Professional Documents
Culture Documents
Appendices (MOST)
Appendices (MOST)
Appendices
Appendices
Appendices - 1
Title
Route Maker Signs for National Highways (First Revision)
Standard Specifications & Code of Practice for Road Bridges, Section I-General Features
of Design (Sixth Revision)
Standard Specifications & Code of Practice for Road Bridges, Section II-Loads and
Stresses (Third Revision)
Type Designs for Highway Kilometre Stones (Second Revision)
Recommended Practice for Borrowpits for Road Embankments Constructed by Manual
Operation
Recommended Practice for 2 cm Thick Bitumen and Tar Carpets (Third Revision)
Tentative Specification for Priming of Base Course with Bituminous Primers
Tentative Specification for Single Coat Bituminous Surface Dressing
Design Criteria for Prestressed Concrete Road Bridges (Post-Tensioned Concrete)
(Second Revision)
Standard Specifications and Code of Practice for Water Bound Macadam (Second
Revision)
Recommended Practice for Bituminous Penetration Macadam (Full Grout)
Standard Specifications and Code of Practice for Road Bridges, Section III-Cement
Concrete (Plain and Reinforced) (First Revision)
Standard Specifications and Code of Practice for Road Bridges, Section VI-Composite
Construction for Road Bridges (First Revision)
Tentative Specification for Two Coat Bituminous Surface Dressing
Standard Specifications and Code of Practice for Road Bridges, Section V-Steel Road
Bridges
Type Designs for Boundary Stones
Type Designs for 200-metre Stones
Tentative Specification for Bituminous Macadam (Base & Binder Course)
Tentative Specification for 4 cm Asphaltic Concrete Surface Course
Standard Letters and Numerals of Different Heights for Use on Highway Signs
Code of Practice for Road Markings (with Paints)
Recommended Practice for the Construction of Earth Embankments for Road Works
Guidelines for the Design of Flexible Pavements (First Revision)
Standard Specifications and Code of Practice for Road Bridges, Section IV-(Brick, Stone
and Block Masonry)
Recommendations for Estimating the Resistance of Soil below the Maximum Scour
Level in the Design of Well Foundations of Bridges.
Tentative Specification for Built-up Spray Grout
Tentative Specification for Bituminous Surface Dressing using Pre-coated Aggregates
Recommended Practice for the Pulverization of Black Cotton Soils for Lime Stabilisation
Recommended Design Criteria for the Use of Cement Modified Soil in Road
Construction
Recommended Design Criteria for the Use of Soil Lime Mixes in Road Construction
Recommended Practice for Treatment of Embankment Slopes for Erosion Control
Tentative Guidelines for the Use of Low Grade Aggregates and Soil Aggregate Mixtures
in Road Pavement Construction
Code of Practice for Road Signs
Recommended Practice for Use and Upkeep of Equipment, Tools and Appliances for
Bituminous Pavement Construction
Appendices - 2
IRC : 75-1979
Number
Designati
on
IRC : 78-1983
IRC : 79-1981
IRC : 82-1982
IRC : 83-1982
IRC : 83-1987
IRC : 87-1981
IRC : 89-1985
IRC : 90-1985
IRC : 93-1985
IRC : 94-1986
IRC : SP : 111977
IRC : SP : 311986
IRC : Special
Report 11,
1992
Appendices - 3
Title
Colour for ready mixed paints and enamels
Paving Bitumen
Ready mixed paints, brushing, for road marking, to Indian Standard Colour No. 356
Golden yellow, white and black
Grey iron castings
Road tar
Cutback bitumen
Structural steel (standard quality)
33 grade ordinary portland cement (fourth revision)
Galvanized steel barbed wire for fencing
Mild steel wire for general engineering purposes
Glossary of terms relating to bitumen and tar
Coarse and fine aggregates from natural sources for concrete
Mild steel and medium tensile steel bars and hard-drawn steel wire for concrete
reinforcement
Mild steel and medium tensile steel bars
Hard-drawn steel wire
Methods of sampling and test for rubber hoses
Digboi type cutback bitumen
Portland slag cement (fourth revision)
Code of practice for plain and reinforced concrete (third revision)
Concrete pipes (with and without reinforcement)
Test sieves
Specification grease graphited (second revision)
Methods of test for strength of concrete
Industrial bitumen (second revision)
Wrought aluminium and aluminium alloys, plates for general engineering purposes
Covered electrodes for metal arc welding of mild steel
Code of procedure for manual metal arc welding of mild steel
Structural steel (High tensile)
Multipurpose grease No. 1, No. 2 and No. 3
Steel castings for general engineering purposes
Common burnt clay building bricks
Method of test for water absorption of natural building stones
Dressing of natural building stones
Hot rolled mild steel and medium tensile steel deformed bars for concrete reinforcement
Rivet bars for structural purposes
High tensile rivet bars for structural purposes
Procedure for testing for hardness number of bitumen mastic
Method of sampling and analysis of concrete
Indian standard methods for testing tar and bituminous materials
Mild steel tubes (fourth revision)
Mild steel tubular and other wrought steel pipe fittings (second revision)
Precision and semi-precision hexagon bolts, screws, nuts and lock nuts (diameter range 6
Appendices - 4
Title
Technical supply conditions for threaded steel fastners
General requirements for the supply of metallurgical materials
Packing paper, waterproof, bitumen-laminated
Covered electrodes for metal arc welding of high tensile structural steel
Method of tests for petroleum and its products
Code of practice for finishing of iron and steel/ferrous metal in buildings : painting and
allied finishes
Operations and workmanship
Portland-pozzolana cement
Classification and identification of soils for general engineering purposes
Methods of sampling and test for quick lime and hydrated lime
Dimensions for round and square steel bars for structural and general engineering
purposes
Plain hard-drawn steel wire for prestressed concrete
Cold-twisted steel bars for concrete reinforcement
High strength deformed steel bars and wires for concrete reinforcement
Preformed filler for expansion joint in concrete pavement and structures (non extruding
and resilient type)
Bitumen impregnated fibre (first revision)
Method of load tests on soils
Carbon steel forging for general engineering purposes
Structural steel (fusion welding quality)
Sand for masonry mortars
Methods for standard penetration test for soils
Code of practice for preparation and use of masonry mortars
Methods of test for aggregates for concrete
Particle size and shape
Estimation of deleterious materials and organic impurities
Specific gravity, density, voids, absorption and bulking
Mechanical properties
Soundness
Measuring mortar making properties of fine aggregates
Alkali Aggregate reactivity
Petrographic examination
Methods of test for soils
Determination of water content
Determination of specific gravity
Fine grained soils
Medium and coarse grained soils
Grain size analysis
Determination of liquid and plastic limits
Determination of moisture content/dry density relation using light compaction
Determination of water content-dry density relation using heavy compaction
Determination of unconfined compressive strength
Direct shear test
Determination of density index (relative density) of cohesionless soils
Laboratory determination of CBR
Determination of total soluble sulphates
Appendices - 5
Number
Designati
on
(Part 28)-1974
(Part 29)-1975
(Part 37)-1976
(Part 40)-1977
IS : 3117-1965
IS : 3466-1967
IS : 3764-1992
IS : 4138-1977
IS : 4332
(Part 1)-1967
(Part 3)-1967
(Part 4)-1968
(Part 5)-1970
(Part 7)-1973
(Part 8)-1969
IS : 4434-1978
IS : 4826
IS : 5317-1969
IS : 5435
(Revised)
IS : 5640-1970
IS : 6006-1970
IS : 6241-1971
IS : 6909-1991
IS : 6925-1973
IS : 7537-1974
IS : 8041-1978
IS : 8112-1989
IS : 8887-1978
IS : 9103-1979
IS : 102621982
IS : 122691987
IS : 123301988
IS : 13321
(Part 1)-1992
IS : 133251992
IS : 13326
(Part 1)-1992
IS : SP 231982
Title
Determination of dry density of soils in-place by the sand replacement method
Determination of dry density of soils in-place by core cutter method
Determination of sand equivalent values of soils and fine aggregates
Determination of free swell index of soils
Specification for bitumen emulsion for roads (cationic type)
Masonry cement
Code of safety for excavation work
Safety code for working in compressed air
Method of test for stabilized soils
Method of sampling and preparation of stabilized soils for testing
Test for determination of moisture content-dry density relation for stabilized soil mixtures
Wetting and drying and, freezing and thawing tests for compacted soil-cement mixtures
Determination of unconfined compressive strength of stabilized soil
Determination of cement content of cement stabilized soils
Determination of lime content of lime stabilized soils
Code of practice for in-situ vane shear test for soils
Hot dipped galvanised coating on sound scaled wires
Specification for bitumen mastic for bridge decking and roads
General requirements for old asphalt macadam mixing plant
Method for determining the aggregate impact value of soft coarse aggregate
Uncoated stress relieved strands for prestressed concrete
Method of test for determination of stripping value of road aggregates
Supersulphated cement
Methods of test for determination of water soluble chlorides in concrete admixtures
Road traffic signals
Rapid hardening portland cement
43 grade ordinary portland cement
Specification for bitumen emulsion for roads (cationic type)
Admixtures for concrete
Guidelines for concrete mix design
Specification for 53 grade ordinary portland cement
Specification for sulphate resisting portland cement
Glossary of terms for geosynthetics part 1:terms used in materials and properties
Determination of tensile properties of extruded polymer geogrids using the wide strip-test
method
Evaluation of interface friction between geo-synthetics and soil-method of test part
1:Modified direct shear technique
Handbook on concrete mixes (based on indian standards)
Appendices - 6
Number Designation
ASTM : D-36
ASTM : D-395
ASTM : D-412
ASTM : D-429
ASTM : D-573
ASTM : D-624
ASTM : D-664
ASTM : D-797
ASTM : D-1075
ASTM : D-1149
ASTM : D-1559
ASTM : D-2172
ASTM : D-2240
ASTM : D-3625
ASTM : D-4533
ASTM : E-11
ASTM : E-810
AASHTO : DM 283
AASHTO : DM 294-70
AASHTO : DM 288-82
AASHTO : DM 17-77
AASHTO : DR 5-80
AASHTO : DM 81-75
AASHTO : DM 82-75
AASHTO : DM 140-80
AASHTO : DM 57-80
AASHTO : DM 147-65
(1980)
AASHTO : DM 216-68
AASHTO : DM 249-79
AASHTO : DM 268-77
AASHTO : DM 282-80
BS : 410-1969
BS : 729-1971
BS : 812-1975
Part 2 Part 3 Part 111 Part 114 BS : 1047-1952
BS : 1154-1970
BS : 1377-1975
BS : 1447-1973
BS : 1449-1956
Part 1-1972
Part 2-1967
BS : 1470-1972
Appendices - 7
Number Designation
IS : 2630
BS : 2870
BS : 3262
Part-1
Part-2
Part-3
BS : 5212 Part 2-1975
BS : 6044
BS : 6088
BS : 6906
Part 1
Part 2
Part 3
Part 4
Part 7
BS : 7542 CRRI and
IOC, New Delhi
Asphalt Institute
GRI-GG1
GRI-GG2
GRI-GG3
Title
Preformed joint filler
Rolled copper and copper alloys : sheet, strip and foil
Hot-applied thermoplastic road marking materials
Specification for constituent materials and mixtures
Specification for road performance
Specification for application of material to road surface
Cold poured joint sealants for concrete pavements
Specification for pavement marking paints
Specification for solid glass beads for use with road marking compounds and
for other industrial uses
Methods of test for geotextiles
Determination of the tensile properties using a wide width strip
Determination of the apparent pore size distribution by dry sieving
Determination of water flow normal to the plane of the geotextile under a
constant head
Determination of the puncture resistance (CBR puncture test)
Determination of in-plane waterflow
Method of test for curing compound for concrete Bituminous Road
Construction Hand Book
The asphalt handbook, manual series No. 4 (MS-4) 1989 edition
Geogrid rib tensile strength
Geogrid junction strength
Tensile creep testing of Geogrids
(GRI denotes standards for test prepared by Geosynthetic Research Institute at Drexel University
Philadelphia, USA)
Appendices - 8
Appendix 3
(Clause 402.3.2. and 403.3.2.)
METHOD OF SIEVING FOR WET SOILS TO DETERMINE THE DEGREE OF
PULVERISATION
1.
2.
It should be spread on the sieve and shaken gently, care being taken to break the
lumps of soils as little as possible. Weight of soil retained on the sieve should be
recorded (W2). Lumps of finer soils in the retained material should be broken
until all the individual particulars finer than the aperture size of the sieve are
separated.
3.
The soil should again be placed on the sieve and shaken until sieving is complete.
The retained material should be weighed (W3).
4.
Weight of soil by per cent passing the sieve can than be calculated from the
expression:
(W1 W2) x 100
(W1 W3)
Appendices - 9
Appendix 4
GUIDELINES ON SELECTION OF THE GRADE OF BITUMEN
(Source: Bituminous Road Construction Handbook, Indian Oil Corporation and
Central Road Research Institute)
A
For bituminous premix carpet, choice is governed by climatic conditions and
intensity of traffic.
(i)
Grade 30/40 for areas where difference between maximum and minimum
atmospheric temperatures is less than 25oC and traffic intensity is greater
than 1500 commercial vehicles per day. For traffic intensity less than
1500 commercial vehicles per day, Grade 50/60 is preferred.
(ii)
(iii)
For bituminous macadam and penetration macadam as also built-up spray grout,
Grade 30/40 (for hot climates) and 60/70 or 80/100 for other climates are
suggested.
For a dense-graded bituminous concrete, a more viscous grade like 60/70 can
withstand stresses of heavier wheel loads better than a less viscous grade of
80/100. Similarly paving bitumen grade 60/70 is more advantageous for roads
with large number of repititions of wheel loads like expressways, urban roads,
factory roads etc. High stability requirement cannot be met effectively by less
viscous bitumen.
Appendices - 10
Appendices - 11
Appendix 5
ANTI-STRIPPING AGENTS USED FOR BITUMINOUS MATERIALS AND
MIXES
1.
Scope
1.1. Anti-stripping agents are used for bituminous materials and mixes to ensure
adhesion between aggregates (hydrophilic in nature) and bitumen, even under
submergence in water. Prior approval of the Engineer shall be taken in respect of both
qualitative and quantitative use of a particular product.
2.
Materials
2.1.
2.2.
Physical and Chemical Requirements: The anti-stripping agents shall
conform to the physical and chemical requirements as detailed in Table A5-1.
2.3.
Storage and Handling: Anti-stripping agents shall be properly
stored in closed containers made of steel or aluminium. Containers made of zinc, copper,
polythene PVC and most types of rubber are not suitable for use. As most of the antistripping agents cause irritation when in contact with human skin and are also irritating to
the eyes, protective gloves for hands and goggles for the eyes shall be used while
handling them, specially in case of liquid anti-stripping agents.
3.
3
3.1.
Additive Dosage: The dosage shall be determined depending on the
nature (stripping value) of the aggregate and the size of aggregate. While the
recommended minimum dose of anti-stripping agent for sprayed work is given in Table
A5-2, the actual dosage shall be determined in the laboratory as directed by the Engineer.
3.2.
Mixing Procedure During Construction: The anti-stripping agent
supplied in liquid, solid or concentrate form shall be thoroughly mixed with liquid
bituminous material or with straight run bitumen. When used with straight run bitumen,
the correct dose of antistripping agent shall be mixed in a hot bitumen tank boiler.
The two constituents shall be agitated till the anti-stripping agent is thoroughly
mixed. The dose of anti-stripping agent shall suitably be increased if the binder is to
remain in bitumen boiler for a longer period.
Appendices - 12
4.
4.1.
Additive Dosage: The dosage shall be determined depending on the
nature (stripping value) of the aggregate and the per cent voids in the mix. While the
recommended minimum doses for different types of bituminous premix materials in
terms of voids content are given in Table A5-3, the actual dosage shall be determined in
the laboratory as directed by the Engineer.
Appendices - 13
Test
Appearance
Odour
Specific gravity 27oC
Pour point oC Maximum
Flash point o (COC) Minimum
Water Content per cent Vol. Maximum
Solubility in diesel oil (HDO or LDO) in
the ratio of 2:98 at 50 oC
Total base value mg KOH/g minimum
Nitrogen content per cent Wt. minimum
Stripping value with bitumen containing 1
per cent Wt. antistripping compound at
40oC 24 hours
Under water coating test
Thermal stability at 163 oC 5 hours
Method
Visual
Smelling
IS : 1202-1978
IS : 1448
IS : 1448
IS : 1448
As given at the end of
Appendix
ASTM D 664
Elemental Analyser
IS : 6241
As given at the end of
Appendix
- do - do -
ASTM D 3625
TABLE A5-2.
Aggregate
stripping
value
0-25
25-50
50-100
Limit
Liquid/Solid
Agreeable
0.860-1.03
42
150
1.0
Complete
200
7.0
No stripping
Complete Coating
Should not lose its
efficacy
95
75
Penetration
Macadam/Built
up spray grout
0.6
0.7
1.0
Surface Dressing
with uncoated
aggregate
0.7
0.8
1.0
4.2 Mixing Procedure During Construction: The required dose of the antistripping agent shall be poured into the hot bitumen tank and allowed 15 to 30 minutes of
circulation or stirred to ensure a homogeneous mix. It is necessary to use a stable
antistripping agent or increase the dose according to expected degradation. Alternatively,
the correct dose shall be injected into the bitumen line by means of a pump. The agent is
fed into the bitumen first before it is sprayed on the aggregate in the mix; thus, no
separate mixing time for mixing the agent with bitumen is required. In rolled asphalt and
bitumen mastic surfacing works, precoated chippings are pressed into the hard surface
while the mix is still hot to make the newly laid surface skid resistant. These chippings
shall be precoated with bitumen treated with antistripping compound.
Appendices - 14
TABLE A5.3.
Stripping
value of
aggregat
e
0-25
25-50
50-100
Appendices - 15
Appendices - 16
The bottle shall be filled to of its volume with distilled water at 40 oC. The
bitumen-antistripping agent blend shall be added in the bottle at the rate of 7.5 per cent
by weight of stone dust. The stopper shall be replaced and the bottle shall be vigorously
shaken for two minutes. The water shall be then drained off and the stone dust shall be
transferred to a piece of paper and examined visually for satisfying complete coating.
The minimum per cent content of antistripping agent at which the stone dust sample is
thoroughly coated shall be recorded. The test shall be repeated at 60 oC in water as well
as 1 per cent solution of Sodium Chloride in water for both the testing temperatures.
(b)
The under water coating test shall further be conducted with coarse
aggregate, passing 19 mm sieve and retained on 13.2 mm sieve. In this
case the per cent content of the cutback-antistripping agent blend shall be
kept at 5 per cent by weight of coarse aggregate. In order to take care of
contamination in water, the test shall also be carried out in the 1 per cent
Sodium Chloride in water.
The minimum per cent content of antistripping agent at which stone dust/coarse
aggregate is thoroughly coated as per (a) and (b) shall be taken as the dose of
antistripping agent.
TESTING FOR THERMAL STABILITY OF ANTISTRIPPING AGENT
Procedure: Blends of antistripping agent and bitumen of 80/100 grade shall be
prepared with 0.00, 0.25, 0.50, 0.75 and 1.00 per cent contents of antistripping agent and
kept in oven at 163 oC for five hours. After the heat exposure, the blend samples are
fluxed with kerosene oil to obtain the consistency of MC 3 and tested for under water
coating test.
Reporting of test results: An antistripping agent shall be deemed to be heat
resistant if the dose requirement before and after heat exposure remains unchanged.
QUANTITATIVE EVALUATION OF RETAINED MARSHALL
STABILITY VALUES AFTER IMMERSION IN WATER
Procedure: For quantitative evaluation, the tests shall be carried out as stipulated
in ASTM D1075 (Effect of Water on Cohesion of Compacted Bituminous Mixtures). The
gradation of aggregates shall be such as to give sufficient voids in the compacted
bituminous mix to bring out the effects of stripping. The gradation of aggregates shall be
as under:
Appendices - 17
Sieve Size
19.00 mm
13.20 mm
9.50 mm
4.75 mm
2.36 mm
600 mic
300 mic
150 mic
75 mic
The Marshall test specimens shall be prepared using 5 per cent bitumen of 80/100
grade by weight of aggregates blended with varying percentages of antistripping agents
from 0 to 1 per cent in steps of 0.25 per cent. The test samples shall give a void content
of about 6 per cent. At least 8 standard Marshall specimens for each of the varying
antistripping agent percentages shall be prepared. Each set of 8 test specimens shall be
sorted out in two groups of 4 each so that the average specific gravity of the specimen in
group I shall be essentially the same as in group II. Group-I shall be tested for Marshall
Stability in the usual procedure ASTM D1559. Group-II specimens shall be immersed in
water for 24 hours at 60 oC + 1 oC and then shall be tested immediately for Marshall
stability as per ASTM D 1559.
Calculation: The numerical index of resistance of bituminous mixtures to the
detrimental effect of water shall be expressed as the index of retained stability:
Average Marshall Stability of Group-II
X 100 per cent
Average Marshall Stability of Group-I
Requirement for acceptance: A minimum of 75 per cent of retained Marshall strength
shall be required for acceptance.
Appendices - 18
Appendix 1000-1
DRAFT DOCUMENT ON IS : 9077-1979 CODE OF PRACTICE FOR
CORROSION PROTECTION OF STEEL REINFORCEMENT IN RB AND RCC
CONSTRUCTION (REVISED)
FOREWORD
This Indian Standard has been revised taking into consideration the experience
gained over the years, developments those have taken place subsequently and also
considering the need for evolving suitable acceptance tests for quality control. In this
regard, the electrochemical tests developed at the Central Electrochemical Research
Institute, Karaikudi, and also the tests specified in ASTMA775/A775 M-90 for powder
epoxy coating have been considered.
This revised standard supersedes earlier standard namely IS : 9077-1979. While
revising this standard, it was decided to cover the various test procedures required to
ensure the quality of individual product as well as the finished products. It was also
decided that this standard should include very stringent test procedures particularly for
finished products so that these procedures can be used to evaluate not only the corrosion
resistance of a particular finished product covered by this standard but also any other
finished product such as galvanising, powder epoxy etc.
1.
SCOPE
1.1
This standard (revised) specifies the recommended practice for surface
preparation, surface pretreatment and anti-corrosive treatment based on inhibited and
sealed cement slurry as an in-situ process for corrosion protection of mild steel
reinforcement/HYSD bars in conventional reinforced concrete structures and
conventional reinforced brickwork constructions. This practice is also applicable for
non-prestressing steels (mild steel reinforcement/HYSD bars) used in prestressed
Concrete structure.
1.2
This standard applies only for in-situ corrosion protection of mild steel
reinforcement/HYSD bars after all bending and shaping operations are completed.
However, this does not preclude the possibility of using this practice as a factory process.
2.
Since presence of oil, grease, dirt, heavy scale and rust will adversely affect the
performance of any anticorrosive treatment, it is essential to adopt suitable surface
Appendices - 19
Surface pretreatment
Sealing treatment
Sealing treatment should make the coating harder and less permeable.
A typical flow diagram is shown in Fig. 1000/1.
3.
3.1
Sand Blasting
De-rusting by Pickling
The pickling weld should be preferably based on hydrochloric acid and should
include an efficient inhibitor to prevent base metal attack.
A typical de-rusting solution should have the following characteristics:
(a)
(b)
(c)
4.
Appendices - 20
(a)
(b)
(c)
(d)
(e)
(f)
5.
5.1
(i)
It should in liquid form ready for mixing with the ordinary portland
cement.
Specific gravity when tested using a standard specific gravity bottle should
be 1.04 + 0.02
pH when tested using a pH meter should be 12.75 + 0.25
Tolerable limit for chloride in inhibitor admixture when tested using
anodic polarisation technique (as per test procedure B) should be 300 + 25
ppm
(ii)
(iii)
(iv)
5.2
This should conform to IS : 269 and should be sieved to pass through 75 microns
IS sieve.
Appendices - 21
Fig. 1000/1
Appendices - 22
5.3
Cement and inhibitor admixture should be mixed in specified proportion
to have suitable consistency. Coating should be applied preferably by brushing.
However, under specific circumstances spraying or dipping is also allowable.
5.4
Sufficient time lag should be allowed in between successive coatings to
ensure final setting of the undercoat. A minimum of 6 to 12 hours may be necessary.
5.5
6.
SEALING TREATMENT
The sealing treatment should be performed over the coated surface immediately
after final setting of the top coat. Sealing treatment can be applied by brushing, spraying
or dipping.
6.1
(a)
Specific gravity when tested using a standard specific gravity bottle should
be 1.09 + 0.02
pH when measured using a pH meter should be 12.25 + 0.25
Tolerable limit for chloride in sealing solution using anodic polarisation
technique should be 450 + 25 ppm (as per test procedure B).
(b)
(c)
7.
7.1.
Finished coating when visually examined should be fairly uniform in
thickness and should be devoid of any defects such as cracks, pinholes, peeling, bulging
etc. No surface area should be left uncoated. No rust spot should be visible to the naked
eye.
7.2.
The minimum thickness of the coating shall be 200 microns. Preferable range is
200 to 400 microns.
7.3.
The bond strength of the coated rebar and concrete shall not be less than that
specified in IS : 456 as per clause No. 0, 2, 5, 11 and 44.1.2 and tested as per IS : 2770
(Part 1).
7.4.
Hardness of the coating when measured using a pencil hardness tester
shall be around 5 H to 7 H.
Appendices - 23
7.5.
Tolerable limit for chloride in 0.04 Normal NaOH medium using anodic
polarisation technique (as per test procedure B) shall be around 4500 to 5000 ppm.
7.6.
No film failure as evidenced by evolution of hydrogen gas at the cathode
or appearance of corrosion products at the anode shall take place during one hour of
testing (as per test procedure C).
8.
GENERAL REMARKS:
It is advisable that severely rusted and heavily pitted reinforcements are not
accepted for treatment.
TEST PROCEDURE A
Determination of phosphate coating weight
7.5 cm x 2.5 cm or 7.5 cm x 5 cm mild steel polished and degreased specimens
are to be used for this test. First the blank loss of unphosphated specimen is to be found
out. For this, the initial weight (W1) is accurately weighed. The specimen is kept
immersed in the Clarks solution or patented inhibited de-rusting solution for 1 minute.
The specimen is removed, rinsed in distilled water and dried using hot air blower. The
specimen is immediately weighed (W2). The difference between W1 and W2 is termed as
blank loss.
Another specimen (polished and degreased) is brushed with phosphating jelly and
kept for 45 minutes. Then the specimen is washed free of jelly, rinsed in clean water and
dried using hot air blower. The phosphated specimen (W 3) is accurately weighed. After
weighing, the specimen is kept immersed in Clarks solution or patented inhibited derusting solution for one minute. Then the specimen is removed, rinsed in distilled water
and dried using hot air blower. The specimen is immediately weighed (W 4). Coating
weight = W3 W4 blank loss.
TEST PROCEDURE B
Anodic Polarisation Technique
Mild steel reinforcement/HYSD Bar test specimens of size 10 mm in dia and 100
mm in length with stems of size 5 mm in dia and 50 mm in length is polished, degreased
and sealed at bottom edge and at the stem with suitable sealers like wax, lacquer. Then
test specimen is kept immersed in test solution and potential is monitored using high
impedance multimeter against suitable reference electrode such as saturated calomel
electrode/copper-copper sulphate electrode. After getting stabilised potential using
appropriate current regulator (0-100 mA), the test specimen is anodically polarised at a
constant current density of 290 A cm using a platinum/stainless steel/TSIA/polished
mild steel reinforcement/HYSD Bar as cathode. Potential with time is followed for 5
Appendices - 24
minutes after current is applied. The maximum chloride concentration upto which the
potential remains constant for 5 minutes is taken as a measure of tolerable limit.
TEST PROCEDURE C
Resistance to Applied Voltage Test
Two mild steel reinforcement/HYSD bars of size not less than 10 mm in dia and
800 mm in length shall be given anti-corrosive treatment as per specified procedure. The
end of the rebars shall be soldered with insulated copper electrical connecting wire (14
gauge) to serve as electrical contact point. Coated rebars at the two ends shall be sealed
with an insulating material to a length of 25 mm at each end. Test area shall be the area
between the edge of the bottom sealed end and immersion line which shall not be less
than 250 mm in this case.
The coated rebars shall be suspended vertically in a non-corrosive plastic
container of size not less than 150 mm x 150 mm square and 850 mm high. The rebars
shall be so suspended as to have a clearance of 25 mm at bottom, 45 mm at the sides and
40 mm in between the rods.
The container shall then be filled to a height of 800 mm with an aqueous solution
of 7 per cent NaCl. A potential of 2 V in between the coated rods shall be impressed for a
period of 60 minutes using a high resistance volt meter for direct current having an
internal resistance of not less than 10 mega Ohms and having a range upto 5 V
(minimum). Storage batteries may be used for impressing the voltage.
During this 60 minutes of testing, there shall not be any coating failure as
evidenced by evolution of hydrogen gas at the cathode or by appearance of corrosion
products of iron at the anode.
Appendices - 25
Appendices - 26
Appendix 1500/I
INFORMATION TO BE SUPPLIED BY THE MANUFACTURERS OF
PROPRIETARY SYSTEMS
1.
GENERAL
1.1.
The information which the manufacturer is required to supply shall be in
such detail as to obviate unsafe use of the equipment due to the intention of the
manufacturer not having been made clear or due to wrong assumptions on the part of the
user.
1.2.
The user shall refer unusual problem or problems of erection/assembly not
in keeping with the intended use of the equipment, to the manufacturer of the equipment.
2.
INFORMATION REQUIRED
2.1.
(a)
(b)
List of items of equipment available, giving range of sizes, spans and such
like, with the manufacturers identification numbers or other references.
(c)
The basis on which the safe working loads have been determined and
whether the factor of safety given applies to collapse or yield.
(d)
(e)
Instructions for use and maintenance, including any points which require
special attention during erection, especially where safety is concerned.
(f)
(ii)
(iii)
Self weight.
(iv)
Appendices - 27
(g)
(v)
(vi)
(vii)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
Appendices - 28
Appendix 1700/I
SPECIFICATION FOR CONSTRUCTION JOINTS
Location
The location of construction joints shall be as shown on the drawing or as
approved by the Engineer. If additional/new joints are approved by the Engineer, the
following considerations for their location shall be taken into account:
(i)
(ii)
(iii)
In beams and slabs, joints should not be near the supports. Construction
joints between slabs and ribs in composite beams should be avoided.
(iv)
For box girders, it is preferable to cast the soffit and the webs without any
joint.
(v)
Appendices - 29
concrete shall be cut back to expose the reinforcements for a length of about 50 mm to
ensure that contaminated concrete is removed.
The joint surface shall not be contaminated with release agents, dust or curing
membrane.
Concreting of Joints
The old surface shall be thoroughly cleaned and soaked with water. Standing
water shall be removed shortly before the new concrete is placed and the new concrete
shall be thoroughly compacted. Concreting shall be carried out continuously upto the
construction joints.
Surface retarders may be used to improve the quality of construction joints.
For a vertical construction joint, a stopping board shall be fixed previously at the
predetermined position and shall be properly stayed to prevent its displacement or
bulging when concrete is compacted against it. Concreting shall be continued right upto
the board.
Appendices - 30
Appendices - 31
Appendix 1800/I
TESTS ON SHEATHING DUCTS
All tests specified below shall be carried out on the same sample in the order
given below.
At least 3 samples for one lot of supply (not exceeding 7000 metre length) shall
be tested.
The tests are applicable for sheathing transported to site in straight lengths where
the prestressing cable is threaded inside the sheathing prior to concreting. These tests are
not applicable for sheathing nor for coiled cable and transported to site as an assembled
unit, nor for sheathing ducts placed in position without threading of prestressing cable
prior to concreting.
(A)
WORKABILITY TEST
A test sample 1100 mm long is soldered to a fixed base plate with a soft solder
(Fig. 1800/I-1). The sample is then bent to a radius of 1800 mm alternately on either side
to complete 3 cycles.
Thereafter, the sealing joints will be visually inspected to verify that no
failure/opening has taken place.
(B)
The test ensures that stiffness of the sheathing is sufficient to prevent permanent
distortion during site handling.
The sample is placed on a horizontal support 500 mm long so that the sample is
supported at all points of outward corrugations.
A load as specified in Table 1 is applied gradually at the centre of the supported
portion through a contact surface 12 mm long. It shall be ensured that the load is applied
approximately at the centre of two corrugations, Fig. 1800/I-2. The load as specified is
applied in increments.
TABLE 1
dia (mm)
25-35
35-45
45-55
55-65
65-75
75-85
85-90
load
250
400
500
600
700
800
1000
(N)
Appendices - 32
(C)
A test specimen is subjected to a tensile load. The hollow core is filled with a
wooden circular piece having a diameter of 95 per cent of the inner dia of the sample to
ensure circular profile during test loading, Fig. 1800/I-3.
A coupler is screwed on and the sample loaded in increments, till reaching the
load specified in Table 2. If no deformation of the joints nor slippage of couplers is
noticed, the test shall be considered satisfactory.
TABLE 2
dia (mm)
25-35
35-45
45-55
55-65
65-75
75-85
85-90
load
300
500
800
1100
1400
1600
1800
(N)
(D)
The sample is sealed at one end. The sample is filled with water and after sealing,
the end is connected to a system capable of applying a pressure of 0.05 MPa, Fig. 1800/I4, and kept constant for 5 minutes using a hand pump with pressure gauge or stand pipe
system can be used.
The sample is acceptable if the water loss does not exceed 1.5% of the volume.
Appendices - 33
Appendices - 34
Appendices - 35
Appendices - 36
Appendices - 37
Appendices - 38
Appendix 1800/III
SPECIFICATIONS FOR GROUTING OF POST-TENSIONED CABLES IN
PRESTRESSED CONCRETE
1. GENERAL
1.1.
The recommendations cover the cement grouting of post-tensioned
tendons of prestressed concrete members of bridges. This also covers some of the
essential protective measures to be adopted for minimising corrosion in PSC bridges.
1.2.
The purpose of grouting is to provide permanent protection to the posttensioned steel against corrosion and to develop bond between the prestressing steel and
the surrounding structural concrete. The grout ensures encasement of steel in an alkaline
environment for corrosion protection and by filling the duct space, it prevents water
collection and freezing.
2. MATERIALS
2.1.
Water
Only clean potable water free from impurities conforming to section 1000 shall be
permitted. No sea or creek water is to be used at all.
2.2.
Cement
Ordinary Portland cement should be used for preparation of the grout. It should
be as fresh as possible and free of any lumps. Pozzolana cement shall not be used.
2.3.
Sand
Admixtures
Appendices - 39
2.5.
Sheathing
All ducts should have grout openings at both ends. For this purpose
special openings should be provided where such openings are not
available at end anchorages. For draped (curved) cables vents shall be
provided at all crown and valley points. It is a good practice to provide
additional air vents at suitable intervals not exceeding 20 m. All grout
openings or vents should include provisions for preventing grout leakage.
(b)
Standard details of fixing couplers, inlets, outlets and air vents to the
duct/anchorage shall be followed as recommended by the supplier of the
prestressing system.
2.5.3. Ducts should be securely fastened at close intervals. All unintended holes
or openings in the duct must be repaired prior to concrete placing. The joints of the
couplers and the sheathing should be made water proof by use of adhesive tape or similar
suitable system capable of giving leak proof joints. Grout openings and vents must be
securely anchored to the duct and to either the forms or to reinforcing steel to prevent
displacement during concreting operations due to weight, buoyancy and vibrations.
2.5.4. Ducts require very careful handling as, being of thin metal, they are
susceptible to leakage due to corrosion in transit or storage, by tearing/ripping in handling
particularly when placed adjoining to reinforcing steel, by pulling apart at joints while
inserting tendons prior to concreting, or by accidental puncturing while drilling for form
ties/inserts. Ducts are also liable to damage by rough use of internal vibrator and sparks
from welding being done close by.
3.
3.1.
EQUIPMENT
Grout Pump
Appendices - 40
must be fitted with a pressure gauge to enable pressure of injection to be controlled. The
minimum pressure at which grout should be pumped shall be 0.3 MPa and the grout
pump must have a relief arrangement for bypass of the grout in case of build up of
pressure beyond 1 MPa. The capacity of the grout pump should be such as to achieve
forward speed of grout of around 5 to 10 metres per minute. The slower rates are
referable as they reduce the possibility of occurrence of voids. If the capacity of the
pump is large, it is usual to grout two or more cables simultaneously through a common
manifold.
Use of hand pumps for grouting, is not recommended. Use of compressed air
operated equipment for injection is prohibited, as it is likely that there will be some air
trapped in grout.
3.3.
Water Pump
Grout Screen
The grouting equipment should contain a screen having a mesh size of 106
micron size of 150 microns if sand is used). Prior to introduction into the grout pump,
the grout should be passed through such screen. This screen should be easily accessible
for inspection and cleaning.
3.5.
Standard details of fixing inlets, outlets and air vents to the sheathing and/or
anchorage should be followed as recommended by specialist supplier of the system of
prestressing. In general, all connections are to be of the Quick couple type and at
change of diameters suitable reducers are to be provided.
4.
4.1.
Water/cement ratio should be as low as possible, consistent with
workability. This ratio should not normally exceed 0.45.
4.2.
Before grouting, the properties of the grout mix should be tested in a
laboratory depending on the facilities available. Tests should be conducted for each job
periodically. The recommended test is described below.
4.3.
Compressive Strength: The compressive strength of 100 mm cubes of
the grout shall not be less than 17 MPa at 7 days. Cubes shall be cured in a moist
Appendices - 41
MIXING OF GROUT
5.1.
Proportions of materials should be based on field trials made on the grout
before commencement of grouting, but subject to the limits specified above. The
materials should be measured by weight.
5.2.
Water should be added to the mixer, first, followed by Portland cement
and sand, if used. Admixture if any, may be added as recommended by the manufacturer.
5.3.
Mixing time depends upon the type of the mixer, but will normally be
between 2 and 3 minutes. However, mixing should be for such a duration as to obtain
uniform and thoroughly blended grout, without excessive temperature increase or loss of
expansive properties of the admixtures. The grout should be continuously agitated until it
is injected.
5.4.
Once mixed, no water shall be added to the grout to increase its fluidity.
5.5.
GROUTING OPERATIONS
6.1.
General
a)
Grouting shall be carried out as early as possible but not later than 2 weeks
of stressing a tendon. Whenever this stipulation cannot be complied with
for unavoidable reasons, adequate temporary protection of the steel against
corrosion by methods or products which will not impair the ultimate
adherence of the injected grout should be ensured till grouting. The
sealing of the anchorage ends after concreting is considered to be a good
practice to prevent ingress of water. For structures in aggressive
environment, sealing of the anchorage ends is mandatory.
Notes:
i)
Application of some patented water soluble oils for coating of steel/VPI powder
injection/sending in of hot, dry, oil-free compressed air through the vents at
frequent intervals have shown some good results.
ii)
Some of the methods recommended for sealing anchorages are to seal the
openings with bitumen impregnated gunny bag or water proof paper or by
building a brick pedestal plastered on all faces enclosing the exposed wires
outside the anchorages.
Appendices - 42
iii)
Any traces of oil if applied to steel for preventing corrosion should be removed
before grouting operation.
iv)
Ducts shall be flushed with water for cleaning as well as for wetting the surfaces
of the duct walls. Water used for flushing should be of same quality as used for
grouting. It may, however, contain about 1 per cent of slaked lime or quick lime.
All water should be drained thorough the lowest vent pipe or by blowing
compressed air through the duct.
v)
The water in the duct should be blown out with oil free compressed air.
Blowing out water from duct for cables longer than 50 m draped up at both ends
by compressed air is not effective, outlet/vent provided at or near the lowest point
shall be used to drain out water from duct.
vi)
The connection between the nozzle of the injection pipe and duct should be such
that air cannot be sucked in.
vii)
All outlet points including vent openings should be kept open prior to
commencement of injection grout.
viii)
Before grouting, all air in the pump and hose should be expelled. The suction
circuit of the pump should be air-tight.
6.2.
Injection of Grout
a)
b)
c)
d)
e)
Appendices - 43
g)
Appendices - 44
Appendices - 45
Grout ______________________________
Time:
Start
_____________________ ;
Finish ______________________________
Equipment:
Cable duct:
Diameter
______________________ ;
Length _____________________________
______________________ ;
Regrouting __________________________
Actual ______________________________
Pre-grouting checks:
Free of blockage
Leakage observed:
Inlet:
Yes/No
Outlet
Yes/No
Vents:
Yes/No
Cable duct
Yes/No
Sealed
Yes/No
Yes/No
Yes/No
Yes/No
____________________________________
Probbing by stiffwire
____________________________________
Remarks
____________________________________
Contractor
Appendices - 46
System Supplier
h)
7.
a)
b)
The temperature of the grout shall not exceed 25 degrees Celsius. For
increasing the workability of grout, its temperature may be lowered by use
of chilled water or by putting ice outside the grout storage container.
c)
When the cables are threaded after concreting, the duct must be
temporarily stiffened during concreting by inserting bunch of strands,
wires or reinforcement or a rigid PVC pipe or any other suitable method.
d)
During concreting, care shall be taken to ensure that the sheathing is not
damaged. Needle vibrators shall be used with extreme care by well
experienced staff only, to ensure against such damage.
e)
f)
g)
In case of stage prestressing, cables tensioned in the first stage should not
remain ungrouted till all cables are stressed. It is good practice, while
grouting any duct in stage prestressing, to keep all the remaining ducts
filled up with water containing 1 per cent lime or by running water
through such ducts till the grout has set. After grouting the particular
Appendices - 47
cable, the water in the other cables should be drained and removed with
compressed air to prevent corrosion.
h)
Care should be taken to avoid leaks from one duct to another at joints of
precast members in particular.
i)
End faces where anchorages are located are vulnerable points of entry of
water. They have to be necessarily protected with an effective barrier.
Recesses should be packed with mortar concrete and should preferably be
painted with water proof paint
j)
Appendices - 48