
gabion box/mattress i.e. assembled, filled with stones and tied up in position
shall be dismantled during the process of construction. The dismantling shall
be made in such a manner that the quality of the surrounding work is least
affected. The stones having least dimension more than or equal to the
specified dimension shall be gathered at one place and the rest at another
place. By displacement of water total volume of these specified stones shall be
determined separately. Ratio of volumes of specified stone and voids including
spalls to the total volume of the gabion box shall be worked out. The test result
shall meet the requirement of the Specifications.
(d) The dismantled portion shall be made good by the Contractor at his own cost
after completion of the test.
(5) Measurement
Gabion wire mesh for boxes and mattresses shall be measured in sq. metre.
The boxes and mattresses shall be physically measured and be verified with their
tolerances.
The binding wires, selvedge wire and tension wires shall not be measured separately.
They are deemed included in the measurement of the gabion boxes and/or
mattresses.
Stone filling in gabions including fixing of gabions in position, tying with binding
wires and tension wires as specified shall be measured in cu.m.
(6) Payment
Gabion boxes, gabion mattresses, stone filling shall be paid as per respective contract
unit rate which shall be the full and the final compensation to the Contractor as per
Clause 112 to complete the work in accordance with these Specifications.
2402 CRIB WALLS
(1) Scope

This Section covers the construction of crib walls at locations shown on the Drawing or
as instructed by the Engineer. Crib walls shall be constructed of reinforced concrete,
timber or steel structural elements as shown on the Drawing and filled with compacted
backfill material.
(2) Materials
(a) Reinforced concrete for headers and stretchers shall comply with the
(b) Timber for headers and stretchers shall comply with the requirements of IS:
883. They shall be treated or untreated, sawn or log as shown on the Drawing
or described in the contract and comply with the requirements of Sub-clause
2302 (1).
(c) Drift pins shall be steel bars of a diameter as shown on the Drawing and shall
comply with the requirements of IS: 1786 –1985. The length of drift pin shall be
equivalent to the combined thickness of three times the depth of one member
plus 100 mm.
(d) Steel crib wall components shall be of the thickness, shape and dimension as
shown on the Drawing and shall comply with the requirements of IS: 2062–
1992. All bolts shall also be of mild steel and shall conform to IS: 2062-1992,
but has a minimum tensile strength of 485 N/sq.mm. and a minimum
percentage elongation of 14. All steel components, bolts, base plates, splice
plates shall be galvanised or painted as shown on the Drawing or described in
the contract. Such protection shall comply with Clause 2209.
(e) Backfill material shall be of such character that it will not sift or flow through the
openings in the wall, shall be free from clay and other deleterious fines, and
shall conform to the requirements set out in Table 24.4.
Table 24.4: Grading and Compaction Requirement of Backfill Material
Combined height of wall and Sieve size Percentage passing Compaction

surcharge (vertical from heel of (mm) by weight requirement
wall to top of Surcharge)
0 to 3 m 75 100 Min. 93% of MDD
in accordance
with IS: 2720 Part
8
3 to 8 m 75 100
4.75 35 – 100 - do -
Over 8 m 75 100
4.75 25 – 70
0.300 5 – 20 - do -
0.075 0 – 5
(3) Construction
(a) Reinforced Concrete Crib Walls

Walls founded on embankment material shall have a minimum depth of 1.5m

below the base of the wall which is compacted to a minimum of 93% of MDD
(IS 2720, Part 8). Where the foundation pressure exceeds 0.27 N/sq.mm. The
embankment material shall comply with the grading in Table 24.4 compacted
to 93% (minimum) of MDD. When walls are founded on original ground it shall
have a bearing value adequate to withstand the foundation pressure of the
wall but shall not be less than 0.2 N/sq.mm. If the original ground is
unsuitable, it shall be removed and replaced to a sufficient depth as approved
by the Engineer, by material complying with the grading requirements of Table
24.4 compacted to 93% (minimum) of MDD. The foundation stretchers shall be
laid true to line, level and slope on a 100 mm thick loose layer of material
complying with Table 24.4. The laying of headers stretches and blocking
pieces shall then proceed. Backfillings to the crib wall shall be carried out in
lifts not exceeding 150 mm and compacted to the compaction indicated in
Table 24.4. The gap between bearing surfaces of headers, stretchers and
blocking pieces shall in no place exceed 3 mm. Where the gap is between
1.5mm and 3mm asbestos sheet packing complying with Sub-clause 3103 (4)
shall be placed between the bearing surfaces. In the case of walls whose
height exceeds 10m, asbestos sheet packing shall be placed between all
bearing surfaces below the 10m level.
(b) Timber Crib Walls
The requirements in respect of the depths and bearing values of the ground
on which the wall is to be founded shall be as for reinforced concrete crib
walls. The foundation stretchers shall be laid true to line, level and slope on a
100 mm thick loose layer of material complying with Table 24.4. Headers and
stretchers shall be secured with drift pins as shown on the Drawing with a
minimum of 4 per joint. Holes for drift pins shall be bored with a bit of the same
size as the pin. All holes that are bored in treated timber shall be swabbed with
two coats of creosote. Back filling shall not commence until all drift pins for the
portion of crib to be filled have been driven. Backfill material shall be placed in
lifts not exceeding 150 mm and compacted to a minimum of 93% of MDD.
Where unsawn timber is used in crib walls the bearing areas shall be wroth
square so that there is true and complete bearing between the elements of at
least 400 sq.cm.
(c) Steel Crib Walls
The requirement for bearing values of supporting ground shall be as for

reinforced concrete crib walls. The base plates shall be laid true to the line,
level and slope on a 200 mm thick loose layer of material complying with Table
24.4. Backfilling shall be as for reinforced concrete walls.

dimensions as indicated on the Drawing with no bulges or sags. The lines of stretchers
and headers shall have a uniform appearance.
Frequency of testing for concrete shall be as specified in Section 2000. Backfill

material shall be tested for gradation for each change in source of material, subject to
a minimum of one test for every 250 m3 of material or part thereof. Minimum three tests
of in-situ density test shall be carried out in each layer of backfill. All the test results
shall meet the specified criteria.
(5) Measurement
Crib walls shall be measured in running meter for each type of headers and stretchers
placed in their final position and accepted.
Excavation and backfilling shall be measured separately as provided in the respective

Sections of these Specifications.
(6) Payment
Each type of headers and stretchers measured as provided above shall be paid at the
contract unit rate which shall be the full and the final compensation to the Contractor
as set out in Clause 112 to complete the work as per these Specifications.
Excavation and backfilling shall be paid separately as provided in respective sections

of these Specifications.
2403 SLOPE STABILISATION AND SURFACE EROSION PROTECTION

(1) Scope
This Clause covers the works related to the furnishing of materials and construction of
slope stabilising measures in dry stone pitching, grouted stone pitching, gabion,
masonry walling, rock dowels and rock anchors/bolts and wire netting on slopes as
shown on the Drawing or as instructed by the Engineer.
(2) Excavation of Soil and Rock
Excavation of soil for landslide stabilisation and slope protection shall include
excavation and removal of existing landslide debris, streambed debris, the trimming of
scarp faces and gully sides and excavation required to construct gabion and masonry
walls or other structures, in accordance with the lines, levels, grades and dimension as
shown on the Drawing or as directed by the Engineer. Excavation may be undertaken
either by machine or by labour or in combination of the both. However, during any
excavation work care must be taken to ensure that the excavation does not endanger
the stability of adjacent slopes. In some locations the Engineer may direct the
Contractor to use labour only during excavation, or issue other directions as to the
method of excavation.

The cutting of access tracks to enable machines to reach otherwise inaccessible areas
shall not be allowed during slope stabilisation works. However, access tracks may be
constructed only with the specific approval of the Engineer where no benching into the
hillside is necessary.
Excavation and removal of rock for landslide stabilization and slope protection shall
include removal of individual rock blocks from a rock face, removal of potentially
unstable rock masses or isolated individual boulders. Excavation and removal of rock
may be undertaken by pneumatic tools, hand tools or other approved methods.
The slopes of cuttings shall be shaped or terraced in accordance with the Drawing and
as required by the Engineer.
(3) Fill Areas
During slope stabilisation work, small areas of fill may be required, such as to infill
gullies. Fill material for such purposes shall consist of suitable material as defined in
Clause 902 and shall be deposited and compacted by approved plant as defined in
Clause 910, in accordance with the lines, levels and grades shown on the Drawing
and as directed by the Engineer.
(4) Dry Stone Pitching
(a) Materials
Stone used for pitching shall be from a quarry or arising from the excavation
and be angular in shape. If river boulders are used they shall be broken into
angular pieces. The stone shall be sound, hard, free from cracks or other
defects. Not less than 80% of the stones, except those used for chinking shall
have individual volumes of not less than .01 cubic metres. Waste concrete
may be used provided it is sound and meets the size requirements of of the
stone. The stones, when immersed in water for 24 hours, shall not absorb
water by more than 5 percent of their dry weight when tested in accordance
with IS: 1124.
(b) Construction
Construction shall comply with Sub-clause 2406 (5).
(c) Tests and Standard of Acceptance
Tests and Standard of Acceptance shall comply with Sub-clause 2406 (5)
except the size of the stone which shall comply as per Sub-clause 2403 (4)
(a).
(5) Grouted Stone Pitching
(a) Materials
Stone shall comply with the requirements specified in Sub-Clause 2403 (4).
Grout shall consist of 1 parts of cement and 3 parts of sand measured

volumetrically and mixed with sufficient water to produce the required

consistency as instructed by the Engineer. Mortar and sand shall comply with
the requirements specified in Clause 2502.
(b) Construction
Method of laying and thickness shall be as for dry stone pitching specified in
Sub-clause 2406 (5). After the stones have been laid on the entire slope, all
spaces between them shall be filled with clean rock fragments, crushed rock
or gravel. More than 15% of the fill materials shall not pass 20 mm sieve. The
material shall be carefully hand tamped into place.
Prior to the application of grout the surfaces of the stones shall be thoroughly
cleaned of adhering dust and then moistened. The interstices between the
stones shall be completely filled with grout throughout the entire thickness of
the stone pitching. Grouting operations shall progress from the bottom of the
slope toward the top. Grout shall be placed in a continuous operation for any
day’s run at any location.
After the grout has been placed, the stones shall be thoroughly brushed so
that their top surfaces are exposed. The grouted pitching shall be cured for a
period of not less than four days after grouting. Curing shall be done with wet
sacking or other approved cover, and shall not be subjected to loading until
adequate strength has developed. Where required, or instructed by the
Engineer, weep holes shall be provided in the pitching.
Stones shall be tested in accordance with these Specifications and shall meet
the prescribed criteria. One set of test (3 tests in a set) shall be carried out for
every change in source of materials.
The finished surface of the grouted pitching shall present an even, tight and
neat appearance with no stones surface varying by more than 25 mm from the
specified surface grades and lines. The average thickness of the pitching,
measured at right angles to the surface, shall not be less than the specified
average thickness.
(6) Gabion Wire Mattress
The materials used shall comply with Clause 2401. The mattresses shall be
assembled and filled in the same manner as for gabions specified in Clause 2401. Ties
and anchorages shall be provided as shown on the Drawing.
(7) Wire Netting
Where required by the Engineer or shown on the Drawing, slopes shall be covered
with wire mesh to prevent small scale ravelling and erosion. The wire mesh shall
confirm to the requirements specified in Clause 2401 and shall have a minimum
thickness of SWG 10. Wire netting shall be constructed in accordance with Sub-clause
2809 (4).

(8) Masonry/Concrete/Reinforced Concrete Walling
Walls of the specified type(s) shall be constructed in accordance with the Drawing and
as directed by the Engineer to act as retaining structures, as revetment structures or
as buttresses.
Materials for masonry walling shall comply with Clause 2602, and construction with
Clause 2603. Mortared masonry shall be coursed and comply with Clause 2607. Dry
masonry shall comply with Clause 2608. Composite masonry shall comply with Clause
2609.
Materials for concrete/reinforced concrete walling shall comply with Section 2000.
In areas where buttresses are to be constructed, the rockface to be supported shall be
thoroughly cleared of all vegetation, and loose or spalling rock fragments prior to
construction of the buttress.
(9) Rock Dowels
(a) Materials
Rock dowels shall consist of deformed high tensile steel bars complying with
IS 1786. Unless otherwise specified, the dowel bars shall be not less than
20mm in diameter and shall be of 1m in length.
Grout shall consist of either cement slurry or cement-sand mortar or concrete

as shown on the Drawing or as instructed by the Engineer. Water cement ratio
shall not exceed 0.45. The grout cover to the dowel shall be at least 6 mm.
Cement, sand, aggregates and water shall comply with the requirements
specified in Section 2000.
(b) Construction
The location, direction and length of each hole for rock dowels shall be
approved by the Engineer. After drilling a hole, the Contractor shall clear the
hole of all drill cuttings, sludge and debris and shall seal the hole to prevent
ingress of foreign matter. Before the rock dowels are installed, the position,
inclination, bearing, length and diameter of the drill holes shall be approved by
the Engineer.
The drill hole shall be thoroughly flushed with clean water immediately before
installation of the rock dowel. Grouting procedure for rock dowels shall be as
The free end of the dowel bar shall be securely bolted with steel bearing plate
and then covered with concrete capping of grade M30/20 to prevent corrosion.

The Contractor shall submit manufacturer’s test certificate for each lot of dowel
bars. The test certificate results shall meet the specified criteria. The Engineer
may ask for testing the bars in independent laboratories and the test results
shall meet the specified requirements.
Six sets of test cubes of grout shall be taken from at least one representative
batch of grout each day the grouting is carried out and the results shall meet
the requirements shown on the Drawing. Unless otherwise shown on the
Drawing, the minimum compressive strength of test cubes shall be as follows:
7 days - 18 N/mm2
28 days - 30 N/mm2
(10) Rock/Earth Anchors
(a) Materials
Rock/earth anchor shall be non-prestressed or partly prestressed and of

quality shown in the Drawing or specified elsewhere in the contract. The
prestressing load shall be as specified on the Drawing. Unless otherwise
shown on the Drawing or specified in the contract, the anchor bar shall have a
diameter of 25 mm. End plates, couplings, nuts, washers and centralizers shall
be of the quality shown on the Drawing.
Grout shall be cement slurry. Cement and water used shall meet the
requirements specified in Section 2000. The water cement ratio shall be
between 0.30 and 0.45 or as instructed by the Engineer.
(b) Construction
The anchor direction both in plan and zenith shall be more or less
perpendicular to the weakened plane as indicated on the Drawing or directed
by the Engineer. However, for the case of gravity grouting, the zenith
inclination of anchor bars shall be kept minimum 15 0 below the horizontal.
Unless otherwise shown on the Drawing or specified in the Contract, the bore
hole shall have 90 mm diameter. Log shall be prepared for each bore hole.
Placing and grouting of anchors shall commence only after the approval from
Engineer.
The bond length of anchor bars shall, in no case, be less than 5 m and the
tendon length shall depend upon the thickness of loose and soft layer above,
as investigated by the Engineer during construction. The free anchor length
(where no grouting is executed) shall be fully corrosion protected with
approved insulating wrapping or polythene or other materials.
Approved commercial grade extra fine aluminium powder in an amount not

exceeding 0.005 % by mass of cement or an approved admixture may be
blended with the cement to ensure necessary expansion of the grout.

Before grouting, the bore hole shall be flushed clean and free of any loose and
clayey materials. Prior to grouting, the grout mixture shall be mixed at least for
3 minutes. The grout shall be used as soon as possible after mixing the
ingredients but in any event within the initial setting time of the cement.
Grouting shall be done by pump or gravity flow. Grout shall be forced into the
bore hole continuously to completely fill up the bore hole to the anchor head.
The injector pipe shall be taken out during and immediately after grouting. The
pointer shall always be intruded into the grouting mass. The amount of grout
mix used shall be recorded. Additional grouting shall be done to ensure filling
of all voids.
Prior to establishing anchors, test anchor shall be made in equivalent/similar

soil/rock conditions through which the anchors are to be placed with the length
similar to the anchors intended to be executed. Test anchors shall be loaded
by hydraulic device. Loading shall be as directed by the Engineer. If the
anchor fails at a lower force, another test anchor shall be established and the
bonding length increased as instructed by the Engineer.
Depending upon the type of rock soil formation and depth of sound rock strata,
the fixed anchor and tendon lengths are subject to vary, so that a minimum
anchor design load (anchor testing) can be obtained. The final decision for the
changr in anchor lengths lies fully on the rock investigation and judgement by
the engineer during construction and the result of anchor tests. In severely
jointed or fractured rocks water permeability test as directed by the Engineer
shall be conducted prior to grouting.
The free end of the anchors shall be fixed with anchor head. The face of
anchor head shall be inclined with vertical to the same angle as the anchor bar
with the horizontal so that the load transfer to the anchor strip shall be axial.
The anchor bar at the anchor head should be fitted to a tolerance of 5mm
concentrically with the tendon, which in turn, should not suffer an angular
deviation in excess of 30 from the axial position.
The Contractor shall submit manufacturer’s test certificate for each lot of
anchor bars. The test certificate results shall meet the specified criteria. The
Engineer may ask for testing the bars in independent laboratories and the test
results shall meet the specified requirements.
the requirements shown on the Drawing. Unless otherwise shown on the
Drawing, the minimum compressive strength of test cubes shall be as follows:
7 days - 18 N/mm2
28 days - 30 N/mm2

Ten percent of the anchors shall be tested in the field to the specified design
load. The sequence of testing shall be decided by the Engineer. The test shall
meet the specified criteria.
(11) Rock Bolts
(a) Materials
Rock bolts shall be such that it is capable of permanently sustaining the

specified working load as shown on the Drawing.
Grout shall be cement slurry mix. The grout shall have a water/cement ratio
not exceeding 0.45. The use of admixtures shall be subject to the Engineer's
approval. Cement and water shall meet the requirements specified in Section
2000.
(b) Construction
Method of installation, rock bolt system, full detail of rock bolt, bearing plate,
washer and nut, fixed length, grease and sheathing, bearing rod construction,
material and curing period, grout of resin details including additives, bleed
pipes, stressing and capping details shall be as specified in the design
Drawing or as instructed by the Engineer.
The holes for the bolts shall be drilled true to the line to the required depth for
any particular bolt. The depth of the hole shall be such that the installed bolt is
located 150mm from the extremity of the hole. The diameter of the drill hole
shall be sufficient to ensure a minimum 10mm annulus of grout or resin and
also permit free entry of the bolt together with any required protection.
Immediately prior to insertion of the rockbolt, the hole shall be cleaned and
blown free of dust. In the event of the drilling encountering any material other
than solid rock, this shall be recorded and reported to the Engineer without
delay.
A detailed record of the grouting of each drill hole including the date performed
and the identification marks of associated test cubes shall be maintained.
Copies of the manufacturer's certificates for the steel bolts to be supplied shall
be furnished by the Contractor. The test results shown in the certificate shall
meet the specified criteria. In addition, the Engineer may ask for testing in
independent laboratories. All test results shall meet the specified
requirements.
the requirements specified in Sub-Clause 2403 (9).
12) Measurement

(a) Excavation for structures, common backfill/previous backfill/filter materials,

gabion mattresses, masonry/concrete/reinforced concrete walling and wire
netting shall be measured as provided under respective Sections of these
Specifications.
(b) Dry stone pitching and grouted stone pitching shall be measured in square
meters.
(c) Rock dowels and rock/earth anchors shall be measured in running meter
placed inside the ground and accepted. The exposed dowels/anchors, steel
bearing plates, bolts, anchor heads and other accessories, if any, shall not be
measured separately.
(d) Rock bolts shall be measured in numbers as placed and accepted. Bearing
plates, washers, nuts, and other accessories shall not be measured
separately.
(13) Payment
(a) The quantity of excavation for structures, common backfill/previous

backfill/filter materials, gabion mattresses, masonry/concrete/reinforced
concrete walling and wire netting shall be paid as provided under respective
Clauses of these Specifications.
(b) The quantities of dry stone pitching, grouted stone pitching, rock dowels,
rock/earth anchors and rock bolts shall be paid as per the respective contract
unit rates. The contract unit rate shall be the full and the final payment to the
Contractor as per Clause 112 to complete the works as per these
Specifications.
2404 SUB-SURFACE DRAINS
(1) Scope
This Clause shall cover the works related to the construction of sub-surface drainage
networks in slopes, slides and under road pavement. The drains shall be either main
or tributary or of other types as shown on the Drawing.
Sub-surface drains shall consist of perforated HDP pipes surrounded by granular
material laid in a trench. If specified in the contract, sub-surface drains shall also
consist of perforated HDP pipes surrounded by geotextile/geomembrane and granular
material laid in a trench.
(2) Materials
The materials used for construction of sub-surface drains shall comply with following
requirements:
(a) Stone
Stones used for filling and lining of sub-surface drains shall comply with the
specifications for dry stone pitching given in Sub-clause 2403 (4).

(b) Cement
Cement shall be Ordinary Portland Cement complying with the requirements

of Section 2000.
(c) Mortar
The mortar used for cement masonry lining shall be as specified in Sub-clause
2403 (5).
(d) Gabion Works
Gabion works shall comply with the requirements specified in Clause 2401.
(e) Filter Material
Filter materials used in drains shall comply with the requirements specified in
Clause 3110.
(f) Geomemebrane
Geomembrane shall be made of PVC or polythene sheets of at least 0.8 mm

thickness, duly protected from ultra-voilet exposure with 2.5 per cent carbon
black, in black colour, supplied in roll form with a minimum of 3 m width. The
joints of these sheets shall be heatbonded or seamed for effective permeation
cut off. While fixing on to a slope, they shall not be punctured or stappled to
impair their use.
(g) Geotextile
Geotextiles used for lining of drain trenches shall be as per the requirements
of Section 600. The type of geotextile to be used for drains shall be approved
by the Engineer prior to starting the works.
(h) Drain Pipe

Drain pipes shall be made of high density polyethylene and shall comply with
series II as specified by NS 40/2040. Jointing of pipes shall be done by fine-
cutting and heating with equipment complying with the prescription of the HDP
pipe manufacturer. Pipes may be jointed with angles to fit the requirements of
the terrain, but angles shall not exceed the maximum specified by the
manufacturer. The joints shall be watertight and develop the same strength as
unjointed HDP material. The method of jointing shall be approved by the
Engineer prior to starting the works. Drain pipes shall be provided with holes
of minimum 5 mm diameter. The pipes shall be perforated by drilling minimum
50 holes per meter length on the upper half of the pipe in a staggered pattern
uniformly distributed. The Engineer might adjust these specifications according
to the site conditions.
(4) Construction

The detailed layout of the drainage network shall be as instructed by the Engineer,
based on the general layout given in the Drawing.
The work shall start with construction at road side and then go up the slope by using
already constructed drains as buttress for new drains.
The main drains shall be placed in naturally existing depressions. The tributary drains
shall be at a maximum inclination of 45 0 to the main drain.
(a) Sub-surface Drains without Geotextile/Geomembrane
Trench for sub-surface drain shall be excavated to the specified lines, grades
and dimensions shown on the Drawing. Following considerations shall be
made while excavating the drain and dumping excess materials.
(i) Depth of excavation shall be according to Drawing.
(ii) Top of structure shall be lower than natural ground.
(iii) No blasting shall be done in slides.

Wherever required or instructed by the Engineer, the Contractor shall provide
trench struts and shoring as per approved design and shall execute in a
manner to resist the earth pressure and in order to protect labour and work.
Where unsuitable material is encountered at the bed of trench, the same shall
be removed to such depth as instructed by the Engineer and backfilled with
approved material shall be compacted as specified in Clause 910.
Laying of pipe in the trench shall be started at the outlet end and proceed
towards the upper end, true to the lines and grades specified. Before placing
the pipe, filter material shall be laid for the full width of the trench bed and
compacted. Unless otherwise shown on the Drawing, the thickness of this
layer shall be 150 mm.
After the pipe installation has been completed and approved filter material
shall be placed over the pipe to the required level in horizontal layers not
exceeding 150 mm and thoroughly compacted to 93% of the MDD (heavy
compaction).
Pitching shall be done as per Clause 2403. The finished slope shall be
reshaped to facilitate proper surface drainage towards drains.
(b) Sub-surface Drains with Geotextile/Geomembrane
Excavation and backfilling shall be carried in the same manner as described

above in (a). After excavating the trench for sub-surface drain, the filter fabric
shall be placed and then the pipe shall be installed in the position as shown on
the Drawing. Surfaces receiving filter fabric shall be free of loose or
extraneous material and sharp objects. Adjacent rolls of the fabric shall be
overlapped to a minimum width 450 mm. The preceding roll shall overlap the
following roll in the direction the material is being spread.

After the installation of pipe, the trench shall be backfilled with the filter
material in the same manner as described above in (a).
Copies of the manufacturer's certificates for geotextile/geomembrane and drain pipe to

be used shall be furnished by the Contractor. In addition, the Engineer may ask for
testing in independent laboratories. All test results shall meet the specified
requirements.
Minimum one set of test for gradation analysis and compaction of filter material shall
be checked for every 50 cu.m. and/or every change in source of material. The results
shall meet specified requirements.
(6) Measurement
Sub-surface drain with/without geotextile/geomembrane shall be measured in running
meter which shall be inclusive of earth excavation, backfill/filter, and
geotextile/geomembrane. Drain pipe shall be measured in running meters separately.
Pitching shall be measure as provided under respective clauses of these
Specifications.
(7) Payment
Sub-surface drains with/without geotextiles/geomembranes, drain pipe and pitching

shall be paid at the respective contract unit rates. The contract unit rates shall be the
full and the final compensation to the Contractor as per Clause 112 to complete the
works as per these Specifications.
2405 DRILLED SUB-SURFACE DRAINS
(1) Scope
This Clause covers the works related to the construction of drilled sub-surface drains
in slopes and slides. The drilled sub-surface drains shall consist of HDP drainpipes
covered by geotextile and placed into drilled holes.
(2) Material
Geotextile used in drilled sub-surface drains shall meet the requirements specified in
the Contract or shown on the Drawing.
Drain pipes shall comply with the requirements specified for Series II high density
polythene pipes in accordance with NS 40/2040. Unless otherwise shown on the
Drawing, the pipe shall have a diameter of minimum 40-mm. The pipes shall be
perforated by drilling minimum 50 holes per meter length on the upper half of the pipe
in a staggered pattern uniformly distributed with a diameter of 3mm (minimum) to 6mm
(maximum).

(3) Construction
Drilling of borehole, minimum diameter 73mm shall be carried out by the Contractor as
shown on Drawing. The drill hole slope shall be 3o to 7o upward or as directed by the
Engineer. The drain pipes shall be covered by a geotextile.
The length of drains shall be decided by the Engineer based on hydro-geologist

conditions encountered.
The pipes shall be secured rigidly in the drill hole outlet.
The Contractor shall submit a sample of geotextile and HDP pipe along with factory
certificate for the approval of the Engineer. It shall be ensured that the geotextile and
the pipe meet the specified criteria.
(5) Measurement
Drilled subsurface drains shall be measured in running meter. No separate

measurement shall be done for geotextile.
(6) Payment
The quantity of drilled sub-surface drains measured as provided above shall be paid at
the contract unit rate which shall be the full and the final compensation to the
Contractor as per Clause 112 to complete the works as per these Specifications.
2406 SCOUR PROTECTION AND RIVER TRAINING WORKS
(1) Scope
This Section covers the works related to the construction of scour protection and river
training works. These works shall include all operations necessary for construction of
appropriate structures adjacent to culverts, piers and abutments, at outfalls of
drainage, along the road side and elsewhere, where protection is required for ensuring
safety of structures against damage by flood/flow of water.
(2) Materials
Stones/rocks used in this section of the specifications shall be hard, dense,

unlaminated natural stone, not liable to deterioration in water and of general quality of
soundness and abrasion resistance prescribed for concrete aggregates. Broken rocks
shall be of regular "cubical" shape and shall not be flaky. Flat or needle shaped rocks
shall not be accepted unless the thickness of the individual piece exceeds 1/3 of their
length. The specific gravity of the stone/rock shall be not less than 2.50 and when
immersed in water for 24 hours, it shall not absorb water more than 5 percent of its dry
weight tested in accordance with IS:1124. Unless otherwise specified the minimum
size/weight of the stone/rock shall be as specified below:
For Rip Rap in river-bed and foundation protection:-

At least two thirds of the total weights of the stone/rock used shall be heavier than
75 kg.
For Plum Concrete:
The size of the stone/rock shall not be larger than 200mm measured in any
direction.
Concrete to be used in plum concrete shall be as specified in Section 2000.
For Dry Stone Pitching/Revetment on Slopes:-
The size and weight of individual stone shall conform to Clause 5.5.5.1 of IRC: 89.
However in no case weight shall be less than 40 kg except for spalls. The total
volume of spalls including voids shall not be more than twenty percent of the total
volume of the pitching.
For use in Gabions:-
As per Clause 2401.

G.I. wire to be used in gabions shall comply with Clause 2401 and the filter shall
comply with Clause 3110.
All materials to be used shall be subject to the approval of the Engineer.
(3) Rip Rap
(a) Construction
The surface where rip rap to be executed shall be made to the line and level
as indicated in the drawing or directed by the Engineer. To achieve this
necessary excavation, filling with compaction and/or levelling shall be done as
per site condition. On the prepared surface stone/rocks shall be placed
individually to provide minimum space among the stones. Needle like shapes
and protrusions on the surfaces of stones shall be chipped off by hammer so
that stones are beded properly and voids are reduced. To avoid sliding of
stones/rocks downwards, the placing of stones shall be started from the lower
edge to proceed towards upper edge. By driving small stones or spalls into
interstices, laid stones shall be tightly wedged so that individual stone shall not
be removed easily. The top surface, the lines, levels and depth of rip rap and
grade shall be as indicated on the drawing or directed by the Engineer.
(b) Tests and Standards of Acceptance

Stone shall be tested for water absorption and specific gravity. The test results
shall meet the specified criteria. At lease 3 set of tests shall be made for every
source of material. About one sq.m (1Mx1M) of the completed rip rap in every
200 sq.m or in part thereof shall be dismantled. The aggregate weight of all
stones obtained from dismantling shall be computed upto full depth. Then
aggregate weight of individual boulders weighting more than 75 kg shall be
obtained. The result shall meet the specified requirement.

The dismantled portions shall be made good after completion of the test.
(4) Plum Concrete
(a) Construction
Composition of the plumb concrete shall be 60 to 70 % M 15/40 concrete and

40 to 30 % of stones by volume or as directed by Engineer. The place to be
filled up with the plum concrete shall be cleaned and chipped for adhesion with
the concrete. Following completion of form work a layer of concrete minimum
100mm thick shall be laid upon which clean and moist stones shall be placed
at a distance of min 100mm measured from face to face in any direction. The
distance between the outer edge of the concrete mass and the nearest face of
the stone to the edge shall not be less than 100 mm. Then another layer of
concrete having thickness not less than 100mm measured from the top of the
stone to the top surface of the layer shall be laid and compacted.
In case the proportion of concrete to stones is to be changed, the clear space

between stones shall be adjusted as directed by the Engineer.
After compaction, again stones shall be placed on the layer as described

above and the process shall be continued until the top layer of the concrete is
completed. The placing of stones shall be staggered both in horizontal and
vertical directions.
(b) Tests and Standards of Acceptance
Stones shall be tested for specific gravity and water absorption test. The test
results shall meet the requirements as specified in these Specifications.
Concrete shall be tested as specified in section 2000.
(5) Pitching/Revetment on Slopes
(a) Dry Stone Pitching
(i) Construction Operations
The pitching shall be provided as indicated on the drawings. The

thickness and the shape of stone pitching shall be as shown on the
Drawing.
Before laying the pitching, the sides of banks or surface of the slope
shall be trimmed to the required slope and profiles and shall be put up
by means of line and pegs at intervals of 3 metres to ensure regular
straight work and a uniform slope throughout. Depressions shall be
filled and thoroughly compacted.

Where required the filter/granular material shall be laid over the

prepared surface starting from bottom and compacted to the thickness
specified on the drawing. If not specified, the minimum compaction to
be achieved shall be 93% of the MDD (heavy compaction).
The lowest course of pitching shall be started from the toe wall and
built up in courses upwards.
Stone shall be placed to the required length, thickness and depth

conforming to the Drawing. Stones shall be set normal to the slope,
and placed so that the largest dimension is perpendicular to the face
of the slope, unless such dimension is greater than the specified
thickness of pitching. The pattern of laying shall be such that the joints
are broken. Wherever necessary spalls shall be used for tight packing
and reduction of voids which shall not exceed fifteen percent of the
total volume of pitching. The top surface of the pitching shall be
smooth.
When full depth of pitching can be formed with a single stone, the
stones shall be laid breaking joints and all interstices shall be filled in
with spalls of the proper size and wedged in with hammers to ensure
tight packing.
When two or more layers of stones must be laid to obtain the design
thickness of pitching, construction method of dry masonry shall be
used and stones shall be well bonded. To ensure regular and orderly
disposition of the full intended quantity of stone as shown, template
cross walls in dry masonry shall be built about a metre wide and to the
full height of the specified thickness at suitable intervals and all along
the length and width of the pitching. The stones shall be packed as
specified within these walls.
(ii) Tests and Standards of Acceptance
Stones shall be tested for water absorption and specific gravity and
shall meet the specified criteria. One set of test (3 tests in a set) shall
be carried out for every change in source of material and shall meet
the specified criteria.
About one sq.m (1mx1m) of the completed stone pitching in every 200
sq.m or in part of it shall be dismantled upto complete depth. The
aggregate volume of the spalls (stones weighing less than 40 kg) and
the aggregate volume of the stones weighing more than or equal to 40
kg shall be obtained. Thus the percentage of total volume of the spalls
and voids shall be determined. The test result shall meet the specified
requirement.
The dismantled portion shall be made good by the Contractor at his

own cost after completion of the test.

The finished surface of pitching shall present an even, tight and neat
appearance with no stones varying by more than 25mm from the
specified surface lines and levels. The thickness of pitching,
measured at right angle to the surface, shall not be less than the
specified thickness.
(b) Grouted Stone Pitching
Grouted stone pitching shall comply with Sub-clause 2403 (5) and shall be
measured as per Sub-clause 2403 (12) and shall be paid Sub-clause 2403
(13).
(c) Gabion Pitching
(i) Construction
The surface on which the gabions are to be laid shall be trimmed to

true lines level and grade as described above in Sub-clause 2406 (5)
(a). On the prepared surface, gabions shall be laid as specified in
Clause 2401.
(ii) Tests and Standard of Acceptance
The Contractor shall produce manufacturers test certificate of the

gabion wires which he proposes to use. Gabion wires shall be tested
as per Clause 2401. The test result shall meet the requirement.
Tests and standard of acceptance for this Clause shall be as per Sub-
clause 2401 (4).
The size, slope of the completed gabions and wire mesh shall meet
the specified requirements when measured:
The tolerance applicable to this measurement shall be as given in

Sub-clause 2401 (3) (g).
(6) Measurement
(a) Levelling, Filling with Compaction, Trimming and/or Earth Excavation
Levelling, filling with compaction, trimming requiring earth excavation or filling

not exceeding 150mm in depth shall be measured in sq.m, whereas
excavation or filling exceeding 150mm in depth shall be measured in cu.m.
Both types of measurements shall not be allowed at the same place. For
computation of quantities initial and final ground levels not exceeding at 5 M in
both directions in plan and plan of the area to be covered shall be recorded by
joint survey i.e. by the contractor and the engineer jointly. Quantities shall be
computed based on these levels using standard methods of measurement.
Levelling, filling trimming and/or earth excavation other than indicated on the
Drawing or instructed by the Engineer shall not be measured.
(b) Rip Rap:-

Rip Rap shall be measured in sq.m.
(c) Plum Concrete:-
Plum Concrete shall be measured in cu.m. Form work shall be measured in

sq.m separately. Struts, bracing supports etc. shall not be measured
separately. They are deemed included in the measurement of form work.
(d) Dry Stone Pitching/Revetment on Slopes:-
Dry stone pitching shall be measured in sq.m.
G.I. wire mesh provided for gabion boxes and mattresses shall be measured
in sq.m. Binding wires, selvedge wire and other accessories shall not be
measured separately. They are deemed included in the measurement of the
G.I. wire mesh.
Stone filling in gabions including fixing the gabions in position, tying with
binding wires and tension wires as specified shall be measured in cu.m.
(7) Payment
Levelling, filling with compaction, trimming and/or earth excavation, rip-rap, plum
concrete, from work, dry stone pitching, gabion boxes, gabion mattress, stone filling
shall be paid as per contract unit rate of the respective item which shall be the full and
the final compensation to the Contractor as per Clause 112 to complete the works as
per these Specifications.

SECTION 2500 - BRICKWORKS FOR STRUCTURES
Page No.
2501 SCOPE 25–1

2503 SOAKING OF BRICKS 25–2
2504 LAYING OF BRICKS 25–2
2505 JOINTS 25–2
2506 JOINTING WITH EXISTING STRUCTURES 25–2
2507 CURING 25–2
2508 SCAFFOLDING 25–3
2509 CONDITION OF EQUIPMENT 25–3
2510 FINISHING OF SURFACES 25–3
2511 TEST AND STANDARD OF ACCEPTANCE 25–4
2513 PAYMENT 25–4
SECTION 2500 - BRICKWORKS FOR STRUCTURES
2501 SCOPE
This Section covers the furnishing of materials and construction of brick works for structures in
accordance with the detail shown on the Drawing and these Specifications or as directed by the
Engineer.
2502 MATERIALS
(1) Bricks
Burnt clay bricks shall conform to the requirements of NS-1/2035 except that
minimum compressive strength when tested flat shall not be less than 8 N/mm 2 for
individual bricks and 10 N/mm2 for average 5 specimens and that the size may be
according to local practice with a tolerance of + 5 percent.
(2) Mortar
Mortar shall comply with IS 2250–1981; Code of Practice for preparation and use of
masonry mortar. The mortar used in work shall have the strength not less than 5 N/mm 2
or 7.5 N/mm2 at 28 days as specified.
However, if provided in the Contract, cement and sand may also be mixed in specified
proportions. Cement shall be proportioned only by weight, by taking its unit weight as
1.44 tonne per cubic metre and sand shall be proportioned by volume after making due
allowance for bulking.
Sand shall comply with Clause 613. Cement shall comply with Clause 614.
The mixing shall be done in a mechanical mixer unless hand-mixing is permitted by the
Engineer. If hand-mixing is allowed, the operation shall be carried out on a clear
watertight platform. In the required proportion cement and sand shall be first mixed dry to
obtain an uniform colour. Then required quantity of water shall be added and the mortar
shall be mixed to produce workable consistency. The mortar shall be mixed for at least
three minutes after addition of water in the case of mechanical mixing. In the case of
hand mixing, the mortal shall be hoed back and forth for about 10 minutes after addition
of water in order to obtain uniform consistency.
Only that quantity of mortar shall be mixed at a time which can be used completely
before it becomes unworkable. Any mortar that has become unworkable due to loss of
water before elapsing the initial setting time of cement, shall be rewet to make it workable
and shall be used in the works. On no account mortar shall be used after elapsing the
initial setting time of cement.
2503 SOAKING OF BRICKS
SECTION 2500 BRICKWORKS FOR STRUCTURES

Page No. 25–1
Bricks shall be soaked in water for a minimum period of one hour before use. When bricks are
soaked they shall be removed from the tank sufficiently in advance so that at the time of laying
they are skin dry. Such soaked bricks shall be stacked on a clean place where they are not spoilt
by dirt, earth, etc.
2504 LAYING OF BRICKS
All bricks work shall be laid in English bond, even and true to line, plumb, level and all joints
accurately kept. Whole bricks used on the face shall be selected ones of uniform size and true
rectangular face.
Bricks shall be laid with frogs up, if any, on a full bed of mortar. When laying, bricks shall be
slightly pressed so that the mortar gets into all the surface pores of bricks to ensure proper
adhesion. All joints shall be properly flushed and packed with mortar so that no hollow spaces are
left.
Before laying bricks in foundation, a layer of not less than 12 mm of mortar shall be spread to
make the surface on which the brick work will be laid even. Immediately thereafter, the first
course of bricks shall be laid.
The brick work shall be built in uniform layers. Corners and other advanced work shall be raked
back. Brick work shall be done true to plumb or in specified batter. No part of it, during
construction, shall rise more than one metre above the general construction level, to avoid
unequal settlement and improper jointing.
Toothing may be done where future extension is contemplated but shall be used as an alternative
to raking back.
2505 JOINTS
The thickness of joints shall not exceed 10 mm.
2506 JOINTING WITH EXISTING STRUCTURES
When fresh masonry is to be placed against existing surface of structures, the surface shall be
cleaned of all loose materials, roughened and wetted as directed by the Engineer so as to effect
a good bond with the new work.
2507 CURING
Green work shall be protected from rain by suitable covering. Masonry work in cement mortar
shall be kept constantly moist on all faces for a minimum period of seven days. The top of the
masonry work shall be left flooded with water so as not to disturb or washout the green mortar.
During hot weather, all finished or partly completed work shall be covered or wetted in such a
manner as to prevent rapid drying of the brick work.
2508 SCAFFOLDING

Page No. 25–2
The scaffolding shall be sound and strong to withstand all loads likely to come upon it. The holes
which provide resting space for horizontal members shall not be left in masonry under one metre
in width or immediately near the skew backs of arches. The holes left in the masonry work for
supporting the scaffolding shall be filled and made good.
2509 CONDITION OF EQUIPMENT
All equipment used for mixing or transporting mortar and bricks shall be clean and free from set
mortar, dirt or other injurious foreign substances.
2510 FINISHING OF SURFACES
(1) General
The surfaces can be finished by 'jointing', 'pointing' or 'plastering', as specified. For a

surface which is to be subsequently plastered or pointed, the joints shall be squarely
raked out to a depth of 15 mm while the mortar is still green. The raked joints shall be
well brushed to remove dust and loose particles and the surface shall be thoroughly
washed with water, cleaned and wetted.
The mortar for finishing shall be prepared as per Clause 2502.

(2) Jointing
In jointing, the face joints of the mortar shall be worked out while still green to give a
finished surface flush with the face of the brick-work. The faces of brick-work shall be
cleaned to remove any splashes of mortar during the course of raising the brick-work.
(3) Pointing
For pointing, the mortar shall be filled and pressed into the raked out joints, before giving
the required finish. The pointing shall then be finished to proper type given on the
Drawing. If type of pointing is not mentioned on the Drawing the same shall be ruled
pointing. For ruled pointing after the mortar has been filled and pressed into the joints
and finished off level with the edges of the bricks, it shall while still green be ruled along
the centre with a half round tool of such width as may be specified by the Engineer. The
superfluous mortar shall then be cut off from the edges of the lines and the surface of the
masonry shall also be cleaned of all mortar.
(4) Plastering
Plastering shall be started from top and worked down. All putlog holes shall be properly
filled in advance of the plastering as the scaffolding is being taken down. Wooden
screeds 75 mm wide and of the thickness of the plaster shall be fixed vertically 2.5 to 4
metres apart to act as gauges and guides in applying the plaster. The mortar shall be laid
on the wall between the screeds using the plaster's float and pressing the mortar so that
the raked joints are properly filled. The plaster shall then be finished off with a wooden
straight edge reaching across the screeds. The straight edge shall be worked on the
screeds with a small upward and sideways motion 50 mm or 75 mm at a time. Finally, the
surface shall be finished off with a plaster's wooden float. Metal floats shall not be used.

Page No. 25–3
When recommencing the plastering beyond the work suspended earlier the edges of the
old plaster shall be scraped, cleaned and wetted before plaster is applied to the adjacent
areas.
No portion of the surface shall be left out in a condition to be patched up later on.
The plaster shall be finished to a true and plumb surface and to the proper degree of
smoothness as required by the Engineer.
The average thickness of plaster shall not be less than the specified thickness. The
minimum thickness over any portion of the surface shall not be less than the specified
thickness minus 3 mm.
Any cracks which appear in the surface and all portions, which sound hollow when
tapped, or are found to be soft or otherwise defective, shall be cut out in rectangular
shape and re-done as directed by the Engineer.
(5) Curing of Finishes
Curing shall be started as soon as the mortar used for finishing has hardened sufficiently
not to be damaged when watered. It shall be kept wet for a period of at least 7 days.
During this period, it shall be suitable protected from all damages.
2511 TEST AND STANDARD OF ACCEPTANCE
Before laying any mortar, the Contractor shall make three sets of mortar test cubes from each
source of sand to demonstrate the compliance of the mortar to the specified strength. Each set
shall comprise two cubes, one to be tested at 7 days and the other to be tested at 28 days.
Testing shall be in accordance with IS 2250. During construction the Contractor shall make and
test mortar cubes at the rate of three for every 10m3 or part of it of brick work to assess the
strength of the mortar subject to a minimum of 3 sample cubes for a days work. The brick shall be
tested for compressive strength and water absorption as per NS-1/2035 and shall meet the
requirement of this Specification.
2512 MEASUREMENT
All brick work shall be measured in cubic metres.
The work of plastering and pointing shall be measured in square metres separately.
2513 PAYMENT
The brick works, plastering and pointing shall be paid at their respective contract unit rate which
shall be the full and the final compensation to the Contractor as per Clause 112 to complete the
work as per these Specifications.
Payment for Sub-standard Works
Brick work not meeting the requirements of the relevant Specifications (termed as substandard
brick work) shall be paid as substandard work provided it is accepted by the Engineer as
substandard work. For the acceptance of such work the Engineer may require further

Page No. 25–4
investigation and/or tests which the Contractor shall conduct at his own cost. Acceptance or
rejection of such work is the sole responsibility of the Engineer and his decision in this respect
shall be the final and binding upon the Contractor.
If accepted as substandard work the payment for such work shall be made at the contract unit
rate reduced by the formula given below
Design strength of mortar - Observed strength of mortar

Percent of reduction, P = X
100
Design strength of mortar
The reduced contract unit rates of substandard brick work and other items contained shall be
the full and the final compensation to the Contractor.

Page No. 25–5
SECTION 2600 - MASONRY FOR STRUCTURES
Page No.
2601 SCOPE 26–1

2604 ASHLAR 26–3
2605 BLOCK-IN-COURSE 26–3
2606 SQUARE RUBBLE - COURSED OR BROKEN COURSES 26–3
2607 RANDOM RUBBLE - COURSED OR UNCOURSED 26–3
2608 DRY RANDOM RUBBLE 26–3
2609 COMPOSITE RANDOM RUBBLE 26–3
2610 TEST AND STANDARD OF ACCPETANCE 26–4
2612 PAYMENT 26–4
SECTION 2600 - MASONRY FOR STRUCTURES
2601 SCOPE
This Section covers furnishing of materials and construction of different types of stone masonry
works in accordance with the Drawing and this Specification or as directed by the Engineer.
2602 MATERIALS
All requirements in respect of stones and cement sand mortar described herein shall be
applicable in all Clauses of this Section, if otherwise not specified.
(1) Stone
The stones to be used shall be durable and angular in shape. If boulders are used they
shall be broken into angular pieces. The stones shall be sound, hard, free from iron
bands, spots, sand holes, flaws, shakes, cracks or other defects. The stone shall not
absorb water more than
5 per cent. The specific gravity of the stone shall not be less than 2.50. Except otherwise
described in the contract, the length of any stone shall not exceed three times its height.
The breadth of the stone on the bed shall not be less than 150 mm nor greater than 3/4
the thickness of the wall. At least 85% of the stones used in masonry, except those used
for chinking as chips or spalls of stones shall have individual volumes of more that 0.01
m3 .The chips or spalls used including voids in the dry stone masonry shall not be more
than 20% of the stone masonry by volume. In case of mortared masonry the total volume
of mortar and spalls taken together shall not be more than 30% of the mortared masonry.
Representative samples of the stones intended for use in the works shall be submitted to
the Engineer for prior approval. Further representative samples shall be submitted for
approval whenever there is a change in the type or strength of the rock that the
Contractor intends to use in masonry work.
(2) Mortar
Mortar for masonry shall conform to Sub-clause 2502 (2). Sand shall comply with IS 2116
and cement shall comply with Clause 614.
2603 CONSTRUCTION
The method of construction described herein shall hold well in all Clauses of this Section,
wherever applicable.
(1) General
Construction shall be carried out in accordance with I.S. 1597-1992, Code of Practice for
construction of stone masonry, Part 1 Rubble stone masonry or Part 2 Ashlar Masonry as
appropriate. All stratified stone possessing bedding planes shall be laid with its natural
bed as nearly as possible at right angles to the direction of load. In the case of arch rings,
the natural bed shall be radial. Facework groins shall be built to a height not exceeding
one metre in advance of the main body of the work and adjacent walling stepped down
SECTION 2600 MASONRY FOR STRUCTURES

Page 26  1
on either side. Masonry face work between the groins shall then be built to a height not
exceeding 500 mm above the backing which shall then be brought up level with the
completed facework. At no time shall the backing be built up higher than the facework.
Except for dry rubble walling, all joints (gaps) shall be sufficiently thick to prevent stone to
stone contact and the gaps shall be completely filled with mortar. Stones shall be clean
and sufficiently wetted before laying to prevent absorption of water from mortar.
Placing loose mortar on the course and pouring water upon it to fill the gaps in stones
shall not be allowed. Mortar shall be fluid, mixed thoroughly and then poured in the joints.
No dry or hollow space shall be left anywhere in the masonry and each stone shall have
all its faces completely covered with mortar of the thickness as specified for joints.
The bed which is to receive the stone shall be cleaned, wetted and covered with a layer
of fresh mortar. All stones shall be laid full in mortar both in bed and vertical joints and
settled carefully in place with a wooden mallet immediately after placement and solidly
embedded in mortar before it has set. Clean and wet chips and spalls shall be wedged
into the mortar joints and bed whenever necessary to avoid thick joints or bed of mortar.
When the foundation masonry is laid directly on rock, the bedding face of the stones of
the first course shall be dressed to fit into rock snugly when pressed down in the mortar
bedding over the rock. For masonry works over rock, a levelling course of M15/40 or
M15/20 concrete 100mm thickness shall be laid over rock and then stone masonry work
shall be laid without foundation concrete block.
In case, any stone already set in mortar is disturbed or the joints broken, it shall be taken
out without disturbing the adjoining stones and joints. Dry mortar and stones thoroughly
cleaned from the joints and the stones shall be reset in fresh mortar. Sliding one stone on
top of another which is freshly laid, shall not be allowed.
Shaping and dressing of stone shall be done before it is laid in the work. Dressing and
hammering of the laid stones which will loosen the masonry shall not be allowed.
Building up face wall tied with occasional through stones and filling up the middle with
stones spalls and chips or dry packing shall not be allowed. Vertical joints shall be
staggered. Distance between the nearer vertical joints of upper layer and lower layer in
coursed rubble masonry shall not be less than half the height of the course.
Masonry in a structure between two expansion joints shall be carried up nearly at one
uniform level throughout but when breaks are unavoidable the masonry shall be raked in
sufficiently long steps to facilitate jointing of old and new work. The stepping of raking
shall not be more than 45 degrees with the horizontal.
Masonry shall not be laid when the air temperature in the shade is less than 3°C. Newly
laid masonry shall be protected from the harmful effects of weather.
(2) Concrete Capping
Where masonry structures are to receive a concrete capping. the joints to the upper
surface of the masonry shall be raked out to a depth of 10 mm prior to placing of the
concrete to the capping. The concrete for capping shall be as per the Drawing or as
directed by Engineer and shall conform to Section 2000.
(3) Pointing

Page 26  2
Where external faces of the mortared masonry work will be backfilled or otherwise
permanently covered up, the mortared joint shall be finished flush to the faces of the
adjacent stonework.
Where mortared masonry faces will remain exposed, the mortar joints shall be pointed to
a consistent style as shown on the Drawing. Pointing shall be carried out using mortar
1:3 by volume of cement and sand or as shown on the Drawing. The mortar shall be filled
and pressed into the raked out joints before giving the required finish. The pointing, if not
otherwise mentioned, shall be ruled type for which it shall, while masonry work is still
green, be ruled along the centre with half round tools of such width as may be specified
by the engineer. The excess mortar shall, then, be taken off from the edges of the lines
and shall not be unnecessarily plastered over the exposed stone works. The thickness of
the joints shall not be less than 3mm for Ashlar masonry.
However, the maximum thickness of joints in different works shall be as follows:
 Random Rubble : 20mm

 Coursed Rubble : 15mm
 Ashlar Masonry : 5mm
2604 ASHLAR
All stones shall be dressed to accurate planes on the beds and joints and they shall be fair and
neatly or fine tooled on the face unless otherwise described in the contract.
2605 BLOCK-IN-COURSE
Beds and joints shall be squared and dressed for a distance of at least 220 mm from the exposed
face. Bond stones shall form at least one sixth of the area of the exposed face and shall extend at
least 900 mm into the wall or for the full thickness of the wall if the latter is less than 900 mm.
Unless described in the contract as tooled or drafted, the exposed face of all stones shall be
blocked and left rough. Arises shall be dressed square at all beds and joints.
2606 SQUARE RUBBLE-COURSED OR BROKEN COURSES
All stones shall be truly squared and dressed for a distance at least 120 mm from the face of the
wall. Bond stones shall be provided at the rate of at least one to every 0.8 m 2 of exposed face
and shall measure not less than 150 mm x 150 mm on the face and not less than 450 mm in
length or the full thickness of the wall, whichever is the less. Vertical joints in any layer shall be
broken in the next layer and the horizontal lapping of the stones shall not be less than 100 mm.
2607 RANDOM RUBBLE - COURSED OR UNCOURSED
All stones shall be carefully set with a bond stone provided at the rate of at least one to every 0.9
m2 of exposed face. Bond stones shall measure not less than 150 mm x 150 mm on the exposed
face and not less than 450 mm in length or the full thickness of the wall, whichever is the less.
2608 DRY RANDOM RUBBLE
Dry random rubble masonry shall be constructed generally to the requirements of coursed
random rubble masonry as specified in Clause 2607 but with the omission of mortar. All stones

Page 26  3
shall be carefully shaped to obtain as close a fit as possible at all beds and joints, any interstices
between the stones being filled with selected stone spalls. The stones in courses shall be laid
perpendicular to the batter face. The exposed tops or capings of dry rubble structures shall be
formed as shown on the Drawing.
2609 COMPOSITE RANDOM RUBBLE
Materials for composite random rubble shall comply with Clause 2602 and construction with
Clause 2603. Mortar masonry shall be coursed and comply with Clause 2607 and the dry stone
insets with Clause 2608. The dry stone insets shall be constructed when the level of the
surrounding mortared masonry surround has reached the top of the dry stone inset.
2610 TEST AND STANDARD OF ACCEPTANCE
Before laying any mortar, the Contractor shall make three sets of mortar test cubes from each
source of sand to demonstrate the compliance of the mix to the specified strength. Each set shall
comprise two cubes, one to be tested at 7 days and the other to be tested at 28 days. During
construction, the Contractor shall make and test mortar cubes at the rate of three cubes for every
10 m3 of masonry to assess the strength subject to a minimum of 3 cubes samples for a days
work. Testing of cubes shall be in accordance with IS 2250. The stones shall be tested for the
water absorption as per IS:1124 and it shall not be more than 5 percent. The stones shall also be
tested for Specification gravity and it shall not be less than 2.65. Sand shall be tested as per
Clause 613 or as directed by the Engineer. At least 3 set of tests for stone and sand shall be
conducted for every source.
About one square meter (1mx1m) measured in front face of the completed stone masonry in
every 100 sq.m or part of it shall be dismantled during the process of construction upto complete
depth and the aggregate volume of the stones having volume more than 0.01m3 shall be
obtained by the method of displacement of water to find the volume of spalls and mortars in the
case of mortared masonry and the volume of spalls and voids in the case of dry masonry. The
dismantling shall be made in such a manner that the quality of the surrounding work is least
affected. While dismantling, the tightness of the joints shall also be compared with the thickness
of joints as specified for assessment of the quality of work. If the volume of spalls and mortars is
more than the specified volume and/or the joints are not filled completely with mortar, then the
entire work which the sample and test represent, shall be rejected.
The dismantled portion shall be made good by the Contractor at his own cost after completion of
the test.
2611 MEASUREMENT
Stone masonry shall be measured in cubic metres. The pointing shall be measured in sq.m.
2612 PAYMENT
The stone masonry and the pointing shall be paid at the respective contract unit prices which
shall be the full and the final compensation to the Contractor as per Clause 112.
Payment for Sub-standard Works
Stone masonry in cement sand mortar not meeting the requirements of the relevant
Specifications (termed as substandard stone masonry in cement sand mortar) shall be paid as
substandard work provided it is accepted by the Engineer as substandard work. For the

Page 26  4
acceptance of such work the Engineer may require further investigation and/or tests which the
Contractor shall conduct at his own cost. Acceptance or rejection of such work is the sole
responsibility of the Engineer and his decision in this respect shall be the final and binding
upon the Contractor.
If accepted as substandard work the payment for such work shall be made at the contract unit
rate reduced by the formula given below
Design strength of mortar - Observed strength of mortar

Percent of reduction, P =
X 100
Design strength of mortar
The reduced contract unit rates of substandard stone masonry in cement sand mortar and
other items contained shall be the full and the final compensation to the Contractor.

Page 26  5
SECTION 2700 - REPAIR OF STRUCTURES
Page No.
2701 SCOPE 27–1

2702 GENERAL 27–1
2703 REPAIR OF MINOR DEFECT IN REINFORCED CONCRETE 27–1
2704 PLACEMENT OF CONCRETE FOR BRIDGE DECKS 27–2
2705 REPLACEMENT CONCRETE FOR THE SIDES AND SOFFITS OF
DIAPHRAGMS, AND SOFFITS OF DECKS 27–3
2706 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN 27–6
2707 EPOXY MORTAR FOR REPLACEMENT OF SPALLED CONCRETE 27–11
2708 EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE 27–14
2709 CEMENT GROUTING 27–14
2710 GUNTING/SHORTCRETE 27–16
2711 REPLACEMENT/RECTIFICATION OF BEARING 27–17
2712 DISMANTLING OF CONCRETE WEARING COAT 27–18
2713 PAINTING OF STEEL BRIDGES 27–19
2714 PROTECTION OF STEEL STRUCTURES AGAINST CORROSION 27–24
2715 REPAIR OF STEEL BEARINGS 27–26
2717 PAYMENT 27–30
2700 - REPAIR OF RCC STRUCTURES
2701 SCOPE
This Section covers the works in connection with the repair of RCC structures such as sealing
of cracks, repair and replacement of concrete, cement grouting, gunting/shortcrete. Repair of
structures shall be carried out in accordance with the repair plans and these Specifications or
as directed by the Engineer.
Implementation of repair schemes shall also conform to provisions of IRC:SP:40.
2702 GENERAL
(1) Environmental Aspects
Care shall be taken to ensure suitable mitigation measures against noise and dust,
pollution and damages to the environs whether temporary or permanent and shall be
taken as incidentals to work.
(2) Phasing
The sequence of work shall be in accordance with the Drawing or as directed by the
Engineer.
(3) Traffic Management
Traffic management shall be in accordance with Section 100 and shall be considered
as incidentals to work.
(4) Safety Precautions
Adequate precautions shall be taken for safety of personnel, road users and existing
services, which, during execution, shall be considered as incidentals to work. Persons
working shall wear safety helmets and rubber gloves and shall be provided with other
safety measures as needed.
(5) Dismantling and Removal of Material
Dismantling and removal of structures shall be executed as per Section 200.
2703 REPAIR OF MINOR DEFECT IN REINFORCED CONCRETE
(1) Preparation of Concrete and Reinforcement
(a) The defective concrete shall be removed by using chipping hammer or by

similar method. The edges of the recess shall be cut square or rectangular for
a minimum depth of 15mm using an angle grinder or diamond saw. The
SECTION 2700 REPAIR OF RCC STRUCTURES

Page 27–1
surface of the remaining concrete shall be free from loose or shattered

aggregate and other unsound material.
(b) Where reinforcement is exposed, the concrete shall be removed for a
minimum of a 100mm beyond any corrosion and 25mm behind the
reinforcement
(c) The reinforcement shall be cleaned to remove all corrosion products using
abrasive blasting or high pressure water jetting. For small areas scrapers or
grinding may be used.
(d) If, as a result of these operations, it is found that the section of a reinforcement
bar is significantly reduced, instruction shall be obtained from the Engineer.
(2) Materials
(a) Repair materials for patching shall be a “Prebatched acrylic polymer modified
cementious mortar' complying with (b), (c) and (d) below.
(b) The water/cement ratio shall not exceed 0.4.
(c) The cement content shall not be less than 400 kg/m 3 of compacted concrete
(d) Calcium chloride or admixture containing chloride salts shall not be used.
(3) Reinstating the Prepared Areas
(a) Mixing, placing and curing shall be carried out strictly in accordance with the
manufacturer instructions with compliance of the followings:
(i) Treatment of existing concrete to prevent suction of moisture from the

repair material
(ii) Manufacturers instructions relating to building up the required depth in
layers
(iii) Manufacturers limits on the temperature at which the repair material
may be used
(b) The patch shall be finished off neatly by wooden float to match with the
existing profile.
(c) When the repair is set, it shall be stoned down with carborundum stone and
dressed over with sand: cement (2:1). Finally it shall be smoothened with a
cement float or very fine carborundum stone until a smooth even face is
obtained.
(d) The repaired areas shall be kept damp for 14 days after casting. Proprietary
membranes shall not be used.
(4) Supervision
All repairs shall be supervised by competent and experienced person in carrying out
such repair works.
2704 PLACEMENT CONCRETE FOR BRIDGE DECKS
(1) General
Replacement concrete shall be grade M30/10 and/or M30/20 or as specified on the

Drawing.
(2) Concrete

Page 27–2
The concrete shall comply with Section 2000 depending upon the nature of the work or
(3) Admixtures
The Contractor shall demonstrate by means of trial mixes the action of the admixture
he proposes to use for the Engineer’s approval.
(4) Minimum Cement Content and Maximum Water/Cement Ratio
The cement content shall not be less than 400 kg/m 3 of compacted concrete and the
water cement ratio shall not be greater than 0.40.
(5) Maximum Chloride Content
The total choloride ion conent of the materials shall not be exceed 0.1 percent of the
mass of cement. Calcium chloride or admixture containing chloride salts shall not be
used.
(6) Placing and Curing

(a) The joint surface shall be saturated of two hours before concrete is placed
against it.
(b) Immediately after placing the concrete and for 14 days thereafter, it shall be
protected against harmful effects of weather including rain, rapid temperatures
changes, frost and from drying out. In all cases the methods of protection
used shall be subject to the approval of the Engineer. Proprietary curing
membranes shall not be used.
(7) Concrete Strength
The Contractor shall determine average strength in accordance with Section 2000.
The strength of the concrete as placed shall be consistent and the deviation shall be
within limit of +/- 5% of the average strength.
2705 REPLACEMENT CONCRETE FOR THE SIDES AND SOFFITS OF DIAPHRAGMS,

AND SOFFITS OF DECKS
(1) General
(a) Replacement concrete shall be of grade M 30/10 and shall be a non-shrink
flowable concrete. Materials shall comply with the following requirements.
(b) Cement shall comply with Section 2000 depending upon the nature of work or
(c) Cement content shall be not less than 400kg/m 3 of compacted concrete.
(d) The content of equivalent sodium oxide in the mix shall be restricted or non-
reactive aggregates shall be used.
(e) The total chloride ion content of the materials shall not exceed 0.1 per cent of
the mass of the cement. Calcium chloride or admixtures containing chloride
salts shall not be used.

Page 27–3
(f) The aggregate shall be well graded with the maximum size not exceeding
10mm.
(2) Delivery and Storage of Materials
(a) The Contractor shall supply following information with each batch or part of a
batch of the material delivered to the site.
(i) Manufacturers'/suppliers' name and address

(ii) Manufacturers'/suppliers' name and address where applicable
(iii) Material identification
(iv) Batch reference number, size of batch and number of containers per
delivery order
(v) Date of manufacture
(vi) Chloride contents with evidence
(b) Containers shall be damp proof and readily emptied of their contents
(c) Containers shall be marked with the following information:
(i) Material identification

(ii) Batch reference number
(iii) Manufacturers'/suppliers' name
(iv) Net weight
(v) Any warnings or precautions concerning the contents
(d) The material shall be stored in a dry place with moderate temperature
(e) Material shall not be older than 3 months or the period specified by the
manufacturer, when incorporated in the works.
(f) The materials shall not be removed from the store for use in the works unless
it is immediately required for mixing.
(3) Site Mixing, Placing and Curing
(a) Mixing and placing shall be carried out strictly in accordance with the
manufacturer's written instructions together with the followings:
(i) The water cement ratio shall not exceed 0.4. The water content shall
be determined during Approval Tests, approved by the Engineer.
(ii) The material shall be incorporated in the works within 20 minutes of
completion of mixing, or within the period as specified by the
manufacturer.
(iii) No extra water shall be added after the original mixing.
(iv) The material shall not be mixed or placed in the works at ambient
temperatures lower than 5oC.
(v) The surface temperature of the concrete shall be maintained at not
less than 5oC until the concrete reaches a strength of 5N/mm 2 as
determined by tests of cubes cured under similar conditions.
(b) Replacement concrete shall not be placed against other concrete which has
been in position for more than 30 minutes unless a construction joint is
formed. In addition, the joint surface shall be saturated for a minimum 2 hours

Page 27–4
before concrete is placed against it. When replacement concrete has been in
place for 4 hours, no further concrete shall be placed against it for a further 20
hours.
(c) Vibration shall not be used
(d) Immediately after placing, the concrete shall be protected for 14 days against
harmful effects of weather including rain, rapid change of temperature, frost
and from drying out. The methods of protection used shall in all cases be
subject to the approval of the Engineer. Proprietary curing membranes shall
not be used.
(e) When the mix proportions have been approved by the Engineer no variations
shall be made in the manufacture, supply, mix proportions or method of the
material without the consent of the Engineer.
(4) Approval Tests
(a) Before work commences on the site all properties of the proposed
replacement concrete shall be demonstrated by the Contractor and the
manufacturer's representative by carrying out the tests specified below.
Where required in the contract, procedure trial shall be carried out on the
model specified in the contract or modified to suit actual reinforcement details
or working condition.
(i) The tests shall be carried out in the presence of and to the satisfaction
of the Engineer who shall receive certified copies of the results of all
tests.
(ii) The mixer and method of mixing shall be the same as that to be used
in the works.
(b) Flow Trough Test
(i) For each flow test, sufficient quantity of the replacement concrete shall
be mixed in a mixer approved by the manufacturer.
(ii) The flow characteristics of the concrete shall be assessed at an
ambient temperature of between 5oC and 20oC in the flow trough
indicated in the contract.
(iii) The temperature of the materials and mixer shall be as close as
possible to those expected during the contact with the original surface.
(iv) The funnel shall be fitted with a rubber bung and charged with 6 litres
of concrete. On the release of the bung the concrete shall flow along
the trough and the length of the flow shall be measured. The minimum
length of flow along the trough for each test shall be 450mm, without
signs of segregation or bleeding.
(c) Flow Tests for Horizontal Soffit Surfaces
The flow characteristics for repairs to soffits shall be assessed by pouring the
concrete mix. The pre-cast concrete slab shall be wetted for 2 hours before
the test, but the surface shall be free of surplus water at the time of test. The
concrete shall be poured from one side of the model until the level of the

Page 27–5
concrete has reached at least 10mm above the underside of the top plate.
The material shall be placed in the model in one pour.
After 24 hours the top plate shall be removed and the exposed surface shall
be lightly brushed with a stiff bristle brush to remove any surface cement skin
which may be covering voids. The exposed surface of the concrete shall be
examined for air-pockets, cracks and other defects.
 The temperature of the mixer and material for each test shall be as in
Sub-clause ………..2705 (4) (b).
 The trial shall be deemed successful if the concrete thus formed is
homogeneous and free from air-pockets.
(d) Compressive Strength Tests
(i) These shall be carried out to determine the compressive strength of

the concrete at 20°c.
(ii) Test cubes shall be made in 100mm metal moulds to BS 1881: Part
108. The moulds shall be carefully filled by pouring concrete through
a funnel to produce void free specimens. There shall be no
compaction. The cubes shall be cured in accordance with BS 1881:
Part 111. Testing shall be carried out in accordance with BS 1881:
Part 116.
(iii) The specified minimum strength shall be established using a set of
three cubes. The requirement shall be satisfied if none of the
compressive strengths obtained is lower than the specified value, and
the difference between the highest and lowest values shall not be
more than 20% of the average.
(5) Batch Acceptance Tests
(a) The material shall be taken at random from one or more containers from the
same batch. Each batch of material delivered to the site shall be tested as
specified below.
(b) Flow trough test shall be carried out as specified in these Specifications.
(c) Flow tests for horizontal surfaces shall be carried out as specified.
(d) Compressive strength tests shall be carried out as specified.
(6) Site Tests
Three cubes from each batch mixed for placing in the Works shall be tested for
compressive strength.
(7) Concrete Strength
(a) The Contractor shall determine this average strength in accordance with these
Specifications. The strength of the concrete as placed shall be consistent and
the deviation shall be within limit of +/-5% of the average strength .
2706 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN
(1) General

Page 27–6
The work of epoxy adhesive for the Structural Concrete Bonding Process shall
conform to these Specifications.
The Contractor shall furnish detailed methodology of construction including sources of
supply of material, tools, equipment and appliances with details of personnel and
supervision to be used on work.
(2) Personnel
The Contractor’s personnel shall be qualified and experienced in epoxy injection

process.
(3) Materials
The materials for injection shall be a suitable two-component low viscosity epoxy resin,
having the required characteristics of bonding with concrete and resistance to moisture
penetration. Epoxy mortar or polysulphide resin may be used for sealing the surface.
The material for epoxy injection shall conform to the following:
(i) The mixing ratio of resin and hardener shall generally be between 1 to
1 and 2 to 1 by volume subject to manufacturer’s recommendation.
(ii) Neither the mixed epoxy adhesives nor their individual components
shall contain solvents and thinners.
(iii) The components shall be free of foreign material. The viscosity of the
individual components shall not change more than  15 percent when
kept in closed containers at 25 degrees Celsius after two weeks.
(iv) Pot Life of Mixed Adhesive at 25 degrees Celsius - 1 hour + 15
minutes*
(v) Set time of mixed Adhesive at 25 degrees Celsius - 3 to 6 hours
(vi) Consistency Requirement
Viscosity of Mixed Adhesive Standard Version Low Viscosity

at 25 degrees Celsius (cps) Version (cps)
(200 – 300) (100 – 190)
* In the case of two component injection system where resin and

hardener get mixed at point of injection pot life at 25 degrees Celsius
shall be not greater than 15 min  10 minutes
(4) Equipment for Injection
The equipment shall be a portable, positive displacement type pump with interlock to
provide positive ratio control of exact proportions of the two components at nozzle. The
pumps shall be generally electrically powered and shall provide in-line metering and
mixing. The tolerance on mix ratio shall be 5 percent by volume. The injection
equipment shall have automatic pressure control capable of discharging mixed
adhesive at any pre-set pressure within the prescribed limits and shall be additionally
equipped with a manual pressure control.

Page 27–7
The injection equipment shall be equipped with sensors on both the components. A
and B reservoirs i.e. reservoirs containing components resin and hardener shall
automatically stop the machine when only one component is being pumped to the
mixing head.
If considered appropriate, suitable compressed air operated epoxy injection gun can
be used with prior approval of the Engineer for manual injection of mix when resin and
hardener had been mixed in a separate unit.
(5) Preparation
Surfaces adjacent to cracks or other areas of application shall be cleaned of dirt, dust,
grease, oil efflorescence or other foreign matter by brushing/water jetting/sand
blasting. Acids and corrosives shall not be permitted for cleaning.
Entry ports shall be provided along the crack at intervals of not more than the
thickness of concrete at the location.
Surface seal material shall be applied to the face of the crack between the entry ports.
For through cracks, surface seal shall be applied to both faces.
Before proceeding with the injection, the surface seal material must gain adequate
strength with respect to concrete strength of the member and injection pressure.
(6) Epoxy Injection
Injection of epoxy adhesive shall begin at lowest entry port and continue until there is
an appearance of epoxy adhesive at the next entry port adjacent to the entry port
being pumped.
When epoxy adhesive travel is indicated by appearance at the next adjacent port,
injection shall be discontinued on the entry port being pumped and entry port shall be
sealed. Thereafter, epoxy injection shall be transferred to next adjacent port where
epoxy adhesive has appeared.
Epoxy adhesive injection shall be performed continuously in this manner until cracks
are completely filled.
If port to port travel or epoxy adhesive is not indicated the work shall be immediately
stopped. In case the volume of the injected material exceeds 2 litres for a particular
entry port, the work shall be stopped and the Specifications shall be reviewed.
(7) Precautions during Application
(a) Unless otherwise specified, at the time of mixing components A and B, i.e.,
resin and hardener, shall be at a temperature between 10 and 35 degrees
Celsius.
(b) Temperature of structural member during epoxy injection shall be between 10
and 35 degrees Celsius unless otherwise specified.

Page 27–8
(c) Immediately prior to use, each component shall be thoroughly mixed with a
clean paddle. The paddle shall be of a type that does not induce air into the
material. Separate clean paddle must be used for each component.
(d) Any heating of the adhesive components may be done by application of
indirect heat in case the work is to be done in cold climate.
(e) Just before use, the two components shall be thoroughly mixed in the rations
specified by the manufacturer. The mixing time shall be in strict accordance
with manufacturer’s recommendations. When mixed, all adhesives with
different coloured components shall have a uniform colour without streaks.
(f) The use of solvents and thinners shall not be permitted except for cleaning of
equipment.
(8) Testing
(a) Material Testing
Prior to approval of the material, the following tests shall be carried out at site
or in an authorised laboratory for each batch of resin and hardener and each
combination thereof at the cost of the Contractor.
(i) Viscosity test for resin and hardener and the mix – three specimens
each.
(ii) Pot life test - three specimens each.
(iii) Bond test - three specimens each.
(iv) Shear test – six specimens each, 3 after 24 hours and the other three
after 72 hours of curing.
Subsequent tests shall be carried out as directed by the Engineer.

Pot Life Tests
(i) 500 gm of resin formulation shall be prepared by thoroughly mixing
the resin and harderner/accelerator/catalyst component in proposed
proportion in a 1 kg capacity hemispheral porcelain bowl by means of
a spatula or any other agitating device. The time and the ambient
temperature shall be noted down.
(ii) With a clean dry 25 mm size painter’s brush, the resin formulation
shall be applied on a clean dry surface such as cement concrete over
15-20 cm length, starting immediately after mixing the formulation and
repeating operation every five minutes. When it becomes just difficult
to spread the resin properly with the brush, the time is noted. The
time elapsed since completion of mixing of resin formulation is taken
as its pot life.
(iii) One pot life test shall be performed on commencement of work and
the same shall be repeated every four hours.
(iv) In case the material fails to satisfy the pot life test it shall not be used
for injection
Where the resin and hardener get mixed at point of injection, the pot life is not
important and no tests may be required.
Bond Test

Page 27–9
A standard 150 mm diameter and 300 mm long concrete cylinder shall be cast
in 2 pieces by providing a separating media at an axis of 45 degrees to the
longer axis of the cylinder.
Three sets of such split cylinders shall be prepared in advance. Two pieces of
each set shall be joined with epoxy mortar at four points to give a clear gap of
about 0.2 mm, which shall be injected with epoxy resin at site. After epoxy has
been cured, load test shall be carried out on the cylinder which shall not be
less than 80 percent of the cube strength of the concrete mix and the failure
shall not take place at the joint injected with epoxy resin.
Shear Tests
Two steel plates, minimum 3 mm thick, shall be bonded with epoxy at site
using the same resin mix as used/proposed to be used for injection. The
assembly shall be kept in mechanical clamp till epoxy is cured. A total of six
specimens shall be prepared for each batch of materials. Three test
specimens shall then be subjected to a shear force along the axis after 24
hours and minimum shear stress before failure shall not be less than 1
N/sq.mm.
The remaining test specimens shall be similarly tested after 72 hours of curing.
The shear stress before failure shall not be less than 2.5 N/sq.mm.
(b) Core Test
If directed by the Engineer, core tests shall be conducted for the acceptance of
the work. The selection of the location of cores shall be made under the
direction of the Engineer in such a way that damage in critical/stressed areas
of the structure is avoided. The procedure for the test shall be as under.
The Contractor shall obtain 5cm diameter initial core samples in the first 50
linear metres. Thereafter, frequency of core sampling shall be as specified or
as agreed by the Engineer.
The depth of the core shall generally be less than 20cm.
Tests and Acceptance Criteria shall be as follows:
(i) Penetration/Visual Examination – a minimum of 90 percent of the

crack shall be full of epoxy adhesive.
(ii) Bond Strength: Concrete failure before adhesive failure or 40 Mpa
with no failure of either concrete or adhesive
If the cores taken in first 50m length pass tests as specified above, epoxy
adhesive injection work at area represented by cores shall be accepted.
If cores fail either by lack of penetration or bond strength, work shall not
proceed further until the areas represented by the cores are reinjected and
retested for acceptance.

Page 27–10
Filling of core holes shall consist of using two-component bonding agent

applied to surfaces of cored holes followed by application of Non-Shrink
cement grout mix placed by hand trowel, thoroughly rodded and tamped in
place, and finished to match finish and texture of existing concrete to the
satisfaction of the Engineer. Materials and procedures for filling testing core
holes shall be submitted to and approved by the Engineer before proceeding
with core testing work.
(c) Test for Injection Equipment
At all times during the course of the work the Contractor shall keep complete
and accurate records and make available to the Engineer of the pressure and
ratio tests specified above so that the efficacy and accuracy of the injection
equipment is verified.
In addition, the Engineer at any time without prior intimation of the Contractor
may request the Contractor to conduct the tests specified below, in his own
presence.
(i) Pressure Test
The mixing head of the injection equipment shall be disconnected and

the two adhesive component delivery lines shall be attached to the
pressure check device, which shall consist of two independent valved
nozzles capable of sensing the pressure. The check device shall be
closed and equipment operated until the gauge pressure in each line
reads 5MPa. The pumps shall be stopped and the gauge pressure
shall not drop below 4 MPa within 2 minutes.
The pressure test shall be run for each injection unit at the beginning
and after break of every shift.
(ii) Ratio Test
The mixing head of the injection equipment shall be disconnected and

the two adhesive components shall be pumped simultaneously through
the ratio check device, which shall consist of two independent valved
nozzles. There shall be a pressure gauge capable of controlling back
pressure by opening or closing valved nozzles capable of sensing the
back pressure behind each valve. The discharge pressure shall be
adjusted to read 5 bars for both adhesive components. Which shall be
simultaneously discharged into separate calibrated containers during
the same time period and the amounts discharged into the calibrated
containers simultaneously during the same period shall be compared
to determine that the volume/discharge conforms to the manufacturer’s
recommended ratio for applicable material.
2707 EPOXY MORTAR FOR REPLACEMENT OF SPALLED CONCRETE
(1) Material

Page 27–11
(a) Formulation
The epoxy resins for use in the mortar shall be obtained from a reputed
manufacturer and the mortar shall be prepared in conformity with the
manufacturer’s recommendations.
They shall generally conform to the following:
Pot Life : 90 minutes at 25 degrees Celsius

60 minutes at 30 degrees Celsius
45 minutes at 35 degrees Celsius
Bond Strength : 12 N/sq.mm
Tensile Strength : 16 N/sq.mm
The Contractor shall carry out tests on the samples made out or requirements
indicated above. The sand content in the mortar shall be in accordance with the
desired consistency.
(2) Proportioning and Mixing
The resin and hardener shall be mixed before adding the dry filler. The mixed ready to
use mortar shall not contain lumps of unwetted filler and should be uniform in colour.
For a total weight of 1 kg or less, hand mixing shall be sufficient. For quantities in
excess of 1 kg, the component shall be mixed for 3 minutes with a slow speed 400-600
rpm electric drill with a Jiffy mixer. The stirrer shall be moved up and down and along
the sides until an even steak free colour is obtained. Whipping in an excessive
amount of air shall be avoided. If no power is available, a flat putty knife may be used
to reach into the corners of the can and hand mixing done for at least 5 minutes.
(3) Surface Preparation
Surface upon which epoxy is to be placed shall be free of rust, grease, oil, paint,
asphalt, loose material, unsound concrete, dust or any other deleterious material.
Since cured epoxy does not provide adequate bond with any material, all overlay,
whether epoxy or cement based, shall be done within pot life of the base epoxy layer.
Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds of
surface impregnates like linseed oil or silicons, including laitance and weak or loose
concrete shall be removed. When bonding to asphalt, the surface should be
roughened so that clean aggregate is exposed. Epoxy bonding agents shall not be
applied when it rains, or in standing water. The surface must be dry.
Two general methods of surface preparation shall be followed:
(a) Mechanical that includes grinding, grit blasting, water blasting and
scarification.
(b) Chemical that includes acid etching with 15 percent by weight of hydrochloric
solution, followed by repeated flushing with high pressure stream of water.

Page 27–12
(4) Application
Epoxy primer coat shall be applied with the help of stiff nylon bristle brushes or hard
rubber rollers or spray gun depending upon the nature of surface and extent of work
area. As far as possible, the coating shall be uniformly thick.
Before the primer coat is fully cured, epoxy mortar shall be applied by means of
trowels and floats. The interval between the application of primer coat and epoxy
mortar shall be approximately 15/30 minutes depending upon the ambient
temperature.
Seal coat shall be applied after 24 hours curing, after mild roughening of the surface of
the mortar.
(5) Coverage
The coverage of resin mix will depend on the system of resin used. However, as a
general guideline the coverage area shall be as under:
(a) Primer Coat. One kg of resin-hardener mix covers an area of 3-6 square
metres per coat depending on the finish of the concrete.
(b) Epoxy Mortar. One square metre of surfaces requires approximately 20-24 kg
of epoxy mortar when laid to a thickness of 10mm.
(c) Seal Coat. 4 to 6 square metres per kg of mix depending on the temperature
of application.
(6) Cleaning and Maintenance of Equipment
Tools and equipment are best cleaned immediately after use since the removal of
cured resin is difficult and time consuming. The bulk of resin shall be removed using a
scraper and remainder washed away completely using solvents such as toluene,
xylene or acetone. Equipments used for epoxy shall always be cleaned before it
hardens. Solvents used for this purpose may be Acetone (flammable), Methyl Ethyl
Kethone (flammable), Methyle Chloride (non-flammable). Cured expoxies may be
removed using Methylene Chloride.
(7) Testing
Epoxy used for making mortar shall conform to all requirements and testing
procedures as laid down in Sub-clause 2706 (8).
(8) Handling Precaution
Epoxy resins may cause irrigation of skin in sensitive persons if incorrectly handled.
The resin and hardener should not be allowed to come into direct contact with skin.
The most effective protection is achieved by wearing rubber or polythene gloves.
(9) Personnel and Environment Safety

Page 27–13
Any skin contact with epoxy materials, solvents and epoxy strippers shall be avoided.
Epoxy resins and particularly epoxy hardeners (B component) may cause a rash on
the skin. The official toxicity classification on the container labels should be looked for
before starting work.
Rubber gloves with a cloth liner and protective clothing shall be worn. Barrier creams
are recommended but are not substitutes for protective clothing. Eyes shall be
protected where splashing could occur while spraying or mixing. Good ventilation shall
be ensured and inhalation of vapours shall be avoided. If materials are sprayed, a
respirator shall be used.
If skin contact occurs, it shall be immediately washed with a cleaner, followed by soap
and water. Should eye contact occur, it shall be flushed immediately with plenty of
water for 15 minutes and a doctor called for.
If contact occurs with the clothing, it shall be immediately changed to prevent further
skin contact, and if the contact occurs with components A or B, the clothing shall be
thrown away. Hardened epoxy is not harmful but will break the clothing.
All emptied, used buckets, rags and containers shall be removed from site. These shall
be stored in waste disposal bags and suitably disposed.
2708 EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE
(1) Epoxy resin used bonding shall be obtained from a reputed manufactures. The pot life
of such bonding epoxy shall be more than 60 minutes at normal temperature.
(2) The entire surface of the existing concrete member shall be thoroughly cleaned by
wire brush and then with compressed air to remove dust and loose particles from the
surface. Any crack or spalling of concrete shall be seated by epoxy injection/epoxy
mortar/grouting as decided by the Engineer. A coating of suitable epoxy resin at the
rate of 0.8 kg/sq.m (minimum) shall then be applied on the surface of the existing
concrete members. Fresh concrete shall then be placed within the pot life of the resin
system.
(3) Testing
Epoxy used for bonding work shall satisfy the criteria mentioned in Clause 2706 (8).
Two concrete cubes of 150 mm size as per approved design mix shall be placed, at a
distance of 150 mm from each other. Epoxy resin system suggested for bonding new
to old concrete shall be applied on the opposite faces of the cubes.
Fresh cement concrete cube of grade as per approved design mix shall be water
cement ratio of 0.4 or less in between two concrete cubes already casted and epoxy
resin applied bor bonding on a 12 mm thick steel spacer. The assembly shall be cured
in water for 28 days and steel spacer removed thereafter.

Page 27–14
The cube assembly shall be subjected to compression load after 28 days of curing,
thereby subjecting the bond to shearing load. Failure must not occur at this joint.
2709 CEMENT GROUTING
(1) Material
Grouting shall normally be performed with a mixure of neat portland cement and water.
Other additives and admixtures may be added to improve the impermeability, strength,
etc. on the approval of the Engineer. The size of the particles and the consistency of
the grout must be suited to the passageways it must follow. Neat grout shall not flow
freely into holes smaller than about three times the largest cement particle. Except in
large cavities where thick mortar can be placed, the sand shall all pass the 28-mesh
sieve and have a large portion passing the 50 and the 100 mm sieves. The proportions
of ordinary portland cement to sand will depend upon the size of the spaces to be filled
and will vary from a neat grout to about 1:1 mix. The amount of water to be added
depends upon the consistency required. Grouts with as little as 16 litres of water per
bag of cement can be handled. It may not be required to use more than 40 litres of
water per bag of cement.
Where necessary and approved by the Engineer, admixtures to portland cement grout
mixtures may be added for delaying the setting time, increasing flow ability, minimising
segregation and shrinkage.
(2) Preparation
The surface shall be cleaned with wire brush and compressed air. 15 mm dia and 150
to 200 mm deep holes along the length of the cracks at a spacing of 500 mm shall be
drilled by wet drilling using rotary percussion drills. Nipples shall be inserted in these
holes.
(3) Proportioning, Mixing and Equipment for Grouting
The cement grout shall be mechanically mixed using a system of power-driven

paddles of high-speed centrifugal pump. The grout pump to be used shall permit close
control of pressures to allow a flexible rate of injection with minimum clogging of valves
and ports. The most satisfactory equipment for injecting grout is a pump of the double-
acting flexible reciprocating type giving a steady flow. The grout pumps shall be so
placed as to reduce the waste in cleaning lines. It is preferable to add 50 percent or
more of the mixing water into the mixer before adding the dry ingredients and then the
remaining water. A continuous supply of grout is preferable to an intermittent one.
Consistency of the grout shall be determined by trials starting with thin grout i.e. about
40 litres of water per bag of cement and progressively decreasing the water content to
about 15 litres per bag of cement.
Where the mixer and pump are combined in one unit, the dry material shall be
screened before mixing. If the mixer and pump are in separate units, the grout shall
pass through a screen before it enters the pump.
(4) Application

Page 27–15
Highest practical pressure within the limits 0, 10 – 0.40 N/mm 2 should be used in order
to force the surplus water from the grout. As the pressure may be distributed
hydraulically over considered areas, vigilance must be exercised to prevent damage or
the needless waste of grout. Grouting is to be done by attaching a packer (consisting
of expansible tube or rubber) to the end of the grout supply pump through the holes
and nipples.
Pressure shall be steady to ensure a continuous flow of grout. Grouting shall be

continued till the hole consumes mix at the rate of not less than 30 litres in 20 minutes
or until refusal at the grouting pressure of 400 kPa at any hole until refusal. Should the
grout escape from an adjacent nipple, it should be plugged or capped. Any seam,
crack or joint through which grout escapes shall be caulked with epoxy mortar as soon
as thick grout appears.
(5) Cleaning of Equipment
After completion of each grouting operation or temporry shutdown, it is advisable to

force clear water through the pump until the discharge lines shows no colour, after
which the pump covers shall be removed and the valve chambers thoroughly cleaned.
(6) Testing
Percolation test done at the end of grouting operation shall give a value of less than 2
lugions.
Note : For specialised treatment like polymer modified cementiitious grout injection,
manufacture's literature and Specification shall be followed.
2710 GUNITING/SHOTCRETE
(1) Material
The gunite is a mixture of cement, sand and water. It shall comprise of 100 parts by
weight of cement, 300 parts by weight of quartz sand, 35-50 parts by weight of water
and 2 parts by weight of approved quick setting compound. In general, dry mix
shortcrete shall be used.
Ordinary Portland cement conforming to IS: 269 shall be used in guniting.

Sand for guniting shall comply with the requirements stipulated in IS:383. In general,
sand shall neither be too coarse to increase the rebound nor too fine to increase the
slump. Sand shall have moisture content between 3 to 6 per cent.
The grading of sand shall lie within the limits given in Table 27.1.
Table 27.1: Grading of Sands
Sieve Designation Per cent Passing the Sieve

4.75 mm 95-100
2.36 mm 65 – 90
1.18 mm 45-75

Page 27–16
0.600 mm 30 – 50
0.300 mm 10 – 22
0.150 mm 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 I of IS: 9012. The percentage of coarse
aggregate shall be kept as 20 to 40 percent of the total aggregate and the mix shall be
suitably designed.
Water/cement ratio for guniting shall fall within the range 0.35 to 0.50 by mass; wet
enough to reduce the rebound. Drying shrinkage may be between 0.06 percent to 0.10
percent. The quick setting compound shall be added at the nozzle with water just
before guniting.
(2) Workmanship
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 under pressure.
The cement, sand and water mix shall be passed through and intimately mixed in a
special manifold and then projected at high velocity to the surface being repaired. The
density of gunite shall not be less than 2000 kg/cu.m. The strength of gunite shall not
be less than 25 N/mm2. 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 shall be ensured from tests that strength of about 25 N/mm 2 at 28 days is available
for the mortar/concrete mix.
The defective concrete shall be cut out to the full depth till sound concrete surface is
reached. Under no circumstances the thickness of concrete to be removed shall 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 shall 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 at the rate of 1.0 kg per 1.5 sq.m. of surface
area.
The exposed reinforcement shall be thoroughly cleaned free of rust, scales etc. by
wire brushing. Wherever the reinforcements have been corroded, the same shall be
replaced or supplemented by additional reinforcement. Before application of gunite, a
coat of neat cement slurry shall be applied on the surface of the reinforcement.

Page 27–17
Sufficient clearance shall be provided around the reinforcement to permit encasement

with sound gunite. Care shall be taken to avoid sand pockets behind the
reinforcement.
A thickness of 25 to 40 mm of gunite can normally be deposited in one operation. If, for

some reason, the total thickness is to be built up in successive operations, the
previous layer shall be allowed to set but not become hard before the application of the
subsequent layer. It shall always be necessary to apply guniting on a damp concrete
surface.
Where required, welded wire fabrics 5cm 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 have to be decided as per field conditions.
The stipulations given in IS: 9012 regarding application of gunite shall 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 is adhered to. In no
cirucumstances shall be rebound material be re-used in the work.
It would be desirable that green gunite is moistened for atleast 7 days. Guniting work
shall not be done during windy rainy conditions.
2711 REPLACEMENT/RECTIFICATION OF BEARING
The replacement/rectification of bearings shall be carried out in accordance with approved

repair plan or as approved by the Engineer.
Lifting of superstructure spans may be carried out by jacking up from below or by lifting the
span from top. Where jacks are employed, their location/number and size shall be selected in
such a manner that no undue stresses are created in the structure. Jacks may be placed on
piers/pier caps or specially erected trestles in accordance with the approved methodology for
lifting of superstructure. All jacks shall be operated from one control panel by a single control
lever. The system shall have provision for manual over ride to control the loads of any
particular jack. The jacks shall be so synchronised that differential lift between individual jacks
shall not exceed 1 mm.
Necessary repair/replacement of bearings shall be carried out as indicated in the repair plan or
a directed by the Engineer. Care shall be taken to plan the execution of repair in the shortest
possible period.
Precautions during lifting of Girders for Rectification of Bearings
Walkie-talkies system or similar audio arrangements should be available for communicating

instructions regarding lifting, stopping, starting etc. The operator shall have a clear view of the
jacks and the lifting of each girder so that the lifting is controlled by reading the dial gauges.
2712 DISMANTLING OF CONCRETE WEARING COAT
(1) Commencement of Dismantling

Page 27–18
(a) Before commencing dismantling, the nature and condition of concrete, the
condition and position of reinforcement shall be ascertained. The Contractor
shall familiarise himself with the structural design and ensure that the overall
stability of the bridge is not affected.
(b) The existing expansion joint assemblies shall be removed carefully along the
entire width of the carriageway. The deck slab for a width of 400 mm on either
side shall be removed for placing of reinforcement, anchor rods, anchor bolts
and other filling assemblies for the new expansion joints and pouring of fresh
concrete. The gap between the girders over the piers shall be cleared of all
debris. A temporary platform in the gap at the end of girders shall be erected to
collect the materials falling down during concreting and fixing of expansion
joints.
(c) The service lines, if any, shall be disconnected/diverted before the dismantling
work starts.
(2) Safety of Existing Structures
Dismantling of concrete wearing coat shall be carried out using jackhammers or

suitable manual methods as approved by the Engineer. Care shall be taken to avoid
any damage to the existing structure including reinforcement or pre-stressing
anchorage for cables if any, located in the deck slab.
(3) Precautions During Dismantling Work
For general guidelines, reference may be made to Section 200. Dismantling work shall
not be carried out at night, or during storm or heavy rain. A warning device shall be
installed in the area to be used to warn the workers in case of mishap/emergency.
Safety helmets conforming to IS: 2925 shall be used by the workmen engaged in
dismantling work. The sheds and tools boxes shall be located away from the work site.
Goggles preferably made up of celluloids and gas masks shall be worn at the time of
dismantling, especially where tools like jack hammers are deployed to protect eyes
from injuries from flying pieces, dirt, dust etc. Leather or rubber gloves shall be worn
by the workers during the demolition of RCC work. Screens made up of GI sheets shall
be placed wherever necessary to prevent the flying pieces from injuring the workers.
Water shall be sprayed to reduce the dust while removing concrete wearing course
with jack hammer. No other work shall be taken up under the span when dismantling
work is in progress.
2713 PAINTING OF STEEL BRIDGES
(1) General
The Contractor shall use the Paint System as described in Sub-clause 2713 (2) for the
repainting of the existing bridge structure, to complete the work in at least 4 separate
coats as specified below.
The painting of the structure shall include the removal of existing paint coats and
preparation of the metal surfaces, the application, protection and drying of the paint

Page 27–19
coats; the protection of pedestrian, vehicular or other traffic on or underneath the

structure; the supply of all tools, equipment, scaffolding, labour and materials (including
paint as specified) necessary for completion of the work involved in painting the
surfaces of the structure.
(2) Paint System
The paint system be supplied by the Contractor shall comprise as given in

Table 27.2.
Table 27.2: Paint System
Coat No. Type No’ coats DFT*,

microns
1 Epoxy Red Oxide Zinc Phosphate Primer 1 30
2 2 pack High Build Epoxy 1 75
3 and 4 2 pack Acrylic Polyurethane 2 35/coat
* DFT – Dry film thickness of the paint coating.

The system shall provide a total minimum dry film thickness of 200 microns, and shall
include for all approved thinners and cleaning agents necessary for the completion of
the work in accordance with these Specifications.
The Contractor shall be responsible for appraising himself of the specified paint
system and the manufacturers recommendations in respect of its storage, preparation,
application, and protection and shall take all necessary measures and precautions to
ensure compliance with the manufacturers recommendations.
(3) Paint Supply
The paint shall be supplied by the Contractor in sealed containers of not more than 5
litres capacity and these shall be used in the order of delivery. Each container shall be
clearly marked on the side to show the name of the manufacturer, registered
description of the material (including purpose, e.g. whether primer, undercoat or finish),
colour, batch number and date of manufacture.
(4) Storage of Paint
Where the Contractor requires storing paint, the paint shall be stored in a secure paint
store and ventilation provided as necessary to maintain the temperature of the paint
store at a temperature between 5 and 25 degrees Celsius. If at any time whilst within
the Contractors possession paint is allowed to exceed these limits, the paint shall be
removed from the Works at the Contractors expense and the cost of the paint, as
determined by the Engineer, shall be debited to the Contractor.
Paint, which has not been used within 12 months of the date of manufacture or the
shelf life recommended by the manufacturer, whichever is the lesser, shall not be used
in the works.

Page 27–20
At the end of each working period, paints which shall have exceeded their "pot life" by
the commencement of the next working period shall be mixed with fresh paint but shall
be removed from the works at the Contractor's expense.
Other types of paints shall be returned to store and kept in sealed containers with not
more than 10% usage.
The Engineer shall have access to the Contractors secure paint store at all times.
(5) Preparation of Surfaces
(a) Standard of Surface finish
Unless otherwise instructed by the Engineer, the Contractor shall prepare all
steel surfaces of the structure, including existing paint coatings applied over a
steel substrate, to the standard described below for the appropriate paint
system.
Unless otherwise specified or instructed, fasteners shall be prepared and

painted to the same standard as adjacent main surfaces.
Prior to coating the finished prepared surfaces shall be free of contamination,

detrimental to subsequent paint coatings, to the satisfaction of Engineer.
The surface shall be free from dust and grit and dry and ready for painting.
Surface preparation shall be continued until the specified standard of surface

finish has been achieved and approved by the Engineer.
(b) Preparation by Blast Cleaning
Preparation by blast cleaning shall be used. Unless otherwise instructed by

the Engineer, the Contractor shall prepare all steel surfaces, including existing
paint coatings applied over steel substrate, down to clean steel.
The quality of finish required for steel surfaces to be painted shall be to the
British Standard BS 7079(Group C and D) (or equivalent Specification
approved by the Engineer).
Mill scale, rust and foreign matter shall be removed to the extent that only
slight traces are remaining as stains in the form of spots and strips. The
surface shall be cleaned with a vacuum cleaner, dry clean compressed air or a
clean brush.
Surfaces shall be virtually free from sharp spikes of parent metal defined as
‘rogue peaks’ (formed by the impact of abrasive particles and which project
above the blast cleaning profile) hackles and inclusions, and any such
irregularities which in the opinion of the Engineer would be detrimental to the
protective system shall be removed.
The maximum amplitude of the surface measured between peaks and

adjacent troughs after surface preparation shall be not greater than 50

Page 27–21
microns when measured by an approved surface profile comparator, unless

otherwise approved by the Engineer. In any event the maximum amplitude
shall not exceed 100 microns.
Prepared surfaces assessed as unsatisfactory shall be blast cleaned again

with fresh abrasive.
Preparation of the steel surface for painting shall, unless otherwise approved
by the Engineer, be by blast cleaning using a dry air/abrasive system.
Abrasives used for blast cleaning shall be either clean, dry sand, mineral grit,
steel shot or steel grit at the option of the Contractor and shall be of a grading
suitable to produce satisfactory results. The use of other abrasives shall be
permitted only with the approval of the Engineer.
It shall be the Contractor’s responsibility to provide the approved abrasive

materials in the quantity and quality necessary to complete cleaning
operations to the satisfaction of the Engineer.
Unwashed sands containing salts or excessive amounts of silt shall not be

approved.
Unless otherwise approved by the Engineer, non-metallic abrasives shall not

be recycled.
(c) Procedures for Treatment of Areas of Mechanical damage or Other

Surface Defects
Score marks and indentations in the surface of a steel substrate shall be

treated by abrading or grinding to bright steel to produce a surface without
short edges or abrupt changes in contour. Damage to unprepared surfaces
shall be treated before blast cleaning. Other surface defects in the steel
substrate, including fissures caused by the removal of hackles or inclusions
shall be similarly treated subject to the approval of the Engineer.
In the case of damage to the paint coating only, surface preparation shall be
done by abrading or other method as agreed with the Engineer. The paint
coatings shall then be restored in accordance with the Specification.
In all cases where paint coats only are to be restored, the edges of paint
coatings shall be bevelled back into sound paint.
(6) Testing of Paints
The Contractor shall provide 500 ml samples for laboratory testing purposes of each
type of paint to be used in the works. The samples shall be taken from the first batch
of each type of paint delivered to the site.
When instructed by the Engineer, the Contractor shall also provide a sample of any
replacement batch of paint.

Page 27–22
Unless permitted by the Engineer, painting, except for procedure trials, shall not start
until the Engineer confirms that the samples are satisfactory.
In addition the Contractor shall provide 500 ml samples for application control
purposes when instructed by the Engineer and only under his supervision.
The Contractor shall provide 500 ml tins with lids for the samples at the start of painting
or before any procedure trials. The quantity of containers supplied shall be sufficient to
avoid any delay in taking samples throughout that work.
(7) Application of Paint
At least 7 days in advance of the commencement of painting operations, the

Contractor shall submit his proposed programme of painting operations to the
Engineer for his approval.
The Contractor shall also supply details of the overall wet film thickness of each coat to
be applied and of the coverage rates, in m²/litre, for each coat of paint to be used in the
works. The calculations shall be based on the volume solids plus an allowance for
surface roughness, uneven application and wastage.
Prior to the commencement of painting on any coat, the Contractor shall carry out
painting procedure trials, in the presence of the Engineer, on a suitably prepared
surface up to 10 square metres or as agreed with the Engineer, employing the paint,
labour and equipment to be used in the works.
The Contractor shall demonstrate his ability to apply the paint in accordance with the
Specification and manufacturers recommendations and shall obtain the Engineer’s
approval to commence the application of a particular coat before starting.
All paints shall be prepared and applied in strict accordance with the manufacturers
instructions and no thinners or cleaners shall be employed other than those
recommended by the manufacturer.
The Contractor shall execute the works only when the conditions at the site, including
temperature and humidity, are suitable for applying the paint to be used and ensure
that the structure to be painted is fully accessible to the Contractor and to the Engineer
for inspection prior to, during and after painting operations.
Paint shall not be applied:
(i) When the relative humidity rises above 90%

(ii) When the ambient temperature falls below 4°C.
(iii) During rain, fog, mist or in a dust laden atmosphere
(iv) When the amount of moisture on the surface to be painted, or that likely to be
caused by subsequent condensation or rain may, in the opinion of the
Engineer, have a harmful effect on the paint.
(v) after 6.00 p.m. and before 6.00 a.m.
(vi) Without the approval of the Engineer
(vii) When wind borne dust may have a harmful effect on the paint.

Page 27–23
Paint shall be applied to surfaces, which have been prepared and cleaned in
accordance with the Specification and approved for painting in advance by the
Engineer.
It shall be the Contractor's responsibility to seek and obtain such approval prior to
commencing painting operations. Where such approval is not obtained, the affected
area of painted surface shall not be approved for payment. The Contractor shall be
responsible for restoring the affected surface to the specified condition required for the
application of the required paint coat at his own expense.
A coat of paint in a system shall be applied by brush only unless otherwise approved in
advance by the Engineer.
Mixing of paints shall be carried out by mechanical mixers. Prior to application, the
paint shall be mixed a sufficient period to thoroughly mix the pigment and shall be kept
thoroughly mixed during its application.
Wet film thickness gauges shall be used where practicable to check that the wet film
thickness for each coat is not less than:
Minimum dry film thickness (mdft) x 100

Volume solids %
During the application of a paint system, the Contractor shall ensure that the
progressive total thickness of the applied coats shall allow the specified minimum total
DFT to be attained without exceeding overall the proposed wet film thickness by more
than 20%. The local dry film thickness for the primer shall not exceed the specified
minimum dry film thickness by ore than 30% and for other paints by more than 75%.
Painting shall be carried out in a neat and workmanlike manner, in accordance with the
approved programme.
Surfaces to be painted shall be free from moisture, dust, grease or any other
deleterious materials that would prevent the bond of the succeeding application.
Each coat of the specified paint system shall be generally free from surface defects,
including cratering, pin-holing, blistering, rivalling, sagging, bittiness, dry spray and
cissing, as defined in BS 2015 "Glossary of Paint Terms". Any deficiencies in the
applied coat shall be rectified to the satisfaction of the Engineer before the application
of a subsequent coat. The finished system shall have an even and uniform
appearance.
Unless otherwise agreed with the Engineer, 1 no. Stripe Coat shall be applied over all
welds and fasteners including washers and to all external corners excepting those of
RHS members. The stripe coat shall be applied over the primer.
Exposure Time for prepared steel surfaces and over-coating times for paints shall be
as follows:
(i) Clean steel prepared by blast cleaning or bright steel prepared by abrading or
grinding shall be primed within 4 hours.

Page 27–24
(ii) Primed surfaces shall have the following coat applied within 7 days or as
recommended by the paint manufacturer.
(iii) Subsequent coats shall be applied within 14 days or such lesser time as
recommended by the paint manufacturer.
(8) Protection Against damage
The Contractor shall make all necessary provisions to prevent damage to completed
coats of paint and to other property from all cleaning, painting, protection, inspection or
other operations.
Paint, stains or damage to surfaces not specified for painting shall be removed or
rectified to the satisfaction of the Engineer at the Contractor's expense.
All painted surfaces that are failed, marred or damaged as a result of operations of the
Contractor shall be repaired by the Contractor, at his expense, with materials and to a
condition equal to that of the coating(s) damaged and utilising a restorative method
Where traffic causes an objectionable amount of dust in the atmosphere during

painting operations the Contractor shall, where directed by the Engineer, water the
offending road surface and shoulders for a sufficient distance at, and on each side of,
the location where painting is being carried out, at his own expense.
(9) Inspection
A specialist shall be appointed by the Engineer where needed to ensure that the works
are carried out by the Contractor in accordance with the Specifications and relevant
contract documents and to approve completed work for payment by the Engineer.
The Contractor shall be required to provide all facilities and assistance necessary to
enable the specialist to safely reach all parts of the bridge structure for inspecting,
measuring or approving the Contractor’s operations at all reasonable times.
Instruments to be provided by the Contractor shall include:
2 no. Inlet/Dry Hydrometers

2 no. Sets Wet Film Gauges
2 no. Elcometers to measure dry film thickness
2714 PROTECTION OF STEEL STRUCTURES AGAINST CORROSION
(1) General
The operations described in this Clause include the application of protective grease
and oil based systems to miscellaneous structural elements.
(2) Protective Systems for Suspension Cables and Hangers
Protective systems include grease and felt systems, grease packing and oil systems.
(3) Protective Systems for Suspension Cables and Hangers

Page 27–25
The Contractor shall use the protective system as described in this Clause for the
existing suspension cables and hangers.
The protective system to the suspension cables and hangers shall include the removal
of existing protective system, either in whole or in part as indicated in the contract, the
preparation of the surfaces of the steel ropes, and the application of the new protection
system.
The Protective System to be applied shall comprise:
(a) The application of a coating of ordinary neutral grease of any reputed make.
(b) A tar-felt sheet cover. The cover shall be fixed to prevent the entry of water
and shall be continuos spirally lapped in a method approved by the Engineer.
The surfaces of the wire ropes shall be prepared by removing existing cover in whole
or in part as indicated in the contract, then cleaning the exposed surface of the wire
ropes to remove dirt, hardened grease and surface rust. Broken or rusted wires and
other damages shall be brought to the attention of the Engineer before any further
work is carried out on the affected area.
The finished prepared surfaces shall be free of contamination detrimental to

subsequent application of grease and cover to the satisfaction of the Engineer. The
surface shall be free from dust and grit and be dry and ready for greasing. Surface
preparation shall be continued until the specified standard of surface finish has been
achieved.
(4) Protective System for Bearings, Inside Cable Saddles, Hanger Saddles and
Hanger Sockets
The protective system shall include the removal of existing protective system, cleaning
of dirt and contaminants and the application of the new protection system.
The Protection System to be applied shall comprise the application of a coating of

ordinary neutral grease of any reputed make.
The finished prepared surfaces shall be free of contamination detrimental to

subsequent application of grease to the satisfaction of the Engineer. The surface shall
be free from dust and grit and be dry and ready for greasing. Surface preparation shall
be continued until the specified standard of surface finish has been achieved.
Oil of an approved make shall be applied to all pins of top and bottom hangers and
bridge bearings. Cracks around any pins or bearing or plates shall be brought to the
attention of the Engineer before any further work is carried out on the affected area.
(5) Repair of Damaged Areas
The Contractor shall make good any damage to the original protective system arising
from his execution of the works.

Page 27–26
2715 REPAIR OF STEEL BEARINGS
( 1) Resetting and Repositioning of Bearings
(a) General
The work on the steel bearings comprises the repositioning of the free roller
bearings and the re-setting of the fixed bearings in the Bridges. In the course
of these operations jacking up of the bridge shall be required to the method as
provided or as directed by the Engineer. To re-set the fixed bearings at their
correct vertical load, additional jacking operations shall be necessary at the
free bearing location to determine the magnitude of the vertical load.
The Contractor shall make available to the Engineer the necessary access
and equipment for him to check, monitor and take measurements throughout
the jacking operations.
(b) Release of Existing Connections
No existing connections shall be released without the prior approval of the

Engineer. Tightening, removal or replacement of bolts shall be in accordance
with the written methods provided by the Engineer.
(c) Bedding of Mechanical Roller Bearings on Concrete Piers
When re-setting an existing roller bearing the following shall apply:
 Any existing bedding material and packing shims remaining beneath the
bearing base plate positions shall be removed by a method approved by
the Engineer. The Contractor shall exercise all due care in preparing the
bedding for bearings to avoid any damage to the structure.
 Any oil or grease on the plinth where bearings are to be re-set shall be
removed with an approved de-greasing compound which shall then be
rinsed off with clean water. All loose particles of concrete, rust, any dust on
the plinths shall be removed by suction or by using a properly filtered oil-
free airline.
(2) Bedding Mortar for Resetting of Bearings
(a) General
Bedding mortar shall satisfy the following performance requirements:
(i) It shall have a compressive strength not less than 60 N/mm²

(ii) The flow characteristics shall be such that the volume as specified in
the contract is completely filled with a homogeneous material when
placed within the range of ambient temperature between 5° C and 25°
or as otherwise directed by the Engineer.
(iii) The physical and chemical properties shall be compatible with those
of all adjoining surfaces.

Page 27–27
Bedding mortar shall at no time be subjected to a loading, which will induce a

compressive stress exceeding 15 N/mm² or 0.25 of its compressive strength at
the time of loading.
(b) Material
(i) The maximum aggregate size in flowable bedding mortars shall not
exceed one quarter of the minimum bedding thickness.
(ii) Proprietary materials shall be stored as follows:
 The material shall be stored in a dry environment at a temperature
of not less than 10°C.
 The containers shall be damp proof, leak proof and easy to empty
of their contents.
 Containers shall be marked with the batch reference number,
component identification, manufacturer's name, net weight and
such warnings or precautions concerning the contents as are
required.
 The material shall not be removed from the store unless
immediately required for mixing and use in the works.
 Material shall not be used after six month from the date of
manufacture or after the period specified by the manufacturer or
supplier.
 The Contractor shall supply with each batch or part of a batch of
the material delivered to the Site, certificates furnished by the
supplier or manufacturer stating the following:
- Manufacturer's name and address
- Manufacturer's agent's name and address where
applicable
- Description of material and brand name
- Batch reference number, size of batch, number of
containers in the delivery order
- Date of manufacture
- The chloride ion content, expressed as a percentage by
mass of the material
 Calcium chloride or admixtures containing chloride salts more
than 0.2% of the mass of cement shall not be used.
 Ordinary Portland Cement shall comply with IS:269
 The weight of soluble alkali in the mix expressed as equivalent
sodium oxide shall be limited unless the aggregate is shown to be
non-reactive.
 Resinous bedding mortars shall be based on thermosetting
organic polymers consisting of stable fluid and/or solid
components, which on mixing react chemically to form a hardened
solid mass. Products shall be formulated from epoxide, polyester,
polyurethane or acrylic resin system or such other formulation as
is approved by the Engineer.
 Fillers or aggregates to be incorporated in accordance with the
manufacturer's recommendations, to extend or modify the

Page 27–28
properties of the resinous composition, shall be pre-bagged, dry

and factory proportioned. The addition of other fillers or
aggregates shall not be permitted.
(3) Site Mixing, Placing and Curing
(i) Mixing placing and curing of proprietary bedding mortar shall be carried out in
accordance with the manufacturer's written instructions together with the
following:
 The material shall not be mixed or placed in the Works at ambient
temperatures of less than 5°C. If for 24 hours before, during or after
placing, the ambient temperature falls below 5°C the Contractor shall
maintain the temperature of the sub-strate and other adjoining surfaced at
not less than 5°C for the duration of the curing period recommended by
the manufacturer.
 For cementitious mortars the water cement ratio shall not exceed 0.35.
The water content shall be determined during the approval tests, and
maintained within +/-2 per cent of the quantity approved by the Engineer in
mortars placed in the Works.
 At ambient temperatures of less than 10°C the temperature of the mixing
water shall be not less than 20°C nor more than 25°C.
(ii) For cementitious bedding mortars, the sub-strate shall be flushed clean with
water two hours before placing and maintained wet until placing commences.
Any free standing water on the surface of the sub-strate shall be removed
before placing the mortar. The underside of the base plate shall be clean and
free from loose rust and loose mill scale at the time of bedding.
 Immediately after placing the mortar shall be protected to prevent evaporation
for at least three days.
 The mortar shall be placed in its final position within 20 minutes of its
discharge from the mixer.
(iii) For resinous bedding mortars the sub-strate shall be dry, free from loose dirt
and dust and shall meet the conditions specified by the manufacturer. The
underside of the base plate shall be clean and free from loose rust and loose
mill scale at the time of bedding.
 The mortar shall be placed in its final position within one hour from its time
of discharge from the mixer or lesser period as specified by the
manufacturer.
 Only full packs of mortar or sub-packs as presented by the supplier shall
be mixed. On-site proportioning shall not be permitted.
(iv) When the proportions have been approved by the Engineer no variations shall
be made in the manufacture, supply, mix proportions or method of mixing of
the material without the consent of the Engineer.
(v) No internal metal shims shall be allowed to remain in the hardened bedding
mortar except where described in the contract.
(4) Approval Tests

Page 27–29
(i) Mortar shall not be used in the Works until it has been approved by the
Engineer. The Contractor shall provide the Engineer with copies of the
manufacturer's Specification.
(ii) Flow Test between Surfaces

 The mortar for each flow test shall be batched in one load strictly
according to the manufacturer's instructions.
 Flow tests shall be conducted between concrete and a rusty steel plate at
ambient temperature of 5°C. The flow characteristics shall be assessed
with the rusty steel plate on top, and with the pre-cast concrete slab on the
bottom. The surface of the concrete slab shall be washed thoroughly with
water and all traces of surface water removed.
 The size of the test apparatus is to represent the actual site condition. The
mortar shall be poured in one corner of the apparatus until the level of the
mortar has reached at least 10 mm above the underside of the top plate.
After 24 hours the top plate shall be removed and the exposed surface
lightly brushed with a stiff bristle brush to remove any surface skin which
may be covering voids. The bedding mortar formed shall be free from
significant voids, cracks and other defects, at both 5°C and 20°C.
 If difficulty is experienced in achieving a satisfactory flow for cementitious
mortars the water content of the mix shall be adjusted and the test
described above repeated. The mortar shall be rejected if further
adjustments of the water content do not produce an acceptable result.
(iii) Compressive strength tests for cementitious bedding mortars shall be carried
out on 100 mm cubes prepared, cast and cured at temperatures given in Table
27.3. The mortar used for strength tests and all subsequent testing shall have
the same water content, as determined from the flow tests and approved by
the Engineer. There shall be no compaction.
Table 27.3: Test Temperatures and Strength (Cementitious Bedding

Mortar)
Cementitious Bedding Mortar

Ambient Test Temperature of 20°C
Mixing water temperature 20°C
Mixer and mould temperature 20°C
Dry mortar material temperature 20°C
Curing temperature 20°C
Minimum 28 day compressive strength 60 N/mm²
(iv) Compressive strength tests for resinous bedding mortars shall comply with BS
6319: Part 2 and shall be carried out on six 40 mm cubes as shown in Table
27.4.
Table 27.4: Test Temperatures and Strength (Resinous Bedding Mortar)
Resinous Bedding Mortar

Ambient Test Temperature of 20°C
Mixer and mould temperature 20°C

Page 27–30
Mortar material before mixing 20°C

Curing temperature 20°C
12 hour} 30 N/mm²
24 hour} min. compressive strength 50 N/mm²
72 hour} 60 N/mm²
2716 MEASUREMENT
Measurement for minor repairs of defective concrete shall be made in cubic meters.
Measurement for replacement concrete shall be made in cubic meters. Measurement for
sealing cracks and injection shall be made by weight (in kg) of epoxy consumed for grouting.
Provision of nipples required for grouting shall be measured in numbers.
Measurement of sealing of cracks and injection shall be made by weight of cement consumed.
in kg for cement grouting. Measurement for application of epoxy mortar for specified thickness
shall be made in square meters. Measurement for bonding of old and new concrete by epoxy
mortar shall be made in square meters.
Measurement for guniting/shotcreting shall be made in square meters. Measurement for

repair/replacement of bearings shall be made in number. Measurement for dismantling of
concrete wearing coat shall be made in square meter of the area of wearing coat dismantled.
Measurement for painting shall be made in square meters. Measurement for protection against
corrosion shall be on lump basis.
2717 PAYMENT
The quantities measured as provided above shall be paid at their respective contract unit rates
which shall be the full and the final compensation to the Contractor as per Clause 112.

Page 27–31
SECTION 2800-BIO - ENGINEERING WORKS
Page No.
2801 SCOPE 28–1

2802 PROVISION OF SEEDS 28–1
2803 PROVISION OF PLANT CUTTINGS 28–3
2804 NURSERY CONSTRUCTION 28–8
2805 NURSERY OPERATION AND MANAGEMENT 28–11
2806 FINAL SLOPE PREPARATION FOR BIO-ENGINEERING 28–15
2807 SITE PLANTING AND SOWING 28–17
2808 JUTE NETTING WORKS 28–28
2809 GABION WIRE BOLSTERS, SUB-SOIL DRAINS AND WIRE NETTING 28–31
2810 SITE PROTECTION 28–34
2811 SITE AFTERCARE AND MAINTENANCE 28–36
SECTION 2800 BIO - ENGINEERING WORKS
2801 SCOPE
This Section covers all the component of bio-engineering works such as provision of seed and
plant cuttings, nursery construction and operation, slope preparation for planting, site planting
and sowing, jute netting, gabion wire bolsters and wire netting, site protection and
aftercare/maintenance.
2802 PROVISION OF SEEDS
The Contractor shall provide or collect seeds of the required species and quantities in
accordance with the requirements described hereafter, as and when required. He shall supply
all necessary expertise, resources and facilities to ensure that these requirements are met in
full. It shall be ensured that the seed is of a high quality.
The Engineer shall give indications as to the expected amounts of seeds required and the time
of availability. But it shall be the Contractor's responsibility to ensure that adequate quantities of
seeds are obtained in a timely manner.
The weights to be specified shall be for sun-dried seeds separated completely from fruiting
bodies and other unwanted parts, and ready for storage and subsequent sowing. There is
usually large discrepancy between this weight and that of the freshly collected, untreated fruits.
Should the Contractor be unable to supply the specified seeds, the advice of the Engineer
should be sought. The Engineer may approve other substitute species, if found appropriate.
Seed shall not be obtained commercially without the Engineer's written authority.
(1) Grass Seed Collection
(a) The species of grass seeds to be collected shall be determined by the

Engineer. The Contractor shall be responsible for determining seed sources,
though these may be specified by the Engineer's instructions. Seeds shall be
collected in or very close to the office of use or the project area as much as
possible.
(b) If the Engineer does not specify the species, then the current approved list of
bio-engineering plants, as determined by the Geo-Environmental Unit of the
Department of Roads shall be referred to.
(c) Seeds shall be collected from as many individual plants as possible. Seeds
shall be collected from the largest and most vigorous plants.
(d) The Contractor shall under no circumstances damage or remove the roots of
grass plants while collecting seed. The Contractor shall be responsible for
safety measures and for making all necessary arrangements with landowners,
farmers and the local District Forest Office, as applicable, before the collection
of seeds.
SECTION 2800 BIO-ENGINEERING WORKS

Page 28–1
(e) Seeds shall only be collected when fully ripe. Seeds collected early shall not
be accepted. The Contractor shall be held liable if the germination rate of
seeds is lower than 70%.
(f) Immediately after collection, seeds shall be separated from flower heads by
the method normally used by farmers for other grasses. Once separated, the
seeds shall be sun-dried before storage.
(g) Seeds shall be stored in a cool, dry, ventilated building with adequate
precautions taken against pests. Containers shall be raised above the floor.
They shall not be kept in the same building in which materials like cement, or
any chemicals, fuels or lubricants are stored. Grass shall be stored in bags
made of cotton. Seeds shall be carefully inspected on a weekly basis to
ensure that there is no deterioration or mould formation, or pest attack. Seeds
shall only be stored after they have been properly dried in the sun beforehand.
(h) Measurement and Payment: Works shall be measured on the basis of actual
quantity collected, weighed in Kilogram and accepted by the Engineer. The
quantities thus measured shall be paid at the unit rates shown in the Bill of
Quantities. Such payment shall be the full and the final compensation to the
Contractor for making arrangements of collection location, provision of safety
measures, collection of seeds, separation of seeds, preparation of seeds, sun
drying, packing and providing the seeds as per these Specifications.
(2) Tree and Shrub Seed Collection
(a) The species of tree and shrub seeds to be collected shall be determined by
the Engineer. The Contractor shall be responsible for determining seed
sources, though these may be specified by the Engineer's instructions. Seeds
shall normally be collected in or very close to the working area.
(b) If the Engineer does not specify the species, then the current approved list of
bio-engineering plants, as determined by the Geo-Environmental Unit of the
Department of Roads shall be referred to.
(c) Seeds shall be collected from as many healthy individual plants as possible. In
any event, they shall be collected from at least ten individual plants. The plants
from which the seeds are collected shall show vigorous growth and good form.
Mis-shaven and stunted plants shall be discarded.
(d) The Contractor shall under no circumstances damage plants while collecting
seed. The Contractor shall be responsible for making all necessary
arrangements with and owners, farmers and the local District Forest Office, as
applicable, before the collection of seeds.
(e) Appropriately trained personnel with appropriate equipment shall be employed

while collecting the seeds. It shall be the Contractor's responsibility to ensure
safe working conditions for his employees or Sub-contractors.

Page 28–2
(f) Seeds shall only be collected when fully ripe. Seeds collected early shall not be
accepted. The Contractor shall be held liable if the germination rate of seeds is
lower than 80%.
(g) Immediately after collection, seeds shall be separated from fruit by the method
normally used by farmers and foresters for this purpose; this shall depend on
the individual species. Once separated, the seeds shall be sun-dried before
storage.
(h) Seeds shall be stored in a cool, dry, ventilated building with adequate
precautions taken against pests. Containers shall be raised above the floor.
They shall not be kept in the same building in which materials like cement, or
any chemicals, fuels or lubricants are stored. If kept in sealed containers, the
seeds shall be carefully inspected on a weekly basis to ensure that there is no
deterioration or mould formation or pest attack. Seeds shall only be stored after
they have been properly dried in the sun beforehand.
(i) Measurement and Payment: Works shall be measured on the basis of actual
quantity collected, accepted and weighed in Kilogram. The quantities thus
measured shall be paid at the unit rates shown in the Bill of Quantities. Such
payment shall be the full and the final compensation to the Contractor for
making arrangements of collection location, provision of safety measures,
collection of seeds, separation of seeds, preparation of seeds, sun drying,
packing and providing the seeds as per these Specifications.
2803 PROVISION OF PLANT CUTTINGS
The species of plants to be collected for vegetative propagation shall be determined by the
Engineer. The Contractor shall be responsible for determining plant material sources, though
these may be specified by the Engineer's instructions. Plants shall normally be collected in or
very close to the working area.
If the Engineer does not specify the species, then the current approved list of bio-engineering
plants, as determined by the Geo-Environmental Unit of the Department of Roads shall be
referred to.
(1) Provision of Grass Cuttings
(a) Cuttings of various types shall be taken from grass species, which are known
to propagate easily by vegetative means.
(b) Cuttings shall be made from as many healthy individual plants as possible.
The plants from which the cuttings are taken shall show vigorous growth and
good form. Grass clumps showing stunted growth shall not be considered as
sources.
(c) Apart from the clumps, which are dugs up to make cutting, the contractor shall
under no circumstances damage other plants. The Contractor shall be
responsible for making all necessary arrangements with landowners, farmers
and the local District Forest Office, as applicable, before the making of
hardwood cuttings.

Page 28–3
(d) The type of cuttings to be made shall depend on the species and shall be as
shown in Table 28.1. If the species used is not listed here, then the latest
technical information provided by the Geo-Environmental Unit shall be
consulted. If the species is still not covered, then stem and root slip cuttings
shall be used.
Table 28.1: Types of Grass cuttings
Local name Botanical name Best Details

Propagation
Amliso 12 Thysanolaena Rhizome Stem: 100-150 mm; rhizome: 50-80 mm
maxima cuttings
Babiyo Eulaliopsis binata Slip cutting Stem: 100-150 mm; root: 20-40 mm
Dhonde Neyraudia reynaudiana Rhizome/stem Rhizome cuttings:- Stem: 100-150 mm;
cuttings rhizome: 40-50 mm
Stem cuttings: 2 nodes plus 20 mm each
sides
Kans Sacccharum spontaneum Slip cuttings Stem: 100-150 mm; root: 30-40 mm
Khar Cymbopogon microtheca Slip cuttings Stem: 100-150 mm; root: 30-40 mm
Khus Vetiver lowsonii Slip cuttings Stem: 100-150 mm; root: 30-40 mm
Napier Pennisetum purpureum Stem cuttings Single node:- 1 node with 30-40 mm top and
100-150 mm bottom;
Double nodes:- 2 nodes plus 30-40 mm
each sides
Narkat Arundo clonax Stem/Slip Stem cuttings:- 2 nodes plus 30-40 mm each
cuttings sides
Slips cuttings:- stem: 100-150 mm; root: 30-
40 mm
Padang Himalaycalamus Rhizome Stem: 750-1200 mm; rhizome: 100-200 mm.
bans hookerianus
Phurke Arunduella nepalensis Rhizome Stem: 100-150 mm; rhizome: 30-40 mm
cuttings
Sito Neyraudia arundinacea Rhizome Stem: 100-150 mm; rhizome: 30-60 mm
cuttings
Tite nigalo Drepanostachyum Rhizome Stem: 750-1200 mm; rhizome 100-200 mm
intermedium
(e) Where roots are required for the cuttings, grass clumps shall be carefully dug
up. They shall not be pulled hard so as to damage the material. They shall be
separated carefully by hand, using a sharp khukuri or knife where necessary.
There shall be no tearing of the plant fabric.
(f) Stem cuttings shall be made using sharp secateurs or khukuri. The top cut
shall be made at right angles to the stem and the bottom cut shall be made at
45° to the stem.
(g) Once cuttings have been made, they shall be wrapped in wet hessian jute
immediately. At all times, cuttings shall be kept moist and as cool as possible,
and shall be wrapped in wet hessian between all operations such as digging
out of the ground, splitting out, trimming and planting. If the hessian jute is not
easily available, the cuttings shall be covered with the thick blanket of off-cut
part of vegetation such as Titepati and Banmara. For this prior approval of the

Page 28–4
Engineer shall be required. Under any circumstances, all cuttings shall be

planted the same day that they are made.
(h) Measurement and Payment: Measurement of grass cuttings shall be made on

the basis of actual numbers of slip or cutting prepared, counted on site and
accepted. The quantities thus measured shall be paid at the unit rate shown in
the Bill of Quantities. Such payment shall be the full and the final
compensation to the Contractor for all arrangements for uprooting of grass
clumps, collection of materials for cuttings and preparation and providing the
cuttings as per these Specifications.
(2) Provision of Hardwood Cuttings
(a) Hardwood cuttings shall be taken from shrubs and trees species which are
known to propagate easily by vegetative means.
(b) Cuttings shall be made from as many healthy individual plants as possible.
The plants from which the cuttings are taken shall show vigorous growth and
good form. Mis-shaven and stunted plants shall not be considered as source.
(c) Apart from the branches from which cuttings are taken, the Contractor shall
under no circumstances damage plants while taking cuttings. The Contractor
shall be responsible for taking safety precautions and for making all necessary
arrangements with landowners, farmers and the local District Forest Office, as
applicable, before the making of hardwood cuttings.
(d) Hardwood cuttings shall be made from stems which are between 6 and 18
months old. Materials outside this range shall not be used. The Contractor
shall be held liable if the success rate of cuttings is lower than 70%.
(e) Hardwood cutting shall be made using sharp secateurs or a sharp saw. The
top cut shall be made at right angles to the stem and the bottom cut shall be
made at 45° to the stem. Under no circumstances shall there be any damage
to the bark of the cutting.
(f) Hardwood cuttings, which are to be planted in the nursery for later
multiplication, shall be normally 150 to 200 mm in length and 20 to 30 mm in
diameter. This size shall not be exceeded for the majority of species unless
specified or approved by the Engineer.
(g) Hardwood cuttings which are to be used in brush layering, palisades and live
stakes shall normally be 450 mm for brush layering on road embankments,
600 mm for brush layering on landslide debris, 600 mm for palisades and 20
to 40 mm in diameter. This length of cuttings shall not be exceeded for the
majority of species unless specified or approved by the Engineer.
(h) The size of cuttings shall be of a minimum length of 1000 mm and 50 mm of

diameter for fascines. All the small branches growing from the main branch
shall be preserved. Those small branches contain the first sprouting buds
which will help to keep alive the main branches as they are buried in the
ground.

Page 28–5
(i) A number of species can be propagated using large truncheon cuttings. In this
category fall chuletro ( Brassaiopsis hainla), dabdabe (Garuga pinnata), kavro
(Ficus lacor), phaledo (Erythrina species ) and Gliricidia sepium. Hardwood
cuttings for these species shall be in the range of 2000 to 2500 mm in length
and 50 to 80 mm in diameter unless otherwise specified.
(j) All trunchen cuttings shall be covered with long mulch during transportation
and storage. Under any circumstances, all cuttings shall be planted within two
days that they are made.
(k) Measurement and Payment: Measurement of hardwood cuttings shall be

made on the basis of actual numbers of cutting prepared, counted on site and
compensation to the Contractor for all arrangements for collection of materials
and preparation of cuttings and providing the cuttings as per the
Specifications.
A) Provision of Bamboo Cuttings
(a) Bamboo cuttings shall be propagated by two different methods i.e traditional
method and single node culm cuttings method.
(b) Cuttings shall be made from as many healthy individual culm as possible. The
culm from which the cuttings are taken shall show vigorous growth and good
form having heavily branched. Mis-shaven and stunted plants shall not be
considered as source.
(c) The Contractor shall be responsible for taking safety precautions and for
making all necessary arrangements with landowners, farmers and the local
District Forest Office, as applicable, before making of cuttings. The traditional
method which will require taking the whole culm and mother rhizome may
eradicate the further development of clump. In this case, the contractor shall
be responsible to make aware of such probability to the owner before taking
the rhizomes from such clump. However, if the sourcing clumps are growing
on steep slopes, the contractor shall not take more than 10% culm from the
sourcing clump.
(d) The type of cuttings to be made which depend on the species shall be as
shown in Table 28.2. Single node culm cuttings or traditional rhizome cuttings
shall be made from the culm which is between 2-3 years old. Materials outside
this range shall not be used without the prior approval of the Engineer. The
Contractor shall be held liable if the success rate of single node culm cuttings
is lower than 60% and in the case of rhizome cuttings not surviving 100%.
(e) Single node cuttings shall be made using sharp log saw. The top and bottom
cut shall be made at right angles to the stem. Under no circumstances shall
there be any damage to the bud and internode section of culm.
(f) The rhizome cuttings shall be made using sharp log saw, axe and secateurs.
(g) Once cuttings have been made, they shall be wrapped in wet hessian jute
immediately. At all times, cuttings shall be kept moist and as cool as possible,

Page 28–6
and shall be wrapped in wet hessian between all operations such as taking
from the parent plant, transporting and planting. Under any circumstances, all
cuttings must be planted within two days of that they are made.
(h) Measurement and Payment: Measurement of bamboo cuttings shall be made
on the basis of actual numbers of cuttings prepared, counted on site and
compensation to the Contractor for all arrangements for purchasing of bamboo
and preparation of cuttings and providing the cuttings as per the
Specifications.
Table 28.2: Types of Bamboo Cuttings
Local name Botanical name Best propagation Details

Choya/tama Dendrocalamus Single node culm / Single node culm cuttings:- 1 node and 150
bans hemiltonii rhizome cuttings mm of each side, straight and fine cut, main
branch should be 200-300 mm long;
Rhizome cuttings:- Culm 2500-3000 mm
length, leave all branches with no leaf
(manually flushed); rhizome: 300-500 mm.
Dhanu bans Bambusa balcooa Single node culm / Single node culm cuttings:- 1 node and 150
rhizome cuttings mm of each side, straight and fine cut, main
Kalo bans Dendrocalamus Single node culm / Single node culm cuttings:- 1 node and 150
hookeri rhizome cuttings mm of each side, straight and fine cut, main
Mal bans Bambusa nutans Single node culm / Single node culm cuttings:- 1 node and 150
Malingo Arundinaria maling Rhizome cuttings Rhizome cuttings:- Culm 2500-3000 mm
bans length, leave all branches with no leaf
Nibha/gopi Ampelocalamus Single node culm / Single node culm cuttings:- 1 node and 150
bans patellaris rhizome cuttings mm of each side, straight and fine cut, main
Nigalo bans Phyllostrachys Rhizome cuttings Rhizome cuttings:- Culm 2500-3000 mm
nigra length, leave all branches with no leaf
Paryang Drepanoschyum Rhizome cuttings Single node culm cuttings:- 1 node and 150
bans hookerieanum mm of each side, straight and fine cut, main

Page 28–7

Tharu bans Bambusa tulda Single node culm / Single node culm cuttings:- 1 node and 150
2804 NURSERY CONSTRUCTION
The Contractor shall provide nurseries to contribute stocks of grasses, shrubs and trees for
planting operations as required by the Engineer. This shall be done according to the
specifications described hereunder, as and when required by the Engineer. The Contractor
shall supply all necessary expertise, resources and facilities to ensure that these requirements
are met.
The Contractor shall note that the establishment and effective operation of plant nurseries is a
skilled business requiring experienced and trained staff. These specifications alone do not
provide all the information needed to set up and run nurseries. The Contractor shall seek the
advice of specialist agencies and shall refer to the large number of reference books available
on the subject.
The purpose of a nursery shall be to supply good quality, healthy plants of the correct type and
species at the precise time they are required.
(1) Nursery Establishment
(a) The Contractor shall provide nursery facilities adequate to supply all of the
stock required for planting operations. Alternatively, he may procure planting
stock from elsewhere at the time of site planting, provided it is of a standard
acceptable to the Engineer and as described hereunder.
(b) In selecting a site for a nursery, if not instructed by the Engineer, the
Contractor shall fulfil the following requirements.
(i) Nurseries shall be as close as possible to all sites to be planted. They

shall be at the same altitude as, and in an identical climatic area to,
the sites to be planted.
(ii) Wherever possible, nurseries shall be established on land owned by

the Department of Roads if it is available and biophysically suitable. If
it is not, other land of His Majesty's Government shall be used if it is
available.
(iii) Nurseries shall have a reliable and adequate supply of water which
remains constant throughout the later part of the dry season.
(iv) Nurseries shall have all weather vehicular access.

Page 28–8
(v) Nurseries shall have a perimeter of stock-proof fencing, effective

against all domestic animals.
(vi) Nurseries shall have a weather- and pest-proof office cum seed store
and proper storage facilities for seed. Seed shall be kept cool, dry and
in sealed containers, as specified in Sub-clauses 2802 (1) and 2802
(2).
(vii) All nurseries shall be provided with at least two above-ground

compost bays, built of stone, brick or timber.
(viii) Where a nursery is established on a slope exceeding 2°, the ground

shall be leveled by terracing before beds are constructed.
(ix) A constant staff of qualified and experienced people must be provided.
(x) There shall be adequate space in each nursery location for all
operations to be performed in the cycle of work. In particular, all plants
shall be spaced out periodically as they grow and there shall be
adequate bed area to accommodate them.
(2) Construction of Nursery Beds
(a) Nursery beds shall be made in a different way according to their purpose.
TheContractor shall ensure that there are adequate beds available for all the
operations to be undertaken in the nursery.
(b) There shall be paths around all beds to ensure the best possible access for
operations such as weeding and watering.
(c) Table 28.3 summarises the construction details of the five main bed types,
which are described in full in paragraphs (d) to (h).
Table 28.3: Construction Details of Nursery Beds
Bed type Bed size Details of construction

Beds for grass Bottom width 1200 Bottom of the bed should be compacted making a camber to facilitate
seeding, grass mm and top width the drainage; 50 mm washed gravel placed above the ground; then 50
slips propagation 1000 mm x 200 mm of 1:1 mix of soil and compost; and topped with 100 mm of 3:1 mix
mm high of seived forest topsoil and washed sand.
Beds for bare Bottom width 1200 Bottom of the bed should be compacted making a camber to facilitate
root tree mm and top width the drainage; 50 mm washed gravel placed above the ground; then 50
seedlings 1000 mm, 200 mm mm of 1:1 mix of soil and compost; and topped with 150 mm of 3:1 mix
high of seived forest topsoil and washed sand.
Seed beds for 1000 mm wide Bed should be provided with brick, flat stone or plank edging as
tree / shrub (external), 170 mm determined by the Engineer; shade should be provided of waterproof
seedlings high with edging; materials or as determined by the Engineer; 50 mm of washed gravel
Shade 900 mm of placed above the compacted and cambered ground; then 50 mm
height on the lower unseived forest soil; 50 mm of 1:3 mix of seived forest soil and washed
side and 1200 mm sand; and topped with 20 mm of washed, seived and sterilised sand.
higher side.
Stand out beds 1000 mm wide Bed should be provided with brick, flat stone or plank edging as
for tree / shrub (external), 150 mm determined by the Engineer; shade should be provided of highly porous
seedlings high with edging; materials or as determined by the Engineer; 50 mm of washed gravel

Page 28–9
Shade 900 mm of placed above the compacted and cambered ground.

height on the lower
side and 1200 mm
higher side.
Beds for the Bottom width 1200 Ground below the bed is dug to a depth of 300 mm. Bed is made with
propagation of mm and top width 100 mm of unseived soil (lower) and 200 mm of seived soil (upper). A
bamboo culm 1000 mm x 300 bund of 100 mm high is formed around the edge. 1500 mm high shade
cuttings and stool mm high of bamboo frame structures and hessian jute is made.
bed for tree and
shrub cuttings
(d) Grass beds shall be constructed to hold grass seeds, grasses being
propagated by vegetative means. These can be of any practical length but
shall be flat and of 1200 mm base width and 1000 mm of top width on
compacted and a cambered ground. They shall rise to a height of 200 mm
above the surrounding ground. They shall be made up as follows: 50 mm of
washed gravel is placed above the ground; then 50 mm of 1:1 mix of soil and
compost; and the bed is topped with 100 mm of 3:1 mix of fertile, loamy forest
topsoil and washed sand. All sieving shall be done with a mesh size of 2 mm
or smaller.
(e) Bare root beds shall be constructed to hold seedlings transplanted from the
seed beds. These can be of any practical length but shall be flat and of 1200
mm base width and 1000 mm of top width on compacted and a cambered
ground. They shall rise to a height of 200 mm above the surrounding ground.
They shall be made up as follows: 50 mm of washed gravel is placed above
the ground; then 50 mm of 1:1 mix of soil and compost; and the bed is topped
with 150 mm of 3:1 mix of fertile, loamy forest topsoil and washed sand. All
sieving shall be done with a mesh size of 2 mm or smaller.
(f) Seed beds shall be made very carefully for germinating small seeds of shrubs
and trees. These can be of any practical length but shall be flat and of one
metre in width on compacted and a cambered ground. They shall rise to a
height of 170 mm above the surrounding ground and provided with shadings
as per the details given in the following paragraph (i). They shall be made up
as follows: 50 mm of washed gravel placed on the ground; then 50 mm of
unsieved forest soil; 50 mm of 1:3 mix of forest soil and washed sand; and the
bed is topped with 20 mm of washed, and sterilised sand. All sieving shall be
done with a mesh size of 2 mm.
(g) Standout beds shall be constructed to hold seedlings in polythene pots. These
can be of any practical length but shall be flat and of one metre width. Bed
floors shall be above surrounding ground level and they shall have a 50 mm
layer of washed gravel on the compacted and cambered ground. They shall
have a surround, preferably made from flat stones, plank or bricks. The bed
shall then be covered with the highly porous shadings as per the details
provided in the following paragraph (i).
(h) Beds for the propagation of bamboo culm cuttings and stool cuttings of trees
and shrubs, shall be made specially. These can be of any practical length but
shall be flat and of 1000 mm width at top and 1200 mm width at bottom. They
shall rise to a height of 300 mm above the surrounding ground. They shall be

Page 28–10
made up as follows: the ground below the bed is dug to a depth of 300 mm;
the bed itself is then made with 100 mm of unsieved soil on the original
surface, and 200 mm of soil above this. All soil sieving shall be done with a
mesh size of 2 mm or smaller. Finally, a bund of 100 mm high shall be formed
around the edge.
(i) Shades shall be constructed over the beds and kept in position over delicate
seedlings during hours of intense sunlight, according to need. Shades shall be
900 to 1200 mm above the ground, and angled so as to be effective for as
much of the day as possible (ie with the lower side to the south). Bamboo
strips laced together with nylon string are particularly suitable in most cases;
but over tree and shrub seed beds, thatched shades with a polythene lining
shall be used.
(3) Measurement and Payment: Work to be measured shall be the actual top area in sq.m
of beds constructed on site and accepted. Only the finished area of the beds shall be
considered after the completion of its shades. However, despite the fact that shades
will be covering larger area than the beds, the final measurement shall be governed by
the area of the top of the bed for payment. The payment shall be the full and the final
compensation to the Contractor for providing all materials to be incorporated, all
labour, tools, equipment and incidentals to complete the works of Nursery
establishment and construction of Nursery beds as per these Specifications.
2805 NURSERY OPERATION AND MANAGEMENT
(a) The contractor shall operate the nursery according to a high standard. The nursery
shall be staffed well tended at all times. It shall be maintained in clean, tidy and efficient
manner at all times. Plants shall always be healthy and vigorous.
(b) Due to the nature of bio-engineering works, nurseries shall normally be operated and
managed by small local contractors with a range of agricultural skills provided it is
specified in the Contract. If provided in the Contract, nurseries may also be operated
and managed by direct employees of the Division Road Office.
(c) Plants shall be kept properly weeded at all times.
(d) Watering, as required for good plant growth, shall be carried out regularly in the cool of
the evening between sunset and dusk. The Contractor shall ensure that the soil in all
beds is kept moist but not saturated at all times. Beds shall be kept moist even when
empty, so that the soil is kept in good condition.
(e) The timing of nursery operations shall be of the utmost importance. Activities such as
seed sowing and the taking of cutting shall be carried out within the critical few weeks
when they will yield the desired results. Most other operations, such as spacing out,
root pruning and watering, shall also be carried out in a timely manner in accordance
with the Nursery Calendar published by the Geo-Environmental Unit of the Department
of Roads. The Contractor shall be responsible to keep works to the strict schedule
required and under no circumstances to permit delays.
(f) Measurement and Payment: The basis of measurement shall be the actual numbers of
plants counted, certified and accepted by the Engineer. Quantities measured as above

Page 28–11
shall be paid at the unit rates entered in the Bill of Quantities. Such payment shall be
the full and the final compensation to the Contractor for executing all the works as
(1) Nursery Production of Grass
(a) Grass shall be propagated in nurseries either by seeding in carefully prepared

beds or by vegetative propagation.
(b) Where grass seeding is required in the nursery, finely sieved fertile soil mixed
with clean sand to a texture of sandy loam shall be placed in beds before the
seeds are sown. Seeds shall be covered with a sheet of hessian jute until they
have germinated, then it shall be carefully removed. Watering of fresh
seedlings shall be done by a fine spray and not by the rose of a watering can.
(c) Grasses to be propagated by vegetative methods shall be of the species
instructed. The Contractor shall obtain adequate quantities of the plant
material required, but under no circumstances shall he to cause serious
depletion of grass stocks in any steep or erosion-prone area.
(d) Vegetative propagation shall normally be by rhizome cuttings. With this

method, the grass shall be treated in exactly the same way as a bamboo being
propagated by the traditional Nepalese farmer's technique. A clump shall be
carefully dug up and brought to the nursery, being kept cool and damp at all
times. Stems shall be cut above the first or second node above the ground:
this usually gives a length of 100 to 200 mm. The clump shall be separated
carefully, with the minimum of damage to the rhizomes and fine roots. Slips
shall be separated out which keep a length of stem and about 50 mm of the
rhizome. Each slip shall have some buds on the rhizome, but in some grasses
these can be difficult to see. The slips shall be planted with the soil surface at
the same level as it was originally, in rows at 200 mm centres; slips shall be at
200 mm centres within the rows. A sheet of hessian jute shall be placed over
the tops of the cuttings. When the new shoots are about 50 mm long, it shall
be removed.
(e) Every two to three months, all grasses shall be lifted from the beds, split
carefully and replanted. It is normal that once split out, three times the
previous bed area is required. This is a standard practice to bulk up the supply
of planting stock without having to degrade the natural vegetation cover in the
region of the nursery.
(f) Measurement and payment: The basis of measurement shall be the actual
area of live grasses covered surfaces in sq.m. Quantities measured as above
shall be paid at the unit rates entered in the Bill of Quantities. Such payment
shall be considered the full and the final compensation to the Contractor for
executing all the works as pecified in these Specifications.
(2) Nursery Production of Trees and Shrubs in Polypots
(a) Trees and shrubs shall be seeded either in seed beds or directly in polythene
pots ("polypots"). Finely sieved fertile soil mixed with clean sand to a texture of

Page 28–12
sandy loam shall be placed in well shaded beds for seeding. Watering of fresh
seedlings shall be by a fine spray, and not by the rose of a watering can.
(b) All pants shall be grown on in pots of dimensions 100x180 mm (4 x 7 inches)

or greater when laid flat. The pots shall be of black, 200 gauge polythene.
They shall have adequate drainage holes at the bottom and be filled with fertile
forest topsoil mixed with clean sand to a texture of sandy loam.
(c) Roots protruding from the bottom of pots shall be pruned with a razor blade on
regular basis which shall not exceed weekly and may need to be more
frequent. Protruding roots shall never be allowed to become more than 25 mm
in length.
(d) When polypot seedlings begin to compete with each other for light, they shall
be re-spaced as required. This would typically mean doubling the bed space
occupied by the plants.
(e) To be acceptable for planting on site, trees and shrubs shall be healthy,
vigorous and showing no signs of damage, wilt, irregular growth, fungal or
pest attack, or nutrient disorders. They shall be at least 300 mm in height
above soil surface level and of good form. The roots shall be in good condition
and there should be no signs of disturbance to the soil in the polythene pot,
even after transport to site.
(f) Measurement and Payment: The basis of measurement shall be the actual
numbers of plants counted, certified and accepted by the Engineer. Quantities
measured as above shall be paid at the unit rates entered in the Bill of
Contractor for executing all the works as specified in these Specifications.
(3) Nursery Production of Hardwood Plants by Vegetative Methods
(a) Trees and shrubs which can be propagated by vegetative methods may be
specified by the Engineer. The Contractor shall produce these by the
appropriate method, as required.
(b) All cuttings and stools shall be made as specified in Sub-clause 2803(2) and
planted in fertile soil beds of the type specified in Sub-clause 2804 (2).
(c) Cuttings shall be planted 300 mm apart in holes slightly larger than their
diameter. They shall be placed at such a depth that only one bud remains
above the soil surface (ie about 30 mm of the cutting).
(d) When plants compete with each other for light, they shall be cut back as
necessary.
(e) To be acceptable for planting on site, trees and shrubs produced in this way
must be healthy, vigorous and showing no signs of damage, wilt irregular
growth, fungal or pest attack, or nutrient disorders. They shall be at least 500
mm in height above soil surface level and of good form.

Page 28–13
(4) Extraction of Plants from the Nursery
(a) The Contractor shall be responsible for extracting plants from nursery beds
and preparing them ready for transport. They shall be extracted from the beds
only on the morning that they are required for planting on site.
(b) Plants shall be hardened off, starting at least two weeks before they are to be
taken out of the nursery. This process shall require a gradual reduction in the
amount of watering and shading. The aim is to prepare them for transfer to a
much more hostile location.
(c) The night before the plants are to be lifted, they shall be thoroughly watered.
This is to make the soil softer and ease the business of extracting the roots.
(d) Plants growing in soil beds shall be carefully lifted from the soil. There shall be
no pulling of stems or roots, but they shall be dug out and extracted with no
strain on any part of the plant.
(e) Plants from soil beds shall be wrapped in wet hessian jute. Hardwood plants
shall have a ball of soil around the roots. Grass clumps can have most of the
soil shaken or washed off.
(f) Polypot seedilings shall be lifted and stacked neatly in metal or wooden trays.
They shall always be lifted by the pot and never by the stem or leaves.
(g) All plants shall to be kept moist, in a cool, shady place, until they are loaded
for transport to site. In the vehicle, they shall not be stacked high. For transport
on rough roads, they shall be packed in carefully so that they do not fall over
or roll around. The vehicle shall be shaded.
(h) Measurement and Payment: The basis of measurement shall be the actual
(5) Compost and Mulch Production
(a) The Contractor shall produce compost and mulch for nursery or site
operations. It shall be produced in a timely manner, in the quantities required.
Compost is normally required to sustain the long term fertility of nursery beds.
Mulch may also be used in the nursery, but normally produced to enhance site
planting works, particularly the direct seeding of grass.
(b) Compost and mulch shall be made from annual and perennial weeds of poor
rooting characteristics, such as ban mara ( Eupatorium adenopherum ) and tite

Page 28–14
pate (Artemesia vulgans ). The greenery shall be collected when there is most
material available but before it forms seeds. This is most often in Shrawan and
Bhadra.
(c) Collected material shall be chopped finely and stored in a mound, compost
bay or pit. The maximum size for chopped compost is 50 mm; the maximum
size for chopped mulch is 150 mm.
(d) Both compost and mulch shall be kept moist but not waterlogged and in an
aerated condition. They shall be completely turned once a month on a regular
schedule. Compost can have cow manure mixed in to assist the process of
decomposition.
(e) Neither compost nor mulch shall be applied until they are fully rotted. By this
time they shall be black and the parts of individual plants shall be
indistinguishable. Early application shall not be allowed as this can lead to a
nutrient loss in the soil if microbes extract nitrogen to decompose the added
organic material.
quantity of compost and mulch provided, accepted and certified by the
Engineer in cu.m. or kg. Quantities measured as above shall be paid at the
unit rates entered in the Bill of Quantities. Such payment shall be the full and
the final compensation to the Contractor for executing all the works as
2806 FINAL SLOPE PREPARATION FOR BIO-ENGINEERING
(a) The Contractor shall prepare slopes for planting operations as required by the
engineer. This shall be done according to the specifications described hereunder, as
and when required. The Contractor shall supply all necessary expertise, resources
and facilities to ensure that these requirements are met.
(b) In the course of all slope preparation works, it shall be essential that no damage is
done to existing vegetation unless the Engineer's instruction specifically requires
certain plants to be removed.
(c) The timing of bio-engineering operations shall be of the utmost importance. Activities
such as planting and seed sowing shall be carried out within the critical few weeks
when they will yield the desired results. All other operations shall be carried out in
timely manner to permit this to happen. The contractor shall be responsible to keep
works to the strict schedule required and under no circumstances to permit delays.
(d) As slope trimming business can be dangerous and risky to personnel, the Contractor
shall be responsible to ensure the safety of his/her and Client's personnel while putting
in the dangerous situation. It shall be essential to have the minimum of safety
measures as listed below for a working gang of 10 people. The proportion of the safety
harness shall be increased according to the requirements and labours employed on
site.

Page 28–15
The Contractor shall provide all safety measures as listed in Table 28.4 for his/her
workers who will be on site and Employer’s personnel who will be supervising the work
within the Contractor’s working premises.
Table 28.4: Materials Required for Safety Measures
S. No. Description Quantity

1. Safety rope (mountainering type or similar make For every workers
having a min 20 mm diameter and 30 metres in
length)
2. Safety belt similar to tree climbers or scafolders For every workers
use
3. Goggles and dust proof masks For every workers
4. Safety hats For every workers
5. Knee pad For every workers
6. First Aid Kit with necessary medicines and 1 box per working gang
bandages.
7. Stretcher 1 no. per working gang
(1) Cut Slope Preparation for Grass Planting
(a) The objective of final cut slope preparation shall be to produce a surface
adequately prepared for grass planting. Grass lines shall be used to provide a
strong surface cover. Grass lines shall be planted over a well prepared
surface. The slope shall not be subject to any undue stress from erosion and
mass movement in its initial stages.
(b) All the construction work shall be checked prior to slope trimming. The site
shall be clear of people and equipment.
(c) Trimming shall be as follows:
new sites: trimming to straight plan section;
retaining wall to be filled behind;
old sites: minor trimming only required on part of site;
keeping rill or gully pattern in plan section;
(d) The Contractor shall ensure that the slope under instruction is trimmed to a
straight angle, according to the Engineer's instructions. Cut slopes to be
planted with grass shall normally be 3 vertical: 2 horizontal, unless otherwise
shown on the Drawing or instructed by the Engineer. In any event, a straight
profile shall be obtained. Concavities shall filled with well compacted material
or dry stone dentition as instructed by the Engineer. Convexities shall be
removed and it shall be ensured that the general profile does not have a
shape giving over-steep segments.
(e) All loose material shall be removed from the slope and tipped elsewhere in an
approved location.
(f) Measurement and Payment: Work shall be measured in square meters on the
basis of actual area of trimmed surface. The payment shall be the full and the
final compensation to the contractor for making arrangements for traffic

Page 28–16
control, trimming, removal of loose materials, all labour, tools, equipment,

safety harness and incidentals to complete the work as specified herein.
(2) Final Preparation of Fill Slopes for Bio-Engineering
(a) The objective of the final preparation of fill slopes shall be to produce a surface
adequately prepared for shrub or tree planting or grass sowing, or a
combination of these. Vegetation shall be used to provide a strong surface
cover. Vegetation shall be planted over a well prepared surface. The slope
shall not be subject to any undue stress from erosion and mass movement in
its initial stages.
(b) The Contractor shall ensure that the slope under instruction is trimmed to a
straight angle, according to the Drawing or instruction of the Engineer. In any
event, a straight profile shall be obtained. All masses of loose debris,
especially where it has previously been tipped at the head of the slope, shall
be removed. Concavities shall be filled with well compacted material or dry
stone dentition as shown on the Drawing or instructed by the Engineer.
Convexities shall also be removed and it shall be ensured that the general
profile does not have a shape giving over-steep segments.
(c) All loose material shall be removed from the slope and tipped elsewhere in an
approved location.
(d) Measurement and Payment: The work shall be measured in square meters on
the basis of actual area of trimmed surface as shown on the Drawing or
instructed and approved by the Engineer. The quantities measured shall be
paid at the unit rates shown in the Bill of Quantities. Such payment shall be the
full and the final compensation to the Contractor for making arrangements for
traffic control, trimming, and removal of loose materials, all labour, tools,
equipment, safety harness and incidentals to complete the work as specified
herein.
2807 SITE PLANTING AND SOWING
(a) The Contractor shall plant or sow grasses, shrubs and trees as shown on the Drawing or
required by the Engineer. This shall be done according to the specifications described
hereunder, as and when required. The Contractor shall supply all necessary expertise,
resources and facilities to ensure that these requirements are met.
(b) Due to the nature of bio-engineering works, they may also be undertaken by small local
contractors with a range of agricultural skills, if so provided in the Contract. If provided
in the Contract. Any bio-engineering site activity may also be managed by direct
employees of the Division Road Office.
(c) It shall be the Contractor's responsibility to ensure that all planting stock, whether provided
from a nursery under a separate contract or through a separate instruction, is of high
quality and is vigorous enough to grow on the site to be planted.

Page 28–17
(d) All seeds and other planting stock shall be of species indigenous to Nepal unless
otherwise specified. All species shall be covered in the current approved lists of
species produced from time to time by the Geo-Environmental Unit of the Department
of Roads. They shall be appropriate for the precise site conditions in which they are to
be planted and the Contractor shall ensure that they apply to the specific altitude and
other environmental characteristics of the site in question.
(e) Activities such as planting and seed sowing shall be carried out within the critical few
weeks when they will yield the desired results. All other operations shall be carried out
in a timely manner to permit this to happen. The Contractor shall be responsible to
keep works to the strict schedule required and under no circumstances to permit
delays.
(1) Sowing of Grasses on Site
(a) The Contractor shall be required to carry out the sowing of grass seeds
according to the Engineer's specific instructions.
(b) If the site for sowing is to be prepared under a separate contract, then it shall
be assumed that the site will already have been prepared for seed sowing.
Nevertheless, it shall be the responsibility of the Contractor to ensure that the
condition of the site is good enough for the successful establishment of
grasses.
(c) The Contractor shall be required to supervise all field operations very closely.
The sowing of grass seeds is a delicate business and shall be approached in
the same way as for agricultural crops. The Contractor shall employ
experienced agricultural labourers for this work.
(d) If seeds have to be provided under a separate contract, then they shall be
properly stored. However, it shall be the Contractor's responsibility to check
that it has been carefully stored and remains fully viable.
(e) Immediately before sowing, the ground surface shall be lightly scarified using
a rake to ease early root penetration. Seeds shall then be laid thinly over the
surface. Under no circumstances shall they be broadcast, because the
lightness of perennial grass seeds and the steepness of the slopes to be
treated give a poor cover using such a technique. The Contractor shall be
responsible for ensuring that the correct quantities of seeds are used, while
giving a good, even cover.
(f) A cover of 25 grammes of grass seed per square metre of surface shall be
achieved unless otherwise specified.
(g) After sowing, a mulch of prepared and dried cut herbs shall be laid over the
whole seeded area in a thin layer. If the mulch is too thick it will prevent light
from getting to the seed and will inhibit germination. Herbs suitable for this and
locally available in large quantities are:
 Tite pate (Artemisia vulgans );
 Tapre (Cassia species);
 Ban mara (Eupatorium adenophorum).

Page 28–18
However, freshly cut herbs shall not be used because of the danger of
resprouting and weeding.
(h) If specified, the mulch should be secured with jute netting of mesh size 300x
500 mm and the netting fixed in place using suitable live pegs or hardwood
cuttings (eg Simali, Vitex negundo) at one metre centres.
(i) Measurement and Payment: Work shall be measured in square meters on the
basis of actual area of grass seeded and covered surface. The payment shall
be the full and the final compensation to the Contractor for making
arrangements for traffic control, providing seeds, collection and application of
mulch, all labour, tools, equipment, safety harness and incidentals to complete
the work as specified herein. If the seeds and mulch are supplied through a
separate contract, costs for the supply of the same shall not be included
herein. However, if the Contractor is responsible for the supply and storage of
seeds and mulch no separate payment shall be made for these items.
(2) Direct Seed Sowing of Shrubs and Trees on Site
(a) The Contractor shall be required to carry out the sowing of shrub and tree
seeds according to the Engineer's specific instructions.
(b) It is assumed that the site will already have been prepared for seed sowing, if
this item has to be executed under a separate contract. Nevertheless, it shall
be the responsibility of the Contractor to ensure that the condition of the site is
good enough for the successful establishment of shrubs and trees.
(c) The Contractor shall be required to supervise all field operations very closely.
As the sowing of any seeds is a delicate business and, therefore, shall be
approached in the same way as for agricultural crops. The Contractor shall
employ experienced agricultural labourers for this work.
(d) Seed shall have been collected and stored well before the time of sowing, if
they have to be supplied under a separate contract. However, it shall be the
Contractor's responsibility to check that it has been carefully stored and
remains fully viable.
(e) Sowing shall start at the top of the slope and the labourers shall work
downwards. Care shall be taken not to disturb areas already seeded.
(f) To sow the seeds, a small hole shall be made in the slope. The tool used to do
this shall depend on the size of the seed. For some seeds, a piece of gabion
wire will be adequate; for others, a piece of mild steel with a flattened end is
required. The hole shall be in the best soil available but if there is little real soil,
then a crevice between two stones is acceptable. Two seeds should be placed
in each hole and a covering of soil or whatever fines are available shall be
placed over them. This covering shall never exceed 10 mm and shall
preferably be about 5 mm; it shall never be less than this. Seeds shall be
placed at 200 to 250 mm centres, as ground conditions dictate.

Page 28–19
(g) In some cases the seed can be broadcast starting at the top of the site and
working down slope as evenly as possible so that the whole site is lightly
covered. This shall be used where the site is still active and only warrants
minimum expenditure, or where the site is naturally rough, providing plenty of
niches in which the seed can catch. Quantities of seed shall depend on the
type of seed involved but are generally half that of the quantities used in the
nursery unless otherwise instructed by the Engineer. With utis ( Alnus
nepalensis) seed it shall be at a rate of 1 gramme of seed per square metre.
(h) Measurement and Payment: Work shall be measured in square meters on the
basis of actual area of grass seeded and covered surface. The payment shall
be the full and the final compensation to the Contractor for making
arrangements for traffic control, providing seeds, collection and application of
mulch, all labour, tools, equipment, safety harness and incidentals to complete
the work as specified herein. If the seeds and mulch are supplied through a
herein. However, if the Contractor is responsible for the supply and storage of
seeds and mulch no separate payment shall be made for these items.
(3) Site Planting of Grass Slips and Cuttings
(a) The Contractor shall be required to carry out the planting of grass seedlings or
rooted cuttings, according to the Engineer's specific instructions. The
configuration of planting shall be determined according to individual site
conditions. It shall be either random, contoured or downslope, as instructed by
the Engineer.
(b) It is assumed that the site shall already have been prepared for planting, if this
is to be prepared under a separate contract. Nevertheless, it shall be the
responsibility of the Contractor to ensure that the condition of the site is good
enough for the successful establishment of grasses, and accords with the
specifications given in Clause 2806.
(c) Using appropriate tools (such as tape measures and spirit levels), planting
lines shall be marked out with string as required. Unless specified differently,
the row spacing to be marked out shall be as shown in Table 28.5.
(d) The Contractor shall be required to supervise all field operations very closely.
Since the planting of grass slips is a delicate business and therefore shall be
approached in the same way as the transplanting of millet seedlings. The
Contractor shall employ experienced agricultural labourers for this work.
Table 28.5: Row Spacing Details
Planting configuration Slope steepness Spacing
Random lines All slopes 100 mm planting drill to drill

Slope less than 35° 100 mm planting drill to drill and 1000 mm between the lines
Contour lines Slope 35°-45° 100 mm planting drill to drill and 500 mm between the lines

Page 28–20
Slope more than 45° 100 mm planting drill to drill and 300 mm between the lines
Slope less than 35° 100 mm planting drill to drill and 500 mm between the lines
Diagonal
Slope more than 35° 100 mm planting drill to drill and 300 mm between the lines
Downslope lines All slopes 100 mm planting drill to drill and 300 mm between the rows
(e) The plants supplied to the Contractor from nursery (if so provided in the
Contract) shall be prepared for planting by the Contractor as given below. The
Contractor shall transport them from the nursery wrapped in hessian jute. At all
times, plants shall be kept moist and as cool as possible, and should be
wrapped in wet hessian between all operations such as extraction from the
bed, pruning and planting. Under any circumstances, all plants supplied shall
be planted within two days of that they are lifted from the nursery.
(f) Grass slips or cutting shall be carefully separated from the clumps to give the
maximum viable planting material. Preparation of slips, cuttings or rhizomes
shall be strictly followed as mentioned in Sub-clause 2803 (1).
(g) Planting shall be started at the top of the slope and under no circumstances
shall new plants be walked on or otherwise disturbed. Using a small bar
(usually made of mild steel and with a flattened end), a hole shall be made that
is just big enough for the roots. The slip or cutting is inserted; care shall be
taken that the roots are not tangled or bent back to the surface. Soil shall then
be replaced around the roots and firmed with the fingers. The spacing of plants
within rows shall be 100 mm unless otherwise specified. Two grass slips shall
be planted in each drill.
(h) If the soil is dry and there is no rain within 16 to 24 hours of planting, the site
shall be watered carefully with a fine spray. The Contractor shall be required to
water for the first two weeks after planting in the event of inadequate rainfall.
(i) If it provided in the Contract that the plants are to be collected from locations
other than nurseries then utmost care shall be taken to minimise disruption to
neighbouring land, in the event that species are collected from areas
surrounding the road. It shall be the Contractor's responsibility to collect the
stock required from a wide area and not to give rise to any soil erosion through
the excessive removal of plants in one locality.
(j) Measurement and Payment: The measurement shall be the actual area of
grass planted and covered surface in square meters for the random planting
and any other patterns of planting up to the 300 mm between the lines. The
contour line planting in 500-1000 mm in any slopes shall be measured in
linear meter. The payment shall be the full and final compensation to the
Contractor for making arrangements for traffic control, providing grass slips or
rhizome, collection of mulch, all labour, tools, equipment, safety harness and
incidentals to complete the work as per these Specifications. If the grass slips
and mulch are supplied through a separate contract, costs for the supply of
the same shall not be included herein. However, if the Contractor is
responsible for the supply slips and mulch, no separate payment shall be
made for these items.

Page 28–21
(4) Site Planting of Shrubs and Trees raised in Polythene Pots
(a) The planting of trees and shrubs is intended to replace or restore something of
the natural vegetation on the slope to be treated. The Contractor shall be
required to carry out the planting of seedlings to the Engineer's specific
instructions.
(b) It is assumed that the site will already have been prepared for planting if it has
to be prepared under a separate contract. Nevertheless, it shall be the
enough for the successful establishment of delicate young plants.
(c) The spacing of plants shall be determined according to individual site

conditions. However, it shall normally be at 1.5 meters interval unless
otherwise specified or instructed by the Engineer.
As the planting of trees and shrubs is a delicate business and should be
approached in the same way as the planting of horticultural seedlings. The
Contractor shall employ experienced agricultural or forestry labourers for this
work.
(e) If the plants are to be supplied to the Contractor from a nursery under a
separate contract, they will be ready for planting. They shall be at least 300
mm in height above the soil surface and hardened off in the normal way. The
Contractor shall collect the plants from the nursery and transport them to site
with all due care. The plants will normally be supplied in polythene pots, which
shall not be removed until the moment of planting. Plants shall be lifted by the
pots, never by the stem or leaves. At all times they are to be kept as cool as
possible. The Contractor shall be responsible for ensuring that the soil around
the roots does not dry out. Under any circumstances, all plants supplied must
be planted within three days of removal from the nursery.
If it is provided in the Contract that the Contractor is responsible for the supply
of plants, he shall maintain the same workmanship and standard as specified
herein.
(f) Planting shall be started at the top of the slope and under no circumstances
shall new plants be walked on or otherwise disturbed.
(g) A planting pit wide and deep enough for the main root to be buried in without
bending it and wide enough for all the roots and surrounding soil ball shall be
made at the time of planting. Some compost if available shall be mixed with
the soil from the slit prior to backfilling around the roots. The polythene pot
must be removed from the seedling by cutting it away with a razor blade. The
plant should then be carefully placed into the hole, the compost and soil
packed in, and all surrounding soil firmed up, taking care not to cause any
damage to the plant or its roots. The surface over and around the pit shall then
be mulched using any appropriate, locally available material, such as manure,
compost, dead leaves or cut herbage. The use of freshly cut ban mara

Page 28–22
(Eupatorium adenophorum ) shall be avoided, since it can resprout from the

buds after being cut.
(h) The Engineer may specify bigger seedlings for specific areas, such as those
to be used intensively for amenity purposes. These will normally have been
growing in a nursery for at least a year and should have well developed roots
as well as aerial parts. They will be provided either as bareroot stock with a
substantial root ball or in pots of a minimum of 100 x 180 mm laid flat
dimensions. When these larger seedlings are planted, the pits shall be of 300
mm diameter and 300 mm depth. In addition, well-rotted compost shall be
mixed with the soil backfill in a ratio of at least one part compost to ten parts
soil.
(i) Measurement and Payment: The measurement shall be made in number of

seedlings planted, counted and accepted by the Engineer at site. The
quantities measured shall be paid at the unit rates shown in the Bill of
Quantities. This payment shall be the full and the final compensation to the
Contractor for making arrangements for traffic control, providing seedlings,
collection and application of mulch, all labour, tools, equipment, safety harness
and incidentals to complete the work as per these Specifications. If the
seedlings and mulch are supplied through a separate contract, costs for the
supply of the same shall not be included herein. However, if the Contractor is
responsible for the supply seedlings and mulch, no separate payment shall be
made for these items.
(5) Site Planting of Hardwood Cutting
(a) Certain trees and shrubs can be planted on site by means of hard wood
cuttings. Where these are specified, the Contractor shall be required to carry
out the planting of cuttings as required in the Engineer's instructions.
(b) It is assumed that the site will already have been prepared for planting, if it is
(c) The spacing of hardwood cutting shall be determined according to individual

site conditions. However, it will normally be at 500 mm centres unless
otherwise specified.
The planting of tree and shrub cuttings is a delicate business and shall be
approached in the same way as the planting of horticultural cuttings (e.g.
those of tea). The Contractor shall employ experienced agricultural or forestry
labourers for this work.
(e) The cuttings supplied to the Contractor will normally be from a nursery as
arranged by separate instructions, and will be ready for planting. If these
cuttings are to be provided by the Contractor himself, he shall make such
arrangements so as to make the cuttings ready for planting. The size of the
cuttings shall be prepared as specified in Sub-clause 2803 (2) unless

Page 28–23
otherwise instructed by the Engineer. The Contractor shall collect the cuttings
from the nursery (if provided in the Contract) and transport them from the
nursery wrapped in hessian jute. At all times, cuttings shall be kept moist and
as cool as possible, and shall be wrapped in wet hessian between all
operations such as cutting from the parent plant, trimming and planting. Under
any circumstances, all plants supplied shall be planted the same day that they
are lifted from the nursery.
(f) Planting shall be started at the top of the slope and under no circumstances
shall new plants be walked on or otherwise disturbed. Using a small bar
(usually made of mild steel and with a pointed end), a hole shall be made that
is just big enough for the cutting. The cutting shall be inserted and the soil shall
be replaced around it and firmed with the fingers. The cutting shall be inserted
to depth such that two-thirds to three-quarters of it is buried.
(g) If the soil is dry and there is no rain within 16 to 24 hours of planting, the site
shall be watered carefully with a fine spray. The Contractor shall be required to
water for the first two weeks after planting in the event of inadequate rainfall.
(h) If it is provided in the Contract that the cuttings to be used are to be from
elsewhere other than nurseries then the Contractor shall obtain them in the
manner described in Sub-clause 2803 (2).
(i) The Engineer may specify bigger cuttings for specific areas, using large
truncheon cuttings. In this category fall chuletro ( Brassaiopsis hainla),
dabdabe (Garuga pinnata), kavro (Ficus lacor), phaledo (Erythrina species),
ghurbis (Leucosceptrum canum) and Gliricidia sepium. Cuttings of these
species should be planted at 1000 mm centres burring upto 500 mm. A large
crowbar shall be used to make the planting hole, but otherwise the technique
shall be as described above for smaller cuttings. Under no circumstances
shall these cuttings be hammered into the ground.
(j) Measurement and Payment: The measurement shall be made on the basis of
per number of cuttings planted, counted and accepted on site by the Engineer.
The quantities measured shall be paid at the unit rates shown in the Bill of
Quantities. This payment shall be the full and final compensation to the
Contractor for making arrangements for traffic control, providing and delivering
seedlings, all labour, tools, equipment, safety harness and incidentals to
complete the work as per these Specifications. If the seedlings are supplied
through a separate contract, costs for the supply of the same shall not be
included herein. However, if the Contractor is responsible for the supply
seedlings, no separate payment shall be made for this item.
(6) Brush Layering, Palisades and Fascines
(a) Under certain conditions, the Contractor shall be required to construct

vegetation structures using hardwood cuttings. Where these are specified, the
Contractor shall be required to carry out the necessary preparation and
planting works as required in the Engineer's instructions.

Page 28–24
(b) It is assumed that the site will already have been prepared for planting, if it has
(c) The cuttings supplied to the Contractor may be from a nursery as arranged
under a separate contract, and will be ready for planting. If the cuttings have to
be arranged by the Contractor, he shall ensure that they are ready for planting.
The cuttings shall be prepared as specified in Sub-clause 2803 (2) or as
instructed by the Engineer. The Contractor shall collect the cuttings from the
nursery and transport them from the nursery wrapped in hessian jute. At all
times, cuttings shall be kept moist and as cool as possible, and shall be
wrapped in wet hessian or in the thick blanket of mulch material (i.e. as tite pati
and ban mara) between all operations such as cutting from the parent plant,
trimming and planting. Under any circumstances, all plants supplied shall be
planted the same day that they are lifted from the nursery.
(d) If the instruction to the Contractor includes the provision of cuttings, then the
Engineer shall specify the species and expected sources, and the Contractor
must then obtain the cuttings required. This shall be done in the manner
described in Sub-clause 2803 (2) except that the size of cuttings will be of a
minimum length of 450-600 mm for brush layering, 600 mm for palisades and
1000 mm for fascines, and minimum diameters of 20-30 mm for brush layering
and palisades and 40-50 mm for fascines.
(e) Cuttings of the following species, if specified for the truncheon cuttings
planting, shall be a minimum of 2500-3000 mm in length: chuletro
(Brassaiopsis hainla), dabdabe (Garuga pinnata), kavro (Ficus lacor), phaledo
(Erythrina species), ghurbis (Leucosceptrum canum) and Gliricidia sepium.
(f) The Contractor shall be required to supervise all field operations very closely.
The planting of tree and shrub cuttings is a delicate business and shall be
approached in the same way as the planting of horticultural cuttings (e.g.
those of tea). The Contractor shall employ experienced agricultural or forestry
labourers for this work.
(g) Planting shall always be started at the top of the slope and under no
circumstances shall new plants be walked on or otherwise disturbed.
(h) Brush layering on road embankment slopes shall be planted as given below,
unless specified differently.
(i) Starting at the top of the area to be treated, and using appropriate
measuring equipment, exact lines should be marked out. From 1.5
meters below the road edge, a precise contour line should be marked
out on every 1 meter down the slope.
(ii) After the line marking is completed, starting at the bottom of slope, a
back sloped terrace (1:10) of approximately 300 mm in width x 100
mm inner depth and 300-400 mm outer depth should be excavated

Page 28–25
along the lines. The terrace must not be allowed to open more than 5
metres length at time before planting work is completed.
(iii) Topsoil or agricultural soil of maximum depth of 100 mm from the

ROW should be collected and laid on the terrace. The minimum
thickness shall be 50 mm unless otherwise instructed by the Engineer.
(iv) Cuttings should then be placed into the terrace at 100 mm centres, the
correct way up and angled so that they are at rightangles to the
maximum slope angle. All cuttings should be inserted to a depth such
that two-thirds of their length is buried.
(v) The terrace should then be partially backfilled with another 50 mm
thick layer of topsoil and another line of cuttings placed (pushing into
the soil) along the terrace at 100 mm centres, and with the individual
cuttings offset to coincide with the gaps between the cuttings in the
first line. This results in cuttings at 50 mm final gap on each brushlayer
(i.e. 21 cuttings per linear metre).
(vi) When a practical working length is completed, formation of second

terrace is then started. As the excavation is undergoing, the partially
backfilled brush layering terrace below should be fully backfilled using
the material comes out of the second terrace and gently compacted.
Any loose or excess material is cleared down the slope making the
complete daylight upon the completion of whole slope.
(i) Brush layering on the landslide debris shall be planted as given below, unless
specified differently.
(i) Starting at the bottom of the area to be treated, and using

appropriatemeasuring equipment, exact lines shall be marked
following a precise contourline at 1 metre interval.
(ii) After the line marking is completed, starting at the bottom of slope, a
back sloped terrace (1:10) of approximately 450 mm in width x 100
mm inner depth and 300-400 mm outer depth shall be excavated
along the lines. The terrace shall not be allowed to open more than 5
metres length at time before planting work is completed.
(iii) Cuttings shall then be placed into the terrace at 100 mm centres, the
correct way up and angled so that they are at rightangles to the
maximum slope angle. All cuttings shall be inserted to a depth such
that two-thirds of their length is buried.
(iv) The terrace shall then be partially backfilled with 50 mm layer of soil
and another line of cuttings placed (pushing into the soil) along the
terrace at 100 mm centres, and with the individual cuttings offset to
coincide with the gaps between the cuttings in the first line. This
results in cuttings at 50 mm final gap on each brushlayer (i.e. 21
cuttings per linear metre).

Page 28–26
(v) When a practical working length is completed, formation of second

terrace shall then be started. As the excavation is undergoing, the
partially backfilled brush layering terrace below shall be fully backfilled
using that material coming out of the second terrace and gently
compacted. Any loose or excess material shall be cleared down the
slope making the complete daylight upon the completion of whole
slope.
(vi) Brushlayering is often done in diagonal or chevron pattern. If it is

instructed so, the procedure given above shall be followed accept
setting out lines, which shall be changed accordingly.
(j) Palisades shall be constructed as given below, unless specified differently.
measuring equipment, exact lines shall be marked out. From 1 metre
below the top of the slope, a precise contour line shall be marked out
every 1 metre down the slope.
(ii) Starting at one end and using a small bar (usually made of mild steel
and with a pointed end), a hole shall be made that is just big enough
for the first cutting. The cutting shall be inserted and the soil shall be
replaced around it and firmed with the fingers. The cutting shall be the
correct way up and angled so that it is vertical. The cutting shall be
inserted to a depth such that two-thirds of it is buried.
(iii) This process shall be repeated along the entire line, with a series of
cuttings placed at 50 mm centres,
(iv) If a double line is specified, then a second line of cuttings shall be

placed in the same way, 100 mm behind the first and with the
individual cuttings offset to coincide with the gaps between the
cuttings in the first line.
(v) The soil around the single or double line shall then be completely
backfilled into any remaining gaps and gently compacted. Any loose
or excess material shall be cleared down the slope before the next
line is planted.
(k) Fascines shall be bundles of hardwood cuttings laid horizontally in trenches,

and parallel to the line of the trench. The bundles shall be thereby completely
buried. Fascines shall be constructed as given below, unless specified
differently.
measuring equipment, exact lines shall be marked out. From 1 metre
below the top of the slope, a precise contour line shall be marked out
every 1 metre down the slope.
(ii) Starting at the bottom as the marking is completed, trenches

approximately 200 mm x 200 mm in depth shall be excavated along
the lines.

Page 28–27
(iii) 600 mm long cuttings of same material that is going to make fascine
shall be planted on the lower side of trench in vertical position as a
peg at 1000 mm interval.
(iv) Cuttings shall then be laid along each trench, so that they lie
horizontally along the trench. There shall be a minimum of six cuttings
together. They shall be overlapped so that no two ends coincide. All
the small branches growing from the main branch shall be protruding
on slope. Under no circumstances, the branches and buds shall be
damaged. The cuttings shall then be tied using jute or coir (coconut
fibre) string at 500 mm intervals to form a bundle. As the fascine is
created, it thereby forms a continuous bundle right across the slope.
(v) The trench shall then be backfilled and gently compacted. The top of
the fascine shall be 50 to 100 mm below the surface. Any loose or
excess material shall be cleared down the slope before the next line is
planted.
(vi) The Engineer may specify that orientations other than along the
contour of the slope are used. In this event, the Contractor shall alter
the laying out of lines accordingly and meet the precise angle
required.
(vii) If the soil is dry and there is no rain within 16 to 24 hours of planting,
the site shall be watered carefully with a fine spray. The Contractor
shall be required to water for the first two weeks after planting in the
event of inadequate rainfall.
(l) Measurement and Payment: Brush layering, Palisades and Fascines shall be
measured separately as per the accepted final product in linear metre. The
payment shall be the full and final compensation to the Contractor for making
arrangements for traffic control, collecting and transporting of cuttings to the
site, all labour, tools, equipment, safety harnesses and incidentals to complete
the work as per these Specifications. If the cuttings are supplied through a
herein. However, if the Contractor is responsible for the supply cuttings, no
separate payment shall be made for this item.
(7) Use of Fertiliser
(a) Under certain circumstances, the use of chemical fertilisers may be specified
in place of farmyard manure or mulching.
(b) Levels of fertiliser application shall vary according to soil type and nutritional
content. However, if nutritional data are not available, the following figures
shall be used as a rough guide:
 Nitrogen (N) : 10 g/m2;

Page 28–28
 Phosphorus (P) : 5 g/m2;

 Potassium (K) : 4 g/m2.
Table 28.6 below lists the chemical composition and percentage of the major plant nutrient
elements in the chemical fertilisers commonly available in Nepal.
Table 28.6: Chemical Composition of Major Plant Nutrient Elements
Commercial name Chemical formula Percentage

(N) (P) (K)
Sulphate of ammonia (NH4)2SO4 21 0 0
Urea CO(NH4)2 46 0 0
Triple superphosphate CaH(PO4) 0 21 0
Muriate of potash KCl 0 0 49
Complexol Unknown 20 20 0
Diammonium phosphate (NH4)2HPO4 18 20 0
2808 JUTE NETTING WORKS
(a) The Contractor shall provide and install jute netting as shown on the Drawing or as
required by the Engineer. This shall be done according to the specifications described
hereunder, as and when required. The Contractor shall supply all necessary expertise,
resources and facilities to ensure that these requirements are met.
(b) The Engineer may instruct that jute jetting applications be used in conjunction with
other techniques, particularly the sowing or planting of grasses. In this event, the
netting shall be applied before the plants are introduced. When planting, the labourers
shall take care only to hold or stand on the pegs and not to disturb the netting except
when carefully placing grass seed underneath on the soil surface.
(1) Supply of Jute Netting
(a) The Contractor shall manufacture or obtain a supply of jute netting to the
Engineer's specification.
(b) The detailed specifications for standard jute netting shall be as follows.
"Standard" jute netting is used for placing on bare slopes and is normally
planted with grasses. (Note: warp ends are the length-ways threads and
weft strands are the cross-ways threads)
(i) Material: High quality, 100% natural jute fibre from the latest
harvest, properly treated and dried.
(ii) Yarn: Handspun 5 to 8 mm.
(iii) Strip size: minimum 1.0 x 10.0 metres;

maximum 1.1 x 11.5 metres.
(iv) Warp ends: 27 ends per 1000 mm.

Page 28–29
(v) Weft strands: 20 to 24 strands per 1000 mm.
(vi) Mesh size: 40 mm square mesh holes.
(vii) Weight: 1.1 to 1.2 kg per square metre.
(c) The detailed specifications for wide mesh jute netting shall be as follows.
"Wide mesh" jute netting is used for holding much on to slopes which have
been sown with grass seed. (Note: warp ends are the length-ways
threads and weft strands are the cross-ways threads)
(i) Material: High quality, 100% natural jute fibre from the latest
harvest, properly treated and dried.
(ii) Yarn: Handspun 3 to 5 mm.
(iii) Strip size: minimum 1.0 x 5.0 metres;

maximum 1.1 x 11.5 metres.
(iv) Warp ends: 7 ends per 1000 mm.
(v) Weft strands: 3 strands per 1000 mm.
(vi) Mesh size: 150 x 450 mm rectangular mesh.
(vii) Weight: 0.2 kg per square metre.
(d) Measurement and Payment: No separate measurement and payment shall be

made for the supply of jute netting. All costs incurred for the supply of jute
netting shall be included in the item rate for the placement of jute netting.
(2) Placement of Small Mesh Size Jute Netting/Standard Jute Netting
(a) The Engineer shall normally instruct the placement of standard jute netting on
slopes in excess of 45°. It is therefore very essential to place the netting in an
effective manner which fulfils the Engineer's purpose.
(b) It is assumed that the site will already have been prepared for the application
of jute netting, if it is to be prepared under a separate contract. Nevertheless, it
shall be the responsibility of the Contractor to ensure that the condition of the
site is good enough for the optimum effect to be attained. In any event, a
smooth profile must be obtained. All loose debris shall be removed.
Concavities shall be filled with well compacted material or dry stone dentition
as shown on the Drawing or as instructed by the Engineer. Convexities shall
also be removed and it is essential that the general profile does not have a
shape giving over-steep segments.
(c) Starting at one end of top of the site to be treated, a roll of netting shall be
pegged 300 mm above the slope to be covered.

Page 28–30
(d) The netting shall be rolled slowly down the slope. Hardwood cuttings, ideally of
simali (Vitex negundo ) or pegs (usually made from split bamboo culms) shall
be hammered through the netting at 1000 mm centres at 100 mm inside of
each edges. They shall protrude about 80 mm on the slope. Labourers shall
stand on these cuttings or pegs and not hang on to the netting. As the full
length of the jute netting is unrolled down the slope, a second round of the
pegs shall be added in between. This will make total allowable spacing of not
more than 500 mm interval. Another strip shall then be started to unroll from
the top. This shall overlap by 100 mm and under no circumstances the
pegging is done through the both layer of jute net instead it shall be pegged
separately. Each strip of jute netting shall be pegged down on the slope
individually.
(e) The tension of the netting shall now be reduced so that it hugs the slope
surface precisely. This is done by pulling up about 200 mm at the bottom of the
netting and hooking it on to the pegs a little higher up. This process shall be
repeated up and across the slope until the netting rests snugly against the
surface and is nowhere tight or pulled away from the surface in minor
concavities. Additional pegs shall be used to hold netting closely against the
face of concave slope segments if necessary.
(f) This process shall be repeated until the entire slope surface is covered. There
shall be no lacing of any jute netting whatsoever.
(g) Finally, the bottom of the netting shall be trimmed to give a tidy finish.
(h) Measurement and Payment: As the actual quantity of jute net and area
covered on slope differ from each other due to the overlapping, payment shall
be made on the basis of final area covered on slope and measured in square
metre (not the quantity of jute net). The payment shall be the full and the final
compensation to the Contractor for making arrangements for safety to traffics,
purchasing of jute, arrangement for looms and shades, fabrication of jute
netting and transportation to the site, all labour, tools, equipment, safety
harnesses and incidentals to complete the work as per these Specifications.
(3) Placement of Wide Mesh Size Jute Netting
(a) In the case of wide mesh jute netting, it shall only be specified for use on
slopes which have already been treated with grass and mulch. These shall
usually be less than 45°. However, the process of placing the netting shall be
similar to that for standard netting.
(b) Unlike the standard mesh jute net, wide mesh jute net is available on shorter
length of 5.5 metres and smaller roll in nature. It shall be opened by two
people by two end laid flat (same as bed sheet is laid) on seeded and mulched
slope.
(c) The netting shall be pegged with hardwood cuttings, ideally of simali ( Vitex
negundo) or pegs (usually made from split bmboo culms) at every 500 mm

Page 28–31
intervals. The Contractor shall ensure that his/her labourers do not damages
the area of seeding and mulching while placing the jute net.
(d) This process shall be repeated until the entire slope surface is covered. The
strips shall then laced together with lengths of the same jute yarn, to form a
continuous net. The lacing shall form joins every 500 mm or less.
(e) The tension of the netting shall now be reduced so that it hugs the slope
precisely and hold the mulch firmly against the surface throughout the area
covered. Additional pegs shall be used to hold netting closely against the face
of concave slope segments.
(f) Finally, the bottom of the netting shall be trimmed to give a tidy finish.
(g) Measurement and Payment: The payment shall be made on the basis of final
area covered on slope and measured in square metre (not the quantity of jute
net). The payment shall be the full and the final compensation to the
Contractor for making arrangements for safety to traffics, purchasing and
transporting of jute net to the site, all labour, tools, equipment, safety
harnesses and incidentals to complete the work as per these Specifications.
2809 GABION WIRE BOLSTERS, SUB-SOIL DRAINS AND WIRE NETTING
The contractor shall provide and install wire bolsters as shown on the Drawing or instructed by
the Engineer. This shall be done according to the specifications described hereunder, as when
required. The Contractor shall supply all necessary expertise, resources and facilities to
ensure that these requirements are met.
(1) Fabrication of Bolster Panels
(a) Bolster panels shall be either 5 x 1 metres or 5 x 2 metres in size, according to

the type of bolster to be used. If the bolster panels are used for the wire
netting, the size of the panel shall be 5.0 m X 5.0 m. They shall be woven with
hexagonal mesh in the same way as normal gabion panels. For the panel
frame, 10 swg galvanised wire shall be used; for the mesh, 12 swg shall be
adequate. Gabion wire shall comply with the requirements of Clause 2401.
(b) Weaving shall start from one of the long sides. A total of 83 coils of wire shall
be spaced evenly along the 5 metre length. This gives a mesh width of about
60 mm. Each weave shall have three twists, as for normal hexagonal mesh.
This shall give a length of about 80 mm to each mesh link. In any event, the
mesh length shall not exceed 90 mm. The mesh shall be turned on to the
larger frame wire at least one and a half turns and made fully secure.
(2) Placement of Contour Bolsters
(a) A contour bolster treatment shall give a series of stone-filled wire tubes of 300
mm diameter, laid in trenches cut across the slope. The tops of all the tubes
shall be flush with the surface of the slope in which they are placed. The

Page 28–32
purpose shall be to check scour of the slope surface by preventing the

development of rills and gullies.
(b) The site to be treated shall be given final preparation immediately before
bolster installation. All small protrusions and depressions shall be obliterated
by cutting, or by infilling and compaction.
(c) Starting at the base of the area to be treated, and using appropriate measuring
equipment, exact lines shall be marked out. From 2 metres above the base of
the slope, a precise contour line shall be marked out every 2 metres up the
slope.
(d) Starting at the bottom, trenches with circular base shall be dug along the lines,
adequate to take the final 300 mm diameter tubes.
(e) Bolster panels shall then be laid along the trenches and shaped to fit neatly
into the base of the trenches, as well as into any curves formed as a result of
the slope contours; each panel shall be securely joined to the next panel, to
form a continuous bolster tube.
(f) The panels shall be packed with stones, closed over and the edges wired
together. All stones must be bigger than the mesh size. The same care shall
be taken as when filling a conventional gabion basket, and stones must be
carefully placed to give good structural integrity.
(g) The ends of the bolsters shall be closed over and wired together. The trenches
around all the bolsters shall then be filled and compacted with material left
from the excavations.
(h) Once all of the lines are in place, all surplus debris shall be cleaned off the
slope. Mild steel bars of at least 16 mm diameter shall then be driven into the
slope through the lower sides of the contour bolsters. These shall be at least
every 2 metres along the lines. Bars shall be 1-2 metres in length on slopes
composed of soft materials, but at the Engineer's discretion, on slopes
comprising hard rocky materials, bars of 1 metre length shall also be
adequate. All bars shall be driven home until the tops protrude no more than
25 mm above the slope surface.
(i) Measurement and Payment: Bolster shall be measured as per the accepted
final product in linear metre. The payment shall be the full and the final
compensation to the Contractor for making arrangements for traffic control,
fabrication of bolster panel including cost of wire, collection and transportation
of boulder/stone to the site, packing of stones/boulders, wiring, supply and
driving of steel bars, excavation and filling, all labour, tools, equipment, safety
harnesses and incidentals to complete the work as specified in these
Specifications.
(3) Placement of Herringbone Bolsters
(a) A herringbone bolster network is in essence a system of wire tubes of between

300 mm to 600 mm in diameter depending on the amount of water flowing

Page 28–33
through the site, laid in trenches cut into the slope. The main bolster shall run
straight down the slope (the spine) with other running into it at an angle of 45°
to the fall of the slope (the herringbones or branches) depending on slope
angle and terrain morphology. The purpose shall be to check scour of the
slope surface by preventing the development of rills and gullies, and to drain
the surface material in a similar way to a French drain. The diagonal
components shall be at 2 to 5 metre centres if measured straight down the
slope.
(b) The site to be treated shall be given final preparation immediately before
bolster installation. All small protrusions and depressions shall be obliterated
by cutting, or by infilling and compaction.
(c) Starting at the base of the area to be treated, and using appropriate measuring
equipment, exact lines shall be marked out: every 7.0 metres across the
slope, a line shall run straight up to the top of the slope (these form the main
bolster spines). From the base of the line, and every 3 metres above this,
other lines of 5 metres length shall be marked at 45° to the main line (these
will form the herringbones).
(d) Starting at the bottom, trenches with circular base shall be dug along the lines,
adequate to take the final 300 mm diameter tubes, or 600 mm diameter tubes
if large (5 x 2 metre) panels are specified.
(e) Bolster panels shall then be laid along the trenches and shaped to fit neatly
into the base of the trenches, as well as into any curves formed as a result of
the slope contours; the panels of the herringbones shall be securely joined to
the panels of the main bolster.
(f) The panels shall be gradually closed together and secured, working up from
the bottom of the slope, while stones are passed in from above to fill them. The
stones shall be randomly packed so as to allow free drainage, and all stones
shall be bigger than 100 mm. The same care shall be taken when filling a
conventional gabion basket, and stones shall be carefully placed to give good
structural integrity.
(g) The upper ends of the herringbones shall be closed over and wired together;
they should touch the ends of the next herringbones but shall not be secured
(hooked) to each other. The trenches around all the bolsters shall then be filled
and compacted with material left from the excavations.
(h) Once all of the lines are in place, all surplus debris shall be cleaned off the
slope. Mild steel bars of at least 16 mm diameter shall then be driven into the
slope through the sides of the main spine bolsters and the lower sides of the
herringbone bolsters. These shall be at least every 2 metres along the lines.
Bars shall be 1-2 metres in length on slopes composed of soft materials, but at
the Engineer's discretion, on slopes comprising hard rocky materials, bars of 1
metre length may be adequate. All bars shall be driven home until the tops
protrude no more than 25 mm above the slope surface.

Page 28–34
(i) Measurement and Payment: Bolster that are accepted by the Engineer shall
be measured in linear metre. The payment shall be the full and the final
compensation to the Contractor for making arrangements for traffic control,
fabrication of bolster panel including cost of wires, collection and
transportation of boulder/stone to the site, excavations and fillings,
boulder/stone packing, all wiring, supply and driving of steel bars, all labour,
tools, equipment, safety harnesses and incidentals to complete the work as
(4) Wire Netting
(a) Wire netting shall be a complete cover on the steep rocky slope where heavily
shattered rock face is eroding away by surface water. The site shall be
prepared as outlined in Clause 2806. A wire mesh panel, normally larger than
bolster, of 5 m x 5m shall be placed over the slope and later plant will be
grown to replace the wire netting.
(b) The site to be treated shall be given final preparation immediately before wire
netting. All loose bulging shall be trimmed off.
(c) Starting at the top of the slope to be treated, wire netting shall be placed
securing well on to the slope. The wire net shall then be stapled down with an
“U” shaped hook.
(d) The hook shall be made of 16 mm diameter M/S rod and a minimum of 1000
mm in length. The hook shall be driven hammering down with the mason’s
hammer at 500 mm interval. This will be effective if driven into the cracked
joint. A shorter length may also be used if the rocky face does not permit the
bar, but the Engineer’s approved and instruction shall be obtained prior to
taking a decision.
(e) The wire netting shall be well secured. If there are any minor concavity and
convexity, the wire shall be secured by hammering down by mason’s hammer.
Additional staples could be used as necessary. If some of the staples become
weak and loose, they shall be jammed with 1:4 cement sand mortar in slurry
form.
(f) Measurement and Payment: Wire netting shall be measured in square metre.
The payment shall be the full and the final compensation to the Contractor for
making arrangements for traffic control, purchasing of wire net, fabrication and
transportation of wire netting to the site, supply and driving of hooks, all labour,
tools, equipment, materials, safety harnesses and incidentals to complete the
work as specified in these Specifications.
(5) Construction of Sub-soil Drains (Sub-surface Drains)
Sub-soil drains shall be installed and paid in accordance with the requirements
specified in Clause 2404.

Page 28–35
2810 SITE PROTECTION
(a) The Contractor shall protect a planted site for the period specified in the Contract.
Protection shall include the prevention of damage to all manner of site works and
plants by people and domestic or wild animals. It shall also include an active role in
tending the plants and improving their growth, as specified below.
(b) The period of maintenance/site protection shall be twelve months unless otherwise
specified in the Contract.
(1) Provision and Role of Site Warden
(a) The Contractor shall be required to provide an adequate number of site

wardens to look after the site to fulfil the specified requirements. The function
of Warden shall be broader than that of watchman, chowkidar, or heralu. It
shall also involve a number of routine maintenance operations.
(b) Warden shall be mature and reliable characters who need little supervision for
the adequate fulfilment of their duties. They shall be active and physically fit.
Old people who are losing their strength shall not be employed. They shall be
experienced agricultural workers familiar with caring for plants. They shall
remain on site through all hours of daylight and through all adverse weather
conditions. They shall eat their meals on site and at no time leave the site
untended for any reason whatsoever.
(c) The role of the Warden shall be primarily to tend the plants. He/she shall take
the initiative in weeding, mulching, replanting failed plants, pruning and
protecting plants against all pests. This shall be an active role requiring
individuals with considerable energy and initiative. The Warden shall work
constantly to maintain and improve the site and its bio-engineering plants.
(d) The Warden shall also be required to protect plants on the site from damage
by local people, domestic and wild animals. In doing this he/she shall use a
friendly approach to the people as far as possible. The Contractor shall
educate the Warden fully in the reasons for his/her job, so that he/she can
communicate with others. He/she also shall have to fulfill an inevitable function
as the ambassador between the Department of Roads and local road
neighbours.
(e) Measurement and Payment: Site Warden employed under the Contract shall
not be paid for separately. All costs associated with the employment of warden
as well as execution of works specified shall be considered to be included in
the item rate of “Site Aftercare and Maintenance”.
(2) Fabrication of Bamboo Tree Guards
(a) The Contractor shall provide bamboo tree guards as shown on the Drawing or
specified in the Contract. This shall be done according to the specification
described hereunder, as and when required. The Contractor shall supply all

Page 28–36
necessary supervision, resources and facilities to ensure that these

requirements are met.
(b) The bamboo strips used to make bamboo tree guards shall be made from mal
bans (Bambusa nutans subsp cupulata) whilst the uprights are to be made
from tharu or dhanu bans ( Bambusa nutans subsp nutans or Bambusa
balcooa). Bamboo tree guards shall be a minimum of 450 mm in diameter by
1300 mm in height so that they are able to provide sufficient protection from
grazing and from the elements for the first 18 months after planting the
seedling.
(c) The guard shall be made by cutting 5 bamboo posts which are a minimum of
50 mm wide by 10 mm thick and at least 1600 mm long. The posts shall be cut
so that they have a strong spear-like point at the bottom that can be driven into
the ground when placing out on site. The bamboo poles used to make the
uprights shall be a minimum of 3 years old.
(d) Bamboo strips, a minimum of 5 mm thick and 50 mm wide shall be cut from
poles that are at least 2 years old. The bamboo used shall be split so that the
outer wall remains intact. Only lengths with the outer wall intact shall be used.
The split bamboo shall be the length of the whole bamboo pole that it is cut
from, or as long as possible. The split bamboo shall be woven in and out of the
bamboo uprights and pulled tight, so that it is firm and strong. The end of each
of the strips shall be woven back into the basket and tied with binding wire to
keep it in place. End pieces shall not be left sticking out and unbound,
because they quickly get broken and the basket starts to unravel from this
point. The split bamboo shall be woven round the poles so that when they are
tightly pressed down there are no gaps in the guard.
(e) Measurement and payment: No separate payment shall be for the fabrication
of the bamboo tree guards. All associated costs shall be considered to be
included in the item rate for “Site Aftercare and Maintenance”.
(3) Placement of Bamboo Tree Guards
(a) Tree guards shall be installed on site at the time of planting, no later than the
second week of July, and shall be placed carefully around the planted
seedlings.
(b) The tree guards shall be placed over the seedling immediately after planting.
The upright posts shall be firmly driven at least 300 mm into the ground so that
the guard is able to resist bashing and rubbing from cows, buffalo, goats and
people. The woven slats shall be pushed down firmly from the bottom upwards
so that they touch one another and are free from large gaps.
(c) Tree guards alone are not adequate protection for small plants. The Contractor
shall provide a site Warden in addition, for the time specified, to maintain the
tree guards and ensure that local people respect them, and generally fulfil all
the requirements of Sub-clause 2810 (1).

Page 28–37
(d) Measurement and Payment: No separate payment shall be made for the
placement of the bamboo tree guards. All the associated costs shall be
deemed to be included in the relevant item rate for “Site Aftercare and
Maintenance”.
(3) Fencing
Fencing shall be executed as described in Section 400 but payment shall be included
in the item rate of "Site Aftercare and Maintenance".
2811 SITE AFTERCARE AND MAINTENANCE
(1) The Contractor shall maintain planted bio-engineering sites as required by the
Engineer. This shall be done according to the specifications described hereunder, as
and when required. The Contractor shall supply all necessary expertise and resources
to ensure that these requirements are met.
(2) The Contractor shall carry out weeding as required throughout the site. All annual
weeds and other unwanted plants shall be cut just above the ground and the aerial
parts will be used to make compost or mulch. Weeds shall not be pulled out by the
roots since this disturbs the ground surface.
(3) Weeding shall be carried out throughout the growing season. It shall be undertaken
with particular diligence at the end of the monsoon, so that there is the minimum
amount of competition during the subsequent dry season.
(4) The Contractor shall carry out mulching as required throughout the site. All plants
required under the bio-engineering specifications will be mulched using material
prepared as specified in Sub-clause 2805 (5), or the aerial parts of weeds cut on the
site or brought from elsewhere for the purpose. The desired plants shall be kept
mulched at all times but especial care shall be taken in the spring, when the soil
moisture deficit is at its greatest.
(5) The Contractor shall replace failed, damaged, diseased and very weak plants, using
fresh, healthy plants of the same species, at the correct time of year for planting. This
replanting operation shall normally be carried out during the monsoon in the year
following the first planting works. Vegetation structures shall be enriched by the
planting of additional cuttings or seedlings, as instructed by the Engineer. Failed
seeding areas shall be reseeded at the appropriate time of year.
(6) In replanting and enrichment works, the Engineer may specify the use of different
species. This shall be done where failures or poor performance of plants may be
attributed to poor stock or an incorrect initial choice of species.
(7) All bio-engineering sites shall be maintained so that there are at least the following two
storeys of vegetation. In certain locations, however, there may be a number of
additional vegetation storeys.
(a) A dense ground cover of healthy grass plants, in the configuration specified at
the time of planting.

Page 28–38
(b) An open canopy of shrubs or trees with a deeper rooting network.
(8) In general it shall be necessary to keep the upper canopy thinned in order to maintain
the lower ground cover. Most grasses require high light intensities and become
degraded if subjected to excessive shade from the overstorey. It shall therefore be the
Contractor's responsibility to thin the canopy as necessary to permit adequate levels of
light to penetrate for the optimum growth of the grass understorey.
(9) All thinning and pruning operations shall be undertaken in accordance with the
guidelines issued by the Geo-Environmental Unit. Since these are skilled silvicultural
operation, the Contractor shall take appropriate professional advice and employ
suitably skilled personnel.
(10) All products from thinning and pruning operations shall be disposed off in accordance
with the regulation of His Majesty's Government. The Contractor shall follow the
instructions of the Engineer in this regard.
(11) Other maintenance operations shall to be undertaken by the Contractor according to

the instructions of the Engineer.
(12) Measurement and Payment: The works shall be measured in a lump sum basis. The
item rate shown in the Bill of Quantities shall be the full and the final compensation to
the Contractor for carrying out all works specified herein including provision of site
protection specified in Clause 2810.
Should at any time the Engineer give any instruction for the proper Site Protection/Aftercare
and Maintenance and the Contractor does not respond within 24 hours, the Engineer shall be
empowered to instruct others to carry out the works. Any costs involved by such actions shall
be borne by the Contractor.

Page 28–39
SECTION 2900 - MAINTENANCE WORKS
Page No.
2901 SCOPE 29–1

2902 RESTORATION OF RAIN CUTS 29–1
2903 MAINTENANCE OF EARTHEN SHOULDERS 29–1
2904 MAINTENANCE OF GRAVEL SHOULDERS AND GRAVEL CARRIAGEWAY 29–2
2905 BITUMINOUS PATCH WORKS 29–3
2906 MAINTENANCE WITH SLURRY SEAL 29–5
2907 MAINTENANCE WITH SURFACE DRESSING 29–8
2908 MAINTENANCE WITH SAND SEAL 29–8
2909 MAINTENANCE WITH FOG SEAL 29–8
2910 REPAIR OF BRICK SHOULDERS/FOOTHPATHS 29–9
SECTION 2900 - MAINTENANCE WORKS
2901 SCOPE
The works mentioned in this Section shall apply to maintenance of road and shall be carried
out manually or by machinery in such a way that the quality of end product meets the specified
requirements. Whenever the Specification is not clear, good engineering practice shall be
applied to the satisfaction of the Engineer.
This Section does not apply to the works as specified in Clause 107 (Maintenance of Road
during Construction and Defects LiabilityPeriod).
2902 RESTORATION OF RAIN CUTS
The work shall consist of restoration of rain cuts in embankment slopes. The material to be
used in the restoration shall be the suitable material conforming to Clause 902.
The affected area shall be cleared of all loose materials and benched to a width of about 300
mm. The height of the bench shall vary according to the slope of the embankment. Suitable
material shall be deposited in layers not exceeding 150 mm and shall be watered/dried as
required and compacted using suitable tools or hand compactor. The final slope and top
surface after completion of the filling shall match with the adjacent slope and surface of the
embankment.
Measurement
The work shall be measured in cubic meter.
Payment
Quantity measured as provided above shall be paid at the contract unit rate which shall be the
full and the final compensation to the Contractor as per Clause 112.
2903 MAINTENANCE OF EARTHEN SHOULDERS
The work shall include making up of irregularities on the shoulders to the required level and
crossfall by adding suitable materials or stripping excess materials and compacting it.
Wherever material is required to be added, the earthen shoulder shall be stripped and
loosened upto 100mm depth measured from the existing ground level. The deficiency of
thickness shall be made up with suitable material as defined in Clause 902 in layers of loose
thickness not exceeding 150 mm. Water shall be added, if required and thoroughly compacted
with appropriate equipment to obtain at least 95 % of the MDD in accordance with IS 2720 Part
8.
SECTION 2900 MAINTENANCE WORKS Page

29–1
Wherever the material from the shoulder is required to be excavated, this shall be done by
manual means using hand tools or appropriate equipment as directed by the Engineer and
shall be compacted, to the 95% of the MDD.
The final surface formed either by addition or excavation of materials shall be uniform, with the
cross slope towards the edge of the road width. The top surface along the inner edge of the
shoulder shall be flushed with that of the adjacent carriageway.
Measurement
Maintenance of earthen shoulder shall be measured in square meter.
Payment
Maintenance of earthen shoulder shall be paid as per contract unit rate which shall be the full
and the final compensation to the Contractor as per Clause 112.
2904 MAINTENANCE OF GRAVEL SHOULDERS AND GRAVEL CARRIAGEWAY
The works shall involve repairing of pot holes and making up of irregularities/loss of materials
by adding fresh gravel and /or stripping excess gravel from the surface.
Gravel shall comply with the requirements of Clause 1204 for shoulders and Clause 1205 for
gravel wearing course.
Pothole Repair
Each pothole shall be inspected and all loose material shall be removed. The area shall be cut
down to the subgrade level in a rectangular shape. The edges shall be cut vertically. The
subgrade shall be cleared of all loose materials and hand compacted. Fresh gravel shall be
placed in the pit in layers not exceeding 150 mm and the gravel shall be brought to optimum
moisture content and well compacted with small rollers or other equipment as directed by the
Engineer. The resulting surface shall match with adjacent surface.
Shoulder/Carriageway Repair
The work shall involve:
(a) Making up the irregularities/loss of material by adding suitable gravel and compacting
the same; and/or
(b) Stripping extra gravel from the surface to achieve the required grade and level.
Wherever extra gravel is required to be added, the existing surface shall be loosened
upto 100mm depth to receive fresh gravel. The deficiency of thickness shall be
corrected by adding suitable gravel in layer of 100 mm. The gravel shall be brought to
optimum moisture content and thoroughly compacted using roller/compactor to
achieve the density as specified in Clause 1205.

29–2
Wherever the existing gravel is required to be excavated, this shall be done manually
or using equipment like grader. The resulting surface shall then be watered, if required,
and thoroughly compacted to achieve the density as specified in Clause 1205.
The finished surface shall have the specified line, level and cross slope. Straight edges
shall be used to check the profiles.
Measurement
The maintenance of gravel shoulder and gravel carriageway shall be measured in square
meters.
Payment
The maintenance of gravel shoulder and gravel carriageway shall be paid at their respective
contract unit rates which shall be the full and the final compensation to the Contractor as per
Clause 112.
2905 BITUMINOUS PATCH WORKS

]
This Clause covers the repair of the potholes and the damaged bituminous surface.
(1) Excavation
The area to be repaired shall be marked out in square or rectangular shape, 30mm
beyond the extent of the damaged area and shall be excavated with all sides vertical
upto required depth.
If the existing road base is damaged, it shall be also excavated to a depth required and
removed as directed by the Engineer.
(2) Bituminous Patching
(a) Shallow Patching
Shallow patching shall consist of repairs to the carriageway surface to a depth

not exceeding 40mm.
The surface of the excavated area shall be swept clean of dust and other
loose materials and shall be primed with MC 30 cutback bitumen. The sides
shall also be tacked/primed with cut back bitumen using brush. The excavated
area shall, then, be filled with hot or cold premix material. The premix shall
have a net bitumen content of 5% to 6% by weight as directed by the Engineer
or as per design mix. The premix shall then be compacted using equipment
After compaction, the surface of the patched area shall be true to the lines and
levels of the surrounding existing surface.
(b) Deep Patching

29–3
Deep patching shall consist of repairs to the carriageway surface to a depth

exceeding 40 mm.
The surfacing and underlying courses shall be cut out in square or rectangular
shape with vertical sides and to the extent and depth specified by the
Engineer. The excavated hole shall be swept clean of dust and all other loose
material.
The excavated area in base and subbase shall be filled with approved
materials complying with the requirements of base or subbase, as applicable,
conforming to Section 1200 and shall be compacted in layers not exceeding
100 mm thickness or as directed by the Engineer.
The surface of the compacted base shall be primed with MC 30 cutback

bitumen and filled with hot or cold premix material and compacted as
described in shallow patching.
After compaction, the surface of the patched area shall be true to the lines and
levels of the surrounding existing surface.
(c) Carriageway Edge Repair
Where loss of bituminous surfacing exists at the edge of the carriageway

without damaging the base, edge repair shall be performed as described for
shallow patching.
Where damage of the edge extends into the base/subbase, the edge repair
shall generally be carried out as specified for deep patching. Excavation shall
be to a minimum width of 750 mm covering not less than 200 mm of the
carriageway and not less than 500 mm of the shoulder. The depth of
excavation shall be as directed by the Engineer.
The excavated area shall be filled with base and/or subbase material to a level
40 mm below the existing level of the road and compacted as mentioned in
deep patching. The surface of compacted base and sides of the excavated
area shall be primed/tacked with MC 30 cut back to a line 100 mm beyond that
of the deep excavation and excavated area shall be filled with hot or cold
premix material and compacted as specified for the shallow patching.
The final surface shall match with the adjacent surface in line and levels.
(3) Tolerances
On completion, the patch shall have the tolerances of -0mm/+6mm, under a straight
edge laid across it.
(4) Measurement
The shallow/deep patching and carriageway edge repair shall be measured separately
in square meters.
Earth excavation and supply of materials to be used deemed included in the
measurement.

29–4
(5) Payment
The shallow/deep patching and carriageway edge repair shall be paid at their
respective contract unit rates which shall be the full and the final compensation to the
Contractor as per Clause 112.
2906 MAINTENANCE WITH SLURRY SEAL
This Clause covers the materials, methods of construction and requirements for the
maintenance works with slurry seal.
Slurry seal shall generally be required in the pretreatment of the pavement surface distress
such as cracks, ravelling etc.
(1) Materials
(a) Stockpilling of Aggregates

Sites for the stockpilling of aggregates shall be prepared in such a manner that
no grass, mud, soil, dust or other deleterious material will be included when
the aggregates are loaded for use.
(b) Bituminous Binders
The binder shall be K3-60 slow setting bitumen emulsion or as agreed by the
Engineer.
(2) Types of Slurry Seal
According to nature and severity of the distress, three types of slurry seal will be
applicable.
- Fine Slurry Seal (i)

- General Slurry Seal (ii)
- Coarse Slurry Seal (iii)
General slurry seal shall be applicable in porous and cracked road surfaces, whereas
fine slurry seal shall be used in case of narrowly cracked road surface. For widely
cracked and ravelled surface, coarse slurry seal with max. aggregate size of 10mm
shall be used as per Clause 1306.
(i) Fine Slurry Seal Mix
A mix, as detailed below will cover approximately 205 sq.m of road.
Aggregate 1 cu.m. (bulk)
Emulsion 250 litres
Cement 17 kg
Water as required
The grading of the aggregate shall be as per Clause 1306.

29–5
(ii) General Slurry Seal Mix
A mix, as detailed below, will cover approximately 180 sq.m. of road.

Emulsion 250 litres
Cement 17 kg
Water as required
(iii) Coarse Slurry Seal Mix
A mix, as detailed below will cover approximately 150 sq.m. of road.

Emulsion 250 litres
Cement 17 kg
Water as required

Maximum batch sizes for each slurry seal mixes will be in the order of 20 kg.
Daily records of consumption of materials and of areas covered shall be kept

and agreed with the Engineer.
(3) Equipment and Mixing
(a) Sufficient equipment for handling and hauling aggregate and binder shall be
used in order to ensure prompt and continuous covering of bituminous slurry
seals as specified. All the necessary ancillary equipment and hand tools to
carry out the work efficiently shall be available.
(b) In general a rotary type concrete mixer will be suitable to prepare slurry seal
mix at the site itself unless otherwise alternative arrangement made by the
Contractor to the satisfaction of the Engineer. The concrete mixer may be
mounted at the back of a flat bottom truck which is also loaded with stock of
materials (aggregate, emulsion, cement) for slurry seal mix. Measured
quantities of material to prepare a batch of slurry seal mix shall be poured into
the drum of the concrete mixture which shall then be rotated manually till an
uniform mix of slurry seal is formed. The time of mixing shall be carefully
controlled. Over mixing shall not be allowed as stripping of the bituminous film
from the aggregate will occur. The slurry seal mix shall then be discharged
over the road surface prepared as mentioned below.
(4) Surface Preparation for Slurry Seal
The road surface shall be broomed and cleaned of all loose or deleterious material by
means of rotary broom and hand broom.

29–6
A tack coat shall be applied by an approved distributor or manually as directed by the

Engineer at the rate to leave residual bitumen emulsion of 0.20 litre/sq.m. During
spraying there shall be no ponding of binder in hollows or depression and any such
excess of binder shall be removed. Portions of kerbs and channels, bridge kerb and
railing which will be exposed, shall be suitably protected when applying tack coat.
(5) Application of Slurry Seal Mix
The slurry seal mix will be applied manually. The mix shall be spread uniformly over
the road surface with the help of brooms, spades and other suitable tools so as to
ensure that all cracks on road surface are properly filled and sealed and resulting
surface becomes impervious to ingress of water. The application of slurry seal mix
shall not be done in adverse weather condition as mentioned in Clause 1102.
Bituminous emulsion in drums shall not be allowed to freeze. In case where it is
suspected that they could freeze then they shall be removed from site.
(6) Measurement
Slurry seal shall be measured in square metres.
(7) Payment
Slurry seal shall be paid at the contract unit rate which shall be the full and the final
compensation to the Contractor as per Clause 112.
2907 MAINTENANCE WITH SURFACE DRESSING
The work shall be done in conformity to Clause 1303, except that the use of small and portable
equipment shall be permitted.
2908 MAINTENANCE WITH SAND SEAL
The works shall be carried out in conformity with Clause 1305, except that the use of small and
portable equipment as well as labour based technique shall be permitted.
2909 MAINTENANCE WITH FOG SEAL
Fog seal shall consist of an application of emulsified bitumen without any aggregate cover for
sealing the fine hair cracks like shrinkage cracks and alligator cracks .
(1) Material
Slow setting K3 - 60 bituminous emulsion shall be used.
(2) Application
The area to be applied with fog seal shall be thoroughly cleaned with compressed air,
scrubbers etc. The cracks shall be cleaned with pressure air jet to remove all dirt, dust
etc. The fog seal shall be applied at the rate of 0.5-0.9 litre/sq.m using equipment like a
pressure tank, with flexible hose and spraying bar. Traffic shall be allowed on the

29–7
surface after the seal has set to a non tacky and firm condition so that it is not picked
up by the traffic.
(3) Measurement
The fog seal work shall be measured in square meter.
(4) Payment
The fog seal work shall be paid at the contract unit rate which shall be the full and the
final compensation to the Contractor as per Clause 112.
2910 REPAIR OF BRICK SHOULDERS/FOOTPATHS
(1) Materials
Damages to the brick shoulders/foothpaths shall be repaired using materials of equal

or higher standard than the original shoulders/footpaths materials.
(2) Construction
The damaged area shall be marked out in rectangular shape and shall be excavated
with all sides vertical.
If the existing base/subbase is damaged it shall be excavated to the required depth

and removed as directed by the Engineer.
The surface of the excavated surface shall be swept clean of dust and loose materials
and shall be filled with base/subase and compacted. On the prepared base brick shall
be laid in the same pattern as the adjoining surfaces and properly tamped.
The repaired surface shall be to the true profile to facilitate free drainage.
(3) Measurement
The brick shoulder/footpath repair work shall be measured in square meter.
(4) Payment
The quantity measured as above shall be paid at the contract unit rate which shall be
the full and the final compensation to the Contractor as per Clause 112.

29–8
SECTION 3000 - SUB-SURFACE GEOTECHNICAL INVESTIGATIONS
Page No.
3001 SCOPE 30–1

3002 FIELD INVESTIGATION 30–1
3003 METHOD OF EXPLORATIONS 30–2
3004 LABORATORY TESTING 30–10
3005 WATER SAMPLES 30–10
3006 CONCLUSIONS AND RECOMMENDATIONS 30–11
3008 PAYMENT 30–11
APPENDIX 30.1 (3 PAGES)
SECTION 3000 - SUB–SURFACE GEOTECHNICAL INVESTIGATIONS
3001 SCOPE
For the design of foundation, the scope of subsurface exploration shall be to determine soil
parameters and rock characteristics and their suitability by insitu testing or testing of
samples/cores taken out of exploration. It shall be planned in such a way that the profiles of
different types of soil and/or rock up to the desired depth for at least in the full length of the
proposed bridge are recorded and other information such as physical/mechanical properties
like grain size distribution, sensitivity, existence of deleterious materials, etc. in soil and/or
ground water etc. are also determined.
3002 FIELD INVESTIGATION
Unless otherwise specified, the field investigation of subsurface shall be carried out in three
phases, namely, Reconnaissance, Preliminary Explorations and Detailed Explorations.
(1) Reconnaissance
It shall include review of available topographic and geological information, aerial

photographs and data from previous investigations and site examination.
(2) Preliminary Explorations
It shall include the study of existing geological informations, previous site reports,
geological maps/aerial photos interpretetions, and sub-surface geological examination.
Geophysical investigations of the site shall also be conducted during this phase in
order to have information about stratifications. Detail subsoil exploration shall be
planned depending on these information.
Preliminary exploration shall be carried out to determine the soil profile showing the
boundaries between the different types of soil and between loose and dense parts in
the same type of deposits. For this purpose, as a first step, a suitable type of sub-
surface sounding (e.g. static or dynamic cone penetration test) shall be carried out. As
many soundings as necessary shall be made until penetration data is complete to
provide the general shape and the trend of boundaries of the various soil deposits.
Exploratory drill holes shall then be made at one or two locations where average
condition prevails and near those points where the penetration diagrams indicate
maximum deviations from the average.
(3) Detailed Explorations
The scope of the detailed exploration shall include boring programme based on data
obtained after preliminary investigations. The bridge site, types of structure with span
arrangement and the location & type of foundation shall be tentatively decided based
on data obtained after preliminary investigations. Extent of explorations, number of
boreholes, type of soundings, types and number of tests, open trial pits, etc., shall be
decided for the execution of the exploration so as to collect adequate data considered
necessary for the detailed design and execution of the related structure.
SECTION 3000 SUB-SURFACE GEOTECHNICAL INVESTIGATIONS Page 30–

1
For bridge works, the investigations shall be comprehensive enough to enable the
designer to estimate or determine the followings:
(a) the engineering properties of the soil and/or rock,

(b) the location and extent of soft layers under the hard founding strata,
(c) the geological condition like type of rock, faults, fissures or subsidence due to
mining, porosity etc.,
(d) the ground water level,
(e) artesian conditions, if any,
(f) the location, type and extent of different layers,
(g) quality of water in contact with the foundation,
(h) probable settlement and probable differential settlement of the foundations,
(i) likely sinking or driving effort,
(j) likely construction difficulties,
(k) the depth and extent of scour,
(l) suitable depth of foundation, and
(m) bearing capacity of the foundation.
3003 METHOD OF EXPLORATIONS
Any of the following methods of exploration or their combination shall be used depending upon
type of structure and strata.
(a) Geophysical Exploration

(b) Test/Trial Pits
(c) Boring
(d) Static Cone Penetration Test
(e) Dynamic Cone Penetration Test
(f) Plate Load Test
(g) In-situ Vane Shear Test
(1) Geophysical Exploration
Use of geophysical methods shall be limited to the detection of voids, buried channels
or rock mass classification.
The two main geophysical methods to be used shall be:
(a) Electrical Resistivity Method.

(b) Seismic Method.
(2) Test/Trial Pits
Test/trial pits shall be used for direct visual examination of the soil and its stratification
including water table. This will also allow for the execution of in-situ tests like plate
bearing tests, shear tests, etc. A test/trial pit shall be at least 1m square at the bottom
of the pit. The depth of the pit shall be 3 m, unless otherwise specified. Below a depth
of about 1.5 m, the sides of the pit shall be supported or shall be excavated at safe
angle. Pits shall be left open for some time so that seepage lines on the sides of the pit
can be examined and the existing ground water level can be indicated.

2
(3) Borings
Boring a hole shall be started by driving casing to prevent it from caving in. Casing
shall be cleaned by means of chopping bit, etc., with the water pumped through drill
rod and water overflows at the top carrying soil particles. The hole shall be advanced
by raising, rotating and dropping the bit into the soil at the bottom of the hole. In rotary
boring, drill bit shall be rotated with the simultaneously application of pressure to
advance the hole. In case where sample disturbance is not critical, hand or powered
auger boring can also be carried out with the prior approval of the Engineer.
(A) General Requirements of Boring/Drilling

The equipment for boring shall be automatic hydraulic or mechanical feed with
properly working indicator of drilling pressure. The equipment shall be with
transmission gear to adjust spindle speed. The Contractor shall supply all
necessary flush water for the execution of boring and pertinent tests. Clear
water shall only be used. Nevertheless, the equipment shall be capable of
handling mud flush.
The barrels for boring shall be double tube core barrel. Only in certain
circumstances, use of single tube core barrel shall be allowed.
The drilling machine shall be equipped with different sizes of casings in order
to allow proper telescoping of definite sizes. The final diameter of the borehole
shall be such that allows extraction of samples with proper dimension in order
to properly conduct tests, such as consolidation, shear, triaxial, permeability,
etc.
(B) Methods of Boring
Boring shall be done by any of the methods mentioned below depending on

the soil type and types of samples required for the investigation.
(a) Auger Boring (Manual and Mechanical)

(b) Percussion Boring
(c) Wash Boring
(d) Rotary Boring
(a) Auger Boring
(i) Hand Auger Boring
In the hand auger boring method, light hand operated

equipment shall be used. The auger and drill rods shall be
lifted out of the borehole without the aid of a tripod and no
borehole casing shall be used. Boreholes up to 200 mm
diameter shall be made in a suitable ground condition up to a
depth of about 5.0 m. Hand auger boreholes shall be used for
ground water observations and to obtain disturbed samples
and small tube samples.

3
(ii) Mechanical Auger Boring
Small portable power augers, shall be suitable for boring to

depth of 10 – 15 m. The hole diameter shall be in the range of
75 to 300 mm.
(b) Percussion Boring
Adaptation of standard boring methods shall be suitable for soil and

weak rock. The size of the borehole casing and tools shall generally
be 100 mm, 150 mm, 250 mm and 300 mm giving a maximum
borehole depth of about 60 m in suitable strata. The drill tools, hooked
on a wire rope using the clutch of the winch for the percussion action,
shall be a clay cutter for dry cohesive soils, a shell or baler for
cohesionless soils and a chisel for breaking up rock and other hard
layers. The clay cutter and shell shall bring up disturbed material for
laboratory testing and identification of strata.
(c) Wash Boring

Wash boring shall be carried out as per IS, BS , ASTM or equivalent
standard.
(d) Rotary Drilling
In rocky strata rotary drill shall be used. Open hole drilling, in which
the drill bit cuts all the material within the borehole, shall be used for
more rapid progress in hard material. Better quality samples of soil
and rocks shall be obtained using core drilling, in which an annular bit
fixed to the bottom of outer rotating tube of a rotary core barrel cuts a
core, which is retained within the inner stationary tube of the core
barrel and brought to the surface for examination and testing.
(C) Size of the Borehole for Sampling
Rotary drills and/or purcussion drilling shall be used for getting undisturbed
soil sample. The size of casing shall be sufficient to provide space for
retrieving undisturbed sample by sampler tube for soil. For rock sample, the
size of casing shall be sufficient enough to allow use of single or double tube
barrel as required for retrieving core sample.
(D) Condition of Boring
While conducting detailed borings, the resistance to the speed of drilling i.e.
rate of penetration, core loss, etc., shall be carefully recorded to evaluate the
different types of strata and to distinguish specially sand from sandstone, clay
from shale, etc.
For good coring either in soil or in rock, the driller shall carefully watch and
record the speed of the rate of cutting of bit, bit pressure, bit feed , pump
pressure and discharge.

4
(E) Extent of Boring
The depth of boring shall depend upon the type of proposed structure, its total
weight, and type of subsoil encountered. Normally tests shall be taken down
below the foundation level depending upon the type of foundation e.g.:
(a) foundation requiring shallow depth: up to a depth where the

magnitude of stress due to
the structure load is equal to
10% of the overburden
pressure, but at least one
boring shall be made deep
enough preferably up to hard
strata or rock to ascertain
the existence of any
exceptionally compressible
stratum that are unsuitable
for foundation
(b) for rock foundation: until sound bed rock is
reached and confirmed by at
least 3 m coring by rotary
drilling. In sound bed rock
more than 6m drilling may
not be required. In residual
profile it may be necessary
to drill further 3 m to
differentiate rock from the
boulder.
The spacing of borings shall be such as to reveal any major changes in the
thickness or properties of the strata over the base area of the structure and in
its immediate vicinity.
A preliminary estimate of spacing may be modified depending upon the

information revealed by boring. The Boring Agency shall notify the Engineer
the situation and shall seek his approval for such modification(s).
(F) Records of Test/Trial Pits and Borings
For all test/trial pits and borings, general information as detailed below shall be
given. A site plan showing the position of the bore holes/trial pits shall also be
attached.
(i) Boring Company
(ii) Location with reference map
(iii) Pit /Bore -hole number
(iv) Reduced level (R.L.) of ground surface or other reference point with
arbitrary permanent Bench Marks
(v) Dates of starting and completion
(vi) Name of supervising engineer and driller
(vii) Dimensions and methods of advancing exploration

5
(viii) Any other information and remark including weather/climatic condition,

difficulties encountered, etc.
(G) Bore Hole Log
The final bore hole log shall be based on the visual examination, description of
the samples, laboratory test results, driller's daily report forms and geology of
the site. All the relevant data collected by the driller, once checked and
amended where necessary, shall be recorded. The bore hole log shall be
maintained in the format shown in Appendix 30.1
The bore log shall contain the elevation at which the water table and the upper
boundary of each of the successive soil strata were encountered, the
investigator's classification of the layer on the basis of general information
obtained from field examination and the value of the resistance obtained by
means of Standard Penetration Test (hammer wt.65 kg & falling height 75 cm
for rotary drilling attached with standard split barrel sampler at the bottom
connected with drill rod ) or Static Cone Penetration as specified. The type of
tools used for boring shall be recorded. If the tools were changed, the depth at
which the change was made and the reason thereof shall also be noted.
Incomplete and abandoned borings shall be described with no less care than
successfully completed drill holes. The notes shall contain everything of
significance observed on the job, such as the elevation at which wash water
was lost from the whole, etc. All field and final logs shall be signed by the
supervising Engineer.
(H) Sample Core Recovery and Core Boxes
Only samples that are unaltered and not damaged by drilling process shall be
considered as core. Core drill shall be so designed that in sound rock,
continuous recovery is achieved. Run shall be short in order to achieve
maximum core recovery. Where there is core loss, it shall be noted on field
borelog. It shall be shown by placing wooden stick in the core box so that
Engineer can judge how much core has been achieved.
For getting disturbed soil (granular) sometime water is circulated down the
hollow rods which return outside them, carrying the rock cutting to the surface
as sludge. These shall be retained as samples in transversing friable rock
where cores cannot be recovered. It shall be ensured that boulders or layers
of cemented soils are not mistaken for bedrock. For laboratory determination
of uniaxial compressive strength of rock materials, the final size or dimensions
(minimum) of the specimen shall be after trimming in the form of circular
cylinder having height to diameter ratio of 2.5 to 3.0 and the diameter of core
shall not be less than 54.7 mm.
Sufficient quantity of core boxes shall be available at site before the

commencement of boring. Further drilling works shall be stopped if it is found
that boring is carried out without core boxes and undisturbed sampler tube.
The core box shall be made of good and durable material. The boxes shall
bear lids and hinges. The files inside the core boxes shall have a length of
1.05 m.

6
Cores shall be placed in core boxes in a proper order and direction. The end
of each core run shall be marked by a cross piece with indication of depth. The
box shall provide information on borehole, depth of corresponding core,
number of box etc. The coreboxes shall be transported to the location
instructed by the Engineer. The provided core with coreboxes shall be
available for inspection as and when required by the Engineer. The boxes
shall be the property of Department of Roads.
The cores shall be carefully extracted out of the core barrel and placed in core
boxes. Core shall correspond each time to the fixed depth with accuracy of 1
cm.
A minimum core recovery of 80 % in hard rock and 50 % in other strata

(except sand strata) shall be achieved. If possible none or minimum quantity of
water shall be added while boring through soft cohesive soils and
cohesionless soils above water table in order to maintain its natural moisture
content and stress condition for further in-situ and laboratory tests.
(I) Sampling
There shall be two types of samples, (a) Disturbed sample and (b)
Undisturbed sample. The usual methods for sampling shall be as stated
below.
(i) Disturbed Sample
(a) Soil
Types of disturbed samples shall be:
 Hand Samples
 Auger Samples
 Sludge Samples
 SPT Sample
 Sample Extracted from Barrel
Disturbed samples shall be obtained in the course of

excavation and boring. For taking samples from below the
ground water level, special type of sampler shall be used.
Where standard penetration test is conducted, representative
samples shall be obtained from the split spoon.
Quantity of samples required for laboratory testing shall not

be less than as shown in Table 30.1.
Table 30.1: Required Quantities of Samples
S.No. Purpose of sample Soil type Wt. of sample

(kg)

7
1. Identification, Natural moisture content, Soil 2

Mechancial analysis and index
properties
2. Identification, Natural moisture content, Sand 5
Mechancial analysis and index
properties
3. Identification, Natural moisture content, Fine to 5
Mechancial analysis and index medium type
properties of gravel
4. Identification, Natural moisture content, Coarse 30
Mechancial analysis and index gravel
properties
(b) Rock
The sludge from percussion borings or rotary borings which

have failed to yield a core shall be collected as disturbed
samples. It may be recovered from circulating water by
settlement in a trough.
The types of disturbed samples shall be:
 Wash Samples from Drilling

 Sludge Samples
(ii) Undisturbed Samples
(b) Soil
Samples shall be obtained in such a manner that moisture

content and structure do not get altered. This shall be
ensured by careful use of correctly designed sampler,
protection and packing.
Type of undisturbed sampling sampler shall be as follows:
A. Block sampling (Hand Samples) shall be carried out by

manual excavation inside the trench or pit.
B. Thin-walled Sampler Tube : for soft and firm soils

(internal diameter 75mm to 250 mm)
C. Open Tube Sampler : for firm to stiff clays, disturbed

samples for weak rock (100mm diameter open tube
sampler, like U100 )
D. Stationary Piston Sampler : for soft sensitive clays,

noncohesive fine grained soil and firm to stiff soils not
containing coarse material.

8
E. Sand Sampler: for silts and sands below the water table
(like Bishop sand sampler)
For compression test, samples of 40 mm diameter and 150

mm to 200 mm length may be sufficient, but for other
laboratory tests, samples of 100 mm diameter and 300 mm
length shall be taken unless otherwise instructed by the
Engineer.
While preparing samples the upper few millimeters of sample

shall be removed.
(b) Rock
A. Block samples : Such samples taken from the rock

formation shall be dressed to a size about 90x75x50 mm
B. Core samples : Cores of rock shall be taken by

means of
rotary drills fitted with a coring bit with core retainer
and the diameter of core shall be as mentioned in Sub-
clause 3003 (3) (H).
Frequency of sampling shall be at every change in stratum

and at intervals not exceeding 1.5 m within a continuous
stratum.
(J) In situ Test on Boreholes
In course of boring works, in situ test as mentioned below shall be carried out
for the determination of bearing capacity. Other tests like permeability, etc.
shall also be carried out as directed by the Engineer. In particular, following
tests shall be conducted:
(i) Standard Penetration Test (SPT)

(ii) Vane Shear Test
(iii) Insitu Deformation Properties and Strength Measurements from a
borehole using Pressuremeter.
(iv) Other tests as applicable.
Where undisturbed soil sampling, in-situ vane shear test and SPT are to be
carried out in one layer, the sequence shall be undisturbed soil sampling
followed by in situ vane shear test and SPT.
(K) Protection, Handling and Labeling of Samples
Care shall be taken in handling, labeling and transportation of samples so that

they shall be received in an acceptable state for identification, examination
and testing.

9
The disturbed material in the upper end of the tube shall be completely
removed before applying wax for sealing. The length and type of sample so
removed shall be recorded.
The soil at the lower end of the tube shall be reamed to a distance of about 20
mm. After cleaning, both ends shall be sealed with wax applied in a way that
shall prevent wax from entering the sample. Wax used for sealing shall not be
heated to more than a few degrees above its melting temperature. The empty
space in the samplers, if any, shall be filled with moist soil, saw dust etc., and
the ends shall be covered with tight fitting caps.
(4) Static Cone Penetration Test
This test shall be carried out for deep foundation of bridges for cohesive soil according
to the stipulations of IS: 4968 (Part 3) or equivalent standard.
(5) Dynamic Cone Penetration Test
This test shall be carried out as per IS: 2131. Wherever applicable, this test shall also
be carried out as per IS: 4968 (Parts 1&2).
(6) Plate Load Test
For cohesionless soil in deep foundation, plate load test shall be carried out as per IS:
1888.
(7) In-situ Vane Shear Test:
Vane shear test shall be conducted as per IS: 4434 on cohesive soil for deep
foundation.
(8) Exploration for Foundation Resting on Rock
The basic information to be obtained from the exploration shall be as follows:
(i) Depth of Rock strata and its variation over the site
(ii) Whether isolated boulder or massive rock formation,
(iii) Extent & character of weathered zone
(iv) Structure of rock- including bedding planes, faults, fissures, solution cavities etc.
(v) Properties of rock material strength, geological formation etc.
(vi) Erodibility of rock to the extent possible.
(vii) Colour of water/sludge
(9) Investigation for Conglomerate
The investigation shall be generally to that required for rock. The samples collected
shall be subjected to suitable tests depending upon the material. Care shall be taken to
ascertain erodibility of the matrix. For shallow foundation, Plate Load Test shall be
conducted.
(10) Investigation for Laterites

10
The investigation shall be generally similar to that required for cohesive soils, use of
penetration tests shall be preferred if suitable correlation charts are available. This may
be static or dynamic penetration tests or vane shear tests. In the case of hard laterite,
recourse may have to be made to core drilling as for soft rocks. For laterites at shallow
depths, Plate Load Test shall be conducted.
(11) Supervision of the Work
The supervision of the work shall be the carried out by a qualified and experienced
Engineer.
The driller shall be experienced and also responsible for recording the information
obtained from the bore hole.
3004 LABORATORY TESTING
Laboratory tests shall be carried out on disturbed, undisturbed samples and on rock extracted
by pitting or boring as per requirements for the related type of structure. Tests shall be carried
out among the followings as per contract or as directed by the Engineer:
 Grain Size Analysis

 Hydrometer Analysis
 Bulk and Dry Density
 Specific gravity
 Natural Moisture Content
 Atterberg's Limit Tests
 Unconfined Compression Test
 Consolidation Test
 Direct Shear Test
 Sulphate and Chloride test
 Vane Shear Test
 Point Load strength test on rock
 Uniaxial compressive strength Test
 Triaxial Tests:
- Unconsolidated Undrained Test
- Consolidated Undrained Test
The above test shall be carried out as per Section 600 of these Standard Specifications.
3005 WATER SAMPLES
If a trial pit has been excavated or a well exists near the site of exploration, water samples shall
be collected. In the case of boring, it shall be collected from the borehole with the help of a
common suction pump having a hose pipe, rubber tubing etc. which can be conveniently
lowered down into the borehole connected at the suction end. Minimum 5 lit. of water sample
shall be collected into a clean vessel and sent to the laboratory for chemical tests. Tests shall
be carried out in accordance with IS: 3025 or equivalent standard as per direction of the
Engineer.

11
3006 CONCLUSIONS AND RECOMMENDATIONS
The investigation shall conclude with the recommendation for the proper type of foundation for
the related structure. The recommendation shall be supported by all details of investigations
and their results.
3007 MEASUREMENT
Boring in rock and/or soil shall be measured separately in linear metre with reference to the
ground level in the following multiples:
(a) from ground level upto 3.00 m of depth

(b) from 3.00 m upto 6.00 m of depth
(c) from 6.00 m upto 9.00 m of depth
(d) from 9.00 m upto 12.00 m of depth
(e) from 12.00 m upto 15.00 m of depth
(f) from 15.00 m upto 18.00 m of depth
(g) from 18.00 m upto 21.00 m of depth
(h) from 21.00 m onward in the multiple of 1m of depth
Trial pits shall be measured in cubic metres. Collection of disturbed and/or undisturbed
samples including provision for transportation and storing of core boxes shall be measured in
number. Each type of tests shall be measured in number. Mobilisation, demobilisation and
shifting of equipment from one borehole to other borehole shall be measured separately.
3008 PAYMENT
Boring, trial pits, collection of samples, testing of samples and submission of reports in required
number shall be paid at their respective contract unit rates which shall be the full and final
compensation to the Contractor as per Clause 112 and also for the cost of all other operations
and incidental works deemed necessary to complete the work as per the these Specifications.
Mobilization, demobilization and shifting of equipment from one borehole to other borehole
shall be paid separately on lump sum basis.

12
SECTION 3100 - MISCELLANEOUS WORKS
Page No.
3101 SCOPE 31–1

3102 PRECAST MEMBERS 31–1
3103 OPEN JOINTS, FILLED JOINTS, BOARD FILLERS AND SHEET PACKING 31–1
3104 WEARING COAT 31–2
3105 RAILINGS 31–3
3106 APPROACH SLAB 31–5
3107 DRAINAGE SPOUTS 31–5
3108 UTILITY FACILITIES 31–6
3109 WEEP HOLES 31–7
3310 FILTER MATERIALS 31–7
SECTION 3100 - MISCELLANEOUS WORKS
3101 SCOPE
This Section cover the works related to the construction of miscellaneous works such as
precast members, joints, wearing coat on drainage structure, railings, approach slab, drainage
spouts and weep holes. These miscellaneous works are to be constructed in connection with
the structures.
3102 PRECAST MEMBERS
(1) Materials
Concrete and reinforcement for precast members shall comply with Section 2000.
(2) Placing Pre-cast Member
Pre-cast concrete members shall be placed in the structure in conformance with the
Drawing and any special provisions for the structure to be constructed. Extreme care
shall be exercised in handling, storing and erecting pre-cast reinforced or pre-stressed
concrete members to avoid twisting, racking or other distortion that would result in
cracking or damage to the members. Pre-cast members shall be handled, transported
and erected in an upright position and the points of support and directions of the
reactions with respect to the member shall be approximately the same as when the
member is in it's final position.
(3) Measurement
Depending upon the nature of works, pre-cast members shall be measured in

numbers, cubic meters or metric tonnes as specified in the Contract. Reinforcement
shall not be measured for payment.
(4) Payment
The quantities measured as provided above shall be paid at the contract unit rate
applicable for the particular type of work. The contract unit rate shall be the full and the
final payment to the Contractor as per Clause 112 to complete the work as per these
Specifications.
3103 OPEN JOINTS, FILLED JOINTS, BOARD FILLERS AND SHEET PACKING
(1) Open Joints
Open joints shall be constructed at the locations shown in the Drawing using suitable
stops, which are to be subsequently removed. When removing the material, care shall
be exercised to avoid chipping or breaking the corners of the concrete. The edges of
the concrete, at the joints, shall be properly finished. Reinforcement shall not extend
across an open joint, unless otherwise shown on the Drawing.
SECTION 3100 MISCELLANEOUS WORKS IN CONNECTION WITH STRUCTURES Page

31–1
(2) Filled Joints
When pre-moulded joint filler or expanded polystyrene joint filler or other type of joint
filler is shown on the Drawing or specified, the filler shall be placed in correct position
before concrete is placed against the filler. Holes and joints in the filler shall be filled
with mastic to prevent the passage of mortar or concrete from one side of the joint to
the other. The edges of the concrete, at the joints, shall be properly finished. When
shown on the Drawing, water stops shall be placed. Unless otherwise specified the
joint filler shall have the prior approval of the Engineer.
(3) Board Fillers
Hardboard joint filler shall be minimum of 3mm thick and approved by the Engineer.
Expanded polystyrene board shall have a minimum flexural strength of 0.25 N/sq.mm.
and a compressive yield strength of 0.11 N/sq.mm minimum and 0.28 N/sq.mm
maximum at 5% compression. Vertical a face of polystyrene against which concrete is
to be placed shall be faced with hardboard of 3mm minimum thickness or other
equivalent material. Other board fillers may be used with the approval of the Engineer.
All board fillers shall be held in place with nails, a waterproof adhesive or other means
(4) Sheet Packing
Asbestos sheet packing shall have the approval of the Engineer. It shall be
approximately 1.6 mm thick unless otherwise shown on the Drawing or specified in the
contract and shall be composed essentially of asbestos firbres bound together with a
cementing medium rendering it tough and pliable. One side shall be coated with
graphite. The deformation of the packing under a load of 70 N/sq.mm shall not be more
than 16% and the loss on ignition shall not be more than 25%. When tested between
planed bronze plates under a load of 5 N/sq.mm the packing shall show a static
coefficient of friction of less than 0.4 after 100 lateral movements at 6.5 mm.
(5) Measurement
Open joints, filled joints, board fillers and sheet packing shall not be measured
separately.
(6) Payment
No separate payment for open joints, filled joints, board fillers and sheet packing shall
be made. The cost of such joints is deemed to be included in the unit rate of the
structures, where those joints are required to be formed.
3104 WEARING COAT
(1) Bituminous Wearing Coat
The wearing coat shall be the asphalt concrete/surface dressing and shall comply with
Section 1300.

31–2
(2) Cement Concrete Wearing Coat
Cement concrete wearing coat shall be provided in case of isolated drainage

structures constructed at those locations where the road is not being asphalted or the
drainage structures are not proposed to be asphalted. It shall not be laid monolithic
with the deck. Concrete shall comply with Section 2000.
The thickness of wearing coat shall be 75 mm. The minimum grade of concrete shall
be M 30/20 with water cement ratio of 0.4.
Curing of wearing coat earlier than what is generally required may be resorted to, so
as to avoid formation of shrinkage cracks in hot weather.
All carriageway and footpaths surface shall have non-skid characteristics.
The cross slope in the deck shall be kept as 2.5 percent. For providing cross camber
no variation in thickness of wearing coat shall be permitted.
(3) Measurement
Wearing coat shall be measured as provided under respective sections of these

specifications.
(4) Payment
Wearing coat shall be paid as provided under respective sections of these

specifications.
3105 RAILINGS
(1) General
(a) Railing includes the portion of the structure erected on and above the kerb or slab
for the protection of pedestrians and traffic as shown on the Drawing.
(b) Railings shall not be constructed until the false work for the span has been
released. For concrete with steel reinforcement, specifications of the items of
concrete and reinforcement mentioned under relevant Sections of these
Specifications shall be applicable.
(c) Railing shall be carefully erected true to line and grade. Posts shall be vertical with
a tolerance not exceeding 0.2%. The pockets left for posts shall be filled up
with the concrete of the same grade as the post.
(d) The type of railing to be constructed shall be as shown on the Drawing.
(e) Expansion joint in the railings shall be maintained to ensure proper functioning of
the joint.
(f) Railing materials, particularly metal railings, shall be handled and stored with care,
so that the material and parts are kept clean and free from damage. Railing
materials shall be stored above the ground on platforms, skids or other
supports and kept free from grease, dirt and other contaminants.
(2) Steel Railings

31–3
Materials, fabrication, transportation, erection and painting for railings shall conform to
the requirements of Section 2200.
All complete steel rail elements, pipe terminal sections, posts, bolts, nuts, hardware
and other steel fittings shall be galvanised or painted with an approved paint as
specified in the Contract.
If galvanized, all elements of the railing shall be free from abrasions, rough or sharp
edges, and shall not be kinked, twisted or bent. If straightening is necessary, it shall be
done by methods approved by the Engineer.
Galvanizing shall be carried out as per Clause 2209. Damaged galvanized surfaces,
edges of holes and ends of steel railing cut after galvanizing shall be cleaned and re-
galvanized.
The railing shall be carefully adjusted prior to fixing in place to ensure proper matching
at abutting joints and correct alignment and camber throughout their length. Holes for
field connections shall be drilled with the railing in place in the structure to the true
grade and alignment.
Unless otherwise specified in the Drawing, metal railing shall be given one shop coat
of paint and three coats of paint after erection if sections are not galvanised.
Steelwork which is to be cast or grouted into concrete shall be unpainted and shall be
cleaned of loose rust, scale, oil and other material which may impair the bond between
concrete and steel.
When shown on the Drawing, the rail elements shall be curved before erection.
(3) Cast-in-Situ Concrete Railings
The portion of the railing or parapet, which is to be cast in place, shall be constructed
in accordance with the requirements of Section 2000.
Forms shall either be of single width boards or shall be lined with suitable material duly
approved by the Engineer. Form joints in plane surfaces shall not be permitted.
All mouldings, panel work and level strips shall be constructed according to the details
shown on the Drawing. All corners in the finished work shall be true, sharp and clean-
cut and shall be free from cracks, spalls or other defects. Casting of posts shall be
done in single pour.
(4) Pre-cast Concrete Railings
Pre-cast members for railings shall be of reinforced cement concrete and shall
conform to the specifications given in Section 2000. The maximum size of the
aggregate shall be limited to 12 mm and the concrete grade shall be M30. The pre-cast
members shall be removed from the moulds as soon as practicable and shall be kept
damp for a period of at least 10 days. During this period they shall be protected from
sun and wind. Any pre-cast member that becomes chipped, marred or cracked before

31–4
or during the process of placing shall be rejected. Care shall be taken to watch the
surface of the cast-in-situ portion of the deck. Railing shall be erected to the true line
and grade with a tolerance not exceeding 0.2% in any one pannel.
(5) GI Pipe Railing with RCC Posts
(a) GI Pipe
GI pipe shall comply with NS: 199/2046 (Heavy Duty).
All GI pipes shall be free from abrasions, rough or sharp edges, and shall not
be kinked, twisted or bent. Any pipe which does not meet the requirements of
the Specifications shall be replaced at the Contractor's expense.
(b) RCC Posts
The concrete grade and type of reinforcements for concrete posts shall be as
indicated in the Drawing. The specifications for concrete and reinforcements
shall be as provided under Section 2000.
(6) Measurement
Railings shall be measured in linear meter of railing installed and accepted. Railing
shall include both horizontal and vertical members, posts including bolts, nuts, fittings
etc.
(7) Payment
Railing, measured as provided above, shall be paid at the contract unit rate. The
contract unit rate shall be the full and the final payment to the Contractor as per Clause
112 to complete the work as per these Specifications.
3106 APPROACH SLAB
(1) General
Reinforced concrete approach slab shall be provided at both ends of the drainage
structure as shown on the Drawing. The width, length and depth of the slab shall be as
shown on the Drawing. The minimum grade of concrete for approach slab shall be
M20/40.
The gap between the approach slab and superstructure shall be watertight by filling
the gap with approved joint filler. The type and thickness of the base of approach slab
shall be as shown on the Drawing and shall be constructed as per the requirements of
Section 1200. The concrete and reinforcements shall conform to Section 2000.
(2) Measurement
Approach slab and its base shall be measured separately in cubic meters.

31–5
(3) Payment
unit rates. The contract unit rates shall be the full and the final payment to the
Contractor as per Clause 112 to complete the work as per these Specifications.
3107 DRAINAGE SPOUTS
(1) Materials and General Requirements
Drainage along longitudinal direction shall be ensured by sufficient number of drainage

fixtures (spouts) embedded in the deck slab. The spouts shall be of not less than
100mm in diameter and shall be of heavy coated galvanised steel with suitable clean
out fixtures or as shown on the Drawing. Steel components shall be of mild steel
conforming to IS: 226. The spacing of drainage spouts shall not exceed 3m and shall
be in staggered pattern. The discharge from drainage spout shall be kept away from
the deck structure. In case of viaducts in urban areas, the drainage spouts shall be
connected with suitably located pipelines to discharge the surface run-off to drains
provided at ground level.
(2) Fabrication
The drainage assembly shall be fabricated to the dimensions shown on the Drawing.
The drainage assembly shall be seam welded for water tightness and then hot-dip
galvanised.
(3) Placement
The whole assembly shall be placed in true position, lines and levels as shown on the
Drawings with necessary cut-out in the shuttering for deck slab and held in place
firmly. Where the reinforcements of the deck are required to be cut, equivalent
reinforcements shall be placed at the corners of the assembly.
The galvanised pipes of drainage spouts shall be extended beyond the

concrete/metallic beams/slabs in such a way that the water from the pipes does not
damage them.
(4) Finishing
After setting of the deck slab concrete, the shrinkage cracks around the assembly shall
be totally sealed with polysulphide sealant or bituminous sealant as per IS:1834 and
the excess sealant trimmed to receive the wearing coat. After the wearing coat is
completed, similar sealant shall be finished to cover at least 50 mm on the wearing
coat surface all round the drainage assembly.
(5) Measurement
Drainage spouts shall not be measured separately. No deduction in concrete volume

shall be made for drainage spouts.
(6) Payment

31–6
Drainage spouts shall not be paid separately. The contract unit rate for concrete shall
be deemed to include costs for forming such spouts.
3108 UTILITY FACILITIES
(1) General
Utility facilities shall be carried in or on structures as shown on the Drawing or

described in the Contract. These facilities may be installed by the authorities
concerned or by the Contractor as described in the Contract or indicated on the
Drawing.
(2) Provision and Installation
Hangers, anchor bolt inserts, manhole frames and covers, sleeves and other
accessories required for such facilities, which must be cast in the concrete shall be
furnished by the respective authorities or the Contractor as described in the contract
and shall be installed by the Contractor in accordance with the details shown on the
Drawing or as directed by the Engineer. Utility facilities which require installation after
the concrete has been cast and before other construction is in place which would
interfere with it's installation, will be installed, either by the authorities concerned or by
the Contractor as directed by the Engineer at such times as the work is ready for their
installation. The Contractor shall notify the Engineer in writing at least 30 days in
advance of the proposed dates, which the work will be ready for installation of
accessories of utilities in the structure. The Engineer, in turn, shall make necessary
arrangements with the utility authorities.
(3) Measurement
Unless otherwise provided in the Contract, utility facility shall not be measured
separately.
(4) Payment
Unless otherwise provided in the Contract, utility facility shall not be paid separately.
The cost of utility facility shall be deemed to be included in the unit rates of different
items of work of structure.
3109 WEEP HOLES
(1) Weep holes
Weep holes shall be provided in solid plain concrete/reinforced concrete, brick/stone

masonry, abutment, wing wall, return walls or other structures as shown on the
Drawing or as directed by the Engineer. Weep holes shall be provided with 100mm dia
polythene pipe for structures in plain/reinforced concrete or brick masonry. In case of
stone masonry, weep holes shall be 100 mm wide, 100 mm high or circular with 100
mm diameter. Weep holes shall extend through the full width of concrete/masonry with
a slope of 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

31–7
lowest at about 150 mm above the low water level or ground level whichever is higher
or as directed by the Engineer. Surfaces of the weep holes shall be smooth and it shall
be ensured that the water is properly driven from the backfill.
(2) Measurement
Weep holes shall not be measured separately. No deduction in the volume of

structures shall be made for weep holes.
(3) Payment
Weep holes shall not be paid separately. The contract unit rate for respective items
shall be deemed to include costs for providing such holes.
3110 FILTER MATERIALS
(1) Materials
Filter materials shall be either gravel with geo-textile/geo-membrane or appropriately

graded sand/gravel material as shown on the Drawing or directed by the Engineer.
Where geo-textile/geo-membrane is provided or shown on the Drawing, the filter
material shall consist of gravel. It shall conform to the grading limits set out in Table
31.1.
Table 31.1: Filter Material Grading Limits
Sieve Size (mm) Percentage Passing by Weight

63 100
37.5 85 – 100
20 0 – 20
10 0–5
0.075 –
Geotextile shall comply with Section 600. Geomembrane shall comply with Sub-clause
2404 (2).
Where no geotextile/geomembrane are provided or shown on the Drawing, the grading

curve required for sand/filter material shall be determined for each site. Grading criteria
requirement for both underlying and overlying material shall be fulfilled. The criteria
shall be as follows:
d15% filter d 50% filter

a) <5 b) < 25
d 85% subsoil d 50% subsoil
d 15% filter
c) >5
d 15% subsoil
Where, d15% designates the 15% size of the material (i.e. the size of the sieve that
allows 15% by weight of the material to pass through it).

31–8
Similarly, d50% and d85% designate the sizes of sieve that allow 50% and 85%
respectively by weight of the material to pass through it.
(2) Construction
Surfaces receiving geo-textile/geo-membrane shall be free of loose or extraneous

materials and sharp objects. Geo-textile/Geo-membrane shall be placed in accordance
with the producer’s instructions or as instructed by the Engineer. The minimum
overlapping shall be 450 mm. If jointed in longitudinal direction by sewing or gluing, the
joint shall have the same strength as the fabric itself.
The filter material shall be compacted layer by layer to a minimum density of 93% of
the MDD (Heavy Compaction).
Copies of manufacturer’s certificate for geo-textile/geo-membrane to be used shall be

furnished by the Contractor. In addition, the Engineer may ask for testing in
independent laboratories. All test results shall meet the specified requirements.
Minimum one set of test for gradation and compaction of filter material shall be
executed for every 50 cu.m. and every change in source of material. The results shall
meet the specified requirements.
(4) Measurement
Geo-textile/Geo-membrane shall be measured in square meter. Overlapping shall not

be measured for payment. Filter material shall be measured in cubic meter. No
separate measurement of geo-textile/geo-membrane and filter material shall be done
in case of sub-surface and drilled sub-surface drains.
(5) Payment
Geo-textile/Geo-membrane and filter material measured as provided above shall be

paid the respective contract unit rates which shall be the full and the final payment to
the Contractor as per Clause 112 to complete the work as per these Specifications.

31–9

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STANDARD SPECIFICATION FOR ROAD AND BRIDGE WORKS

His Majesty's Government of Nepal

BHADRA, 2057/AUGUST, 2000

Final Review and Compilation by

SECTION 200 SITE CLEARANCE

1. The Bureau of Indian Standard (BIS) Hand book - 1996

SECTION 600–MATERIALS AND TESTING OF MATERIALS

SECTION 700–PIPE DRAINS, PIPE CULVERTS AND CONCRETE CHANNELS

701 PIPE DRAINS AND PIPE CULVERTS 7–1

801 GENERAL 8–1

901 SCOPE 9–1

1001 SCOPE 10–1

SECTION 1100–ROADWORKS OVERALL REQUIREMENTS

1101 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY

SECTION 1200–SUBBASE, BASE, HARD SHOULDER AND GRAVEL WEARING COURSE

SECTION 1300–BITUMINOUS SURFACE AND BASE COURSE

SECTION 1400–KERBS AND FOOTPATHS

SECTION 1500–TRAFFIC SIGNS, ROAD MARKING, ROAD MARKER STONES AND

1501 PERMANENT TRAFFIC SIGNS 15–1

SECTION 1600–PILING FOR STRUCTURES

1601 SCOPE 16–1

1801 SCOPE AND DEFINITIONS 18–1

1901 EXPANSION JOINTS 19–1

SECTION 2100–PRESTRESSED CONCRETE

SECTION 2300–TIMBER CONSTRUCTION

2301 SCOPE 23–1

SECTION 2400–MISCELLANEOUS STRUCTURES

2401 GABIONS 24–1

SECTION 2500–BRICKWORKS FOR STRUCTURES

2501 SCOPE 25–1

SECTION 2600–MASONRY FOR STRUCTURES

2601 SCOPE 26–1

SECTION 2800 BIO–ENGINEERING WORKS

2801 SCOPE 28–1

SECTION 2900–MAINTENANCE WORKS

SECTION 3100–MISCELLANEOUS WORKS

101 OFFICES FOR ENGINEER 1–1

SECTION 100 - GENERAL

101 OFFICES FOR ENGINEER

102 ACCOMODATION OF TRAFFIC

(2) General Requirements

(3) Temporary Diversions

(a) Provisions of Diversions

(b) Survey Beacons and Monuments

Diversions shall be constructed so as not to damage or displace

SECTION 100 GENERAL Page

where this is not possible, arrangements shall be made to have survey

(c) Access to Properties

(i) Maintenance of Diversions

SECTION 100 GENERAL Page 1 –

(j) Removal of Diversions

(4) Accommodation of Traffic Where the Road is Constructed in Half Widths

Materials and equipment stored on or adjacent to the existing roadway shall be so

(5) Traffic Safety and Control

The barricades erected on either side of the carriageway/portion of the carriageway

SECTION 100 GENERAL Page 1 –

(6) Measurement and Payment

Unless otherwise provided in the contract, no separate measurement and/or payment

103 PUBLICLY AND PRIVATELY OWNED SERVICES