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MOST Specifications For Road Bridges PDF
MOST Specifications For Road Bridges PDF
(Roads Wing)
SPECIFICATIONS
FOR ROAD
AND BRIDGE
WORKS
(Third Revision)
Published by
Indian Roads Congress
New Delhi 1997
<<
SPEd FICATIONS
FOR ROAD
AND BRIDGE
WORKS
(Third Revision)
r~
...
<<
First Published
Reprinted
First Revision
Reprinted
Reprinted
Reprinted
Second Revision
Reprinted
Reprinted
Reprinted
Reprinted
July, 1993
Third Revision
Reprinted
Reprinted
Reprinted
Repri ntccl
August, 1988
April, 1990
June, 1992
February, 1993
Reprinted
Reprinted
April, 1973
November, 1975
May, 1978
September, 1981
October, 1983
April, 1986
February, 1988
April, 1995
January, 1997 (Incorporates Corrigendum
NoJ &2andCol. 12&l5ofp.662)
January, 1998
January, 1999
May, 1999
February, 2000
<<
New Delhi
November, 1994.
<<
M. V. SASTRY
Director General ( Road Development)
CONTENTS
SECTION
NO.
SECTION
TITLE
CLAUSE
NO.
100
GENERAL
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
<<
CLAUSE TITLE
IN1RODUCTION
DEFINITIONS
MATERIALS AND TEST STANDARDS
SIEVE DESIGNATIONS
SCOPE OF WORK
CONSTRUCTION EQUIPMENT
CONTRACT DRAWINGS
SITE INFORMA11ON
SET11NG OUT
PUBLICUTILITIES
PRECAUTIONS FOR SAFEGUARDING
THE ENVIRONMENT
ARRANGEMENT FOR TRAFFIC
DURING CONSTRUCTION
GENERAL RULES FOR THE
MEASUREMENT OF WORKS FOR
PAYMENT
SCOPEOFRATHS FOR
DIFFERENT ITEMS OF WORK
METHODOLOGY ANDSEQUENCE OF
WORK
CRUSHED STONE A~GGREGAThS
APPROVAL OF MATERIALS
SUPPLYOFQUARRYSAMPLES
USE OFSURFACES BY
CONSTRUCTION TRAFFIC
SITE OFFICE FOR ENGiNEER AND
OTHER SUPERVISORY STAFF
FIELD LABORATORY
SFTE RESIDENTIAL
ACCOMMODATION FOR
ENGINEER AND OTHER
SUPERVISORY STAFF
PROVIDING AND MAINTAINING
WIRELESS COMMUNICATION
SYSTEM
PROVIDING AND MAINTAINING
VEHIQ..ES FOR THE ENGINEER
SUPPLY OF COLOUR RECORD
PHOTOGRAPHS AND ALBUMS
SUPPLY OF VIDEO CASSETIES
PAGE
NO.
3
3
6
6
7
8
9
9
10
11
13
14
17
19
21
21
21
21
22
22
26
30
32
33
35
36
Contents
11
SECTION
NO.
SECTION
TITLE
CLAUSE
NO.
200
SITE
CLEARANCE
201
202
41
44
300
EARTHWORK~
EROSION
CONTROL AND
DRAINAGE
301
49
302
303
304
305
306
307
308
309
310
311
312
313
CLAUSE TITLE
PAGE
NO.
57
61
63
67
83
85
87
90
94
95
95
96
101
400
SUB-BASES,
BASES (NONBITUMINOUS)
AND
SHOULDERS
401
402
403
404
405
406
407
408
409
410
500
BASES AND
SURFACE
COURSES
(BITUMINOUS)
501
502
503
504
505
506
<<
GRANULAR SUB-BASE
LIME TREATED SOIL FOR IMPROVED
SUB-GRADE/SUB-BASE
CEMENT TREATED SOIL SUBBASE/BASE
WATER BOUND I ACADAM
SUB-BASE/BASE
CRUSHED CEMENT CONCRETE
SUB-BASE/BASE
WET MIX MACADAM SUB-BASE!
BASE
SHOULDERS, ISLANDS AND MEDIAN
CEMENT CONCRETE KERB AND
KERB WITH CHANNEL
FOO11~ATHSAND SEPARATORS
CRUStIER-RUN MACADAM BASE
PREPARATION OF SURFACE
PRIME COATOVER GRANULAR BASE
TACK COAT
BITUMINOUS MACADAM
BITUMINOUS PENETRATION
MACADAM
BUILT-UP SPRAY GROUT
105
109
112
121
123
128
130
132
133
139
145
148
149
157
160
Contents
ill
SECTION
NO.
SECTION
TITLE
CLAUSE
NO.
507
508
509
510
511
163
170
177
185
186
DRYLEANCEMENTCONCRETE
SUB-BASE
CEMENT CONCRETE PAVEMENT
ROLLED CEMENT CONCRETE BASE
211
255
801
802
803
804
805
806
807
808
809
810
811
TRAFFIC SIGNS
OVERHEAD SIGNS
ROAD MARKINGS
I-IECTOMETREJIULOMETRE STONES
ROAD DELINEATORS
BOUNDARY STONES
FENCING
TUBULAR STEEL RAILING
CONCRETE CRASH BARRIER
METAL BEAM CRASH BARRIER
ROAD TRAFFIC SIGNALS
273
278
901
902
GENERAL
CONTROL OF ALIGNMENT LEVEL
AND SURFACE REGULARITY
QUALITY CONTROL TESTS DURING
CONSTRUCtiON
299
301
513
514
515
516
517
CONCRETE
PAVEMENT
601
602
603
700
GEOSYNTHETICS
701
702
703
704
705
800
900
<<
TRAFFIC SIGNS,
MARKINGS &
OTHER ROAD
APPURTENANCES
QUALITY
CONTROL
FOR ROAD
WORKS
PAGE
NO.
512
600
CLAUSE TITLE
903
189
192
194
197
202
204
220
247
257
259
263
266
282
288
289
289
289
290
291
292
295
305
iv
SECTION
NO.
1000
Contents
SECTION
TITLE
CLAUSE
NO.
MATERIALS
FOR
1001.
STRUCTURES
1002.
1003.
1004.
1005.
1006.
1007.
1008.
1009.
1010.
1011.
1012.
1013.
1014.
1015.
1100
PILE
FOUNDATIONS
1101.
1102.
1103.
1104.
1105.
1106.
1107.
1108.
1109.
1110.
1111.
1112.
1113.
1114.
1115.
1116.
1117.
Ills.
1119.
1200.
WELL
FOUNDATIONS
1201.
1202.
1203,
1204.
1205.
1206.
<<
1207.
CLAUSE TITLE
GENERAL
SOURCES OF MATERiAL
BRICKS
STONES
CAST iRON
CEMENT
COARSE AGGREGATES
SANtVFINE AGGREGATES
STEEL
WATER
TIMBER
CONCRETE ADMLXTURES
REINFORCED CONCRETE PIPES
STORAGE OF MATERIALS
TESTS AND STANDARD OF
ACcEPTANCE
DESCRIPIlON
SUIT-SURFACE INVESTIGATION
TYPE OF PILES
MATERIALS
TEST PILES
PRECAST CONCRETE PILES
CAST.!N.SITU CONCRETE PILES
STEEL PILES
TIMBERPILES
DRIVING EQUIPMENT
DRIVING
PILECAP
PAGE
NO.
323
323
323
323
324
324
325
326
326
329
330
330
331
331
334
339
339
340
340
341
341
344
347
348
348
349
352
353
353
IMPORTANT CONSIDERATIONS,
INSPECTION/PP..ECAU11ONS
FOR DIFFERENT TYPES OF PILES
TOLERANCES
TESTS AND STANDARDS OF
ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
354
DESCRIPTION
361
361
362
GENERAL
SElliNG OUT AND PREPARATIONS
FOR SINKING
CUlliNG EDGE
WELL CURB
WELL STEIN ING
WELL SINKING
356
357
357
358
364
364
365
366
Contents
SECTION
TITLE
BRICK
MASONRY
1210.
1211.
1211
1213,
TOPPLUG
WELLCAP
TOLERANCES .
TESTS AND STANDARDS
OF ACCEPTANCE
MEASUREMENT FOR PAYMENT
1301.
1302.
1303.
1304.
1306,
1307,
130&
1309,
1310.
1311.
1312.
13 13.
FORMWORK
377
377
377
RATE
377
DESCRIPTION
MATERIALS
PERSONNEL
CEMENT MORTAR
SOAKING OF BRICKS
JOINTS
LAYING
JOINTING OLD AND NEW WORK
CURING
381
381
381
381
382
382
382
383
383
384
384
384
386
SCAFFOLDING
EQUIPMENT
FINISHING OF SURFACES
ARC}IITEC11JRAL COPING FOR
1316.
RATE
1401.
391
1408.
DESCRIPTION
MATERIALS
PERSONNEL
TYPE OFMASONRY
CONSTRUCTION OPERATIONS
ARCHITECTURAL COPING FOR
WING/RETURN/PARAPET WALLS
TESTS AND STANDARD
OF ACCEPTANCE
MEASUREMENTS FOR PAYMENT
1409.
RATE
398
1501,
1502.
DESCRIPTION
401
401
401
1402.
1403.
1404,
1405.
1406.
1503.
1504.
1505.
1506.
1507.
<<
375
376
376
376
1315.
1407,
1500
SANDFILLING
WING/RETURNiPARAPET WALL
ACCEPTANCE OF WORK
MEASUREMENTS FOR PAYMENT
1314.
STONE
MASONRY
NO.
BO11OM PLUG
1305.
1400
PAGE
1208
1209.
1214.
1215.
1300
CLAUSE TITLE
CLAUSE
NO.
SECTION
NO.
MATERIALS
DESIGN OF FORMWORKE
WORKMANSHIP
FORMED SURFACE AND FINISH
PRECAUTIONS
PREPARATION OF FORMWORK
BEFORE CONCRETING
386
386
387
391
391
391
391
397
397
397
402
403
404
404
(.on ten Is
Ti
SECTION
NO.
SECTION
TITLE
CLAUSE
NO.
1508.
1509.
1510.
1511.
1512.
1513.
1600
STEEL REINFORCEMENT
(UNTENSIONED)
1601.
1602.
1603.
l6O~
1605.
1606.
1607.
1608.
1609.
1700
STRUCTURAL
CONCRETE
1701.
1702.
1703.
1704.
1705.
1706.
1707.
1708.
1709.
1710.
1711.
1712.
1713.
1714.
1715.
17 16.
1717.
1718.
1800
PRESTRESSINC
1801.
1802.
1803.
1804.
1805.
1806.
1807.
<<
CLAUSE TITLE
REMOVAL OF FORMWORK
RE-USE OFFORMWORK
SPECIALISED FORMWORK
TESTS AND STANDARDS
OF ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
DESCRIPTION
GENERAL
PROTECTION OF REINFORCEMENT
BENDING OF REiNFORCEMENT
PLACING OF REINFORCEMENT
BAR SPLICES
TESTING AND ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
PAGE
NO.
405
406
406
407
407
407
411
411
411
411
412
413
415
415
415
DESCRIPTION
MATERIALS
GRADES OF CONCRETE
NOPORTIONING OF CONCRETE
ADMIXTURES
SIZE OF COARSE AGGREGATE
EQUIPMENT
MIXING CONCRETE
TRANSPORTING, PLACING AND
COMPACTION OF CONCRETE
CONSTRUCTION JOINTS
CONCRETING UNDER WATER
ADVERSE WEAThER CONDITIONS
PROTECTION AN!) CURING
FINISHING
TOLERANCES
TESTS AND STANDARDS OF
ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
419
419
419
42!
424
424
425
426
427
DESCRIPTION
439
439
441
MATERIALS
TESTING OF PRESTRESSING
STEEL AND ANCHORAGES
WORKMANSHIP
SUPERVISION
TENSIONING EQUIPMENT
POST.TENSIONING
428
428
430
431
432
433
433
435
435
441
445
445
446
(on t~n
vii
SECTiON
SECTION
CLAUSE
T1TLE
NO.
CLAUSE TITLE
NO.
1808.
GROUTING OF PRESTRESSEI)
TENDONS
PRE-TENSIONING
SAFETY PRECAUTIONS
447
DURING TENSIONING
TRANSPORTATION ANI)
STORAGE OF UNITS
TOLERANCES
TESTS AND STANDARDS
OF ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
450
451
1901.
1902.
DESCRIPTION
1903.
1904.
1905.
1906.
MATERIALS
455
455
455
458
471
481
488
1809.
1810.
1811,
1812.
1813.
1814.
1815.
1900
STRUCTURAL
STEEL
1907.
1908.
1909.
2000
2100
BEARINGS
OPEN
FOUNDATIONS
FABRICATION
ERECrION
PAINTING
TESTS AND STANDARDS
OF ACCEPTA ICE
MEASUREMENFS FOR PAYMENT
RATE
451
451
451
452
488
489
DESCRIPTION
GENERAL
STEEL BEARINGS
SPECIAL BEARINGS
ELASTOMERIC BEARINGS
493
493
493
498
POT BEARINGS
INSPECTION AND TESTING
TESTS AND STANDARDS OF
ACCEPTANCE
513
519
519
2009.
2010.
RATE
519
519
2101.
2102.
2103.
2104.
2105.
DESCRIPTION
2107.
2108.
SUB-STRUCTURE 2201.
2202.
<<
GENERAL
447
2001.
2002.
2003.
2004.
2005.
2006.
2007.
2008.
2106,
2200.
PAGE
NO.
MATERIALS
GENERAL
WORKMANSHIP
TESTS AND STANDARDS OF
500
523
523
523
523
525
ACCEPTANCE
TOLERANCES
MEASUREMENTS FOR PAYMENT
526
RATE
526
DESCRIPTION
MATERIALS
529
529
52.6
Contents
SECTION
NO.
SECTION
TITLE
CLAUSE
NO.
2203.
2204.
2205.
2206.
2.207.
2208.
2209.
2210.
2300
CONCRETE
SUPERSTRUCTURE
2301.
2302.
2303
2304.
2305.
2:306.
2307.
2308.
2309,
2400
SURFACE AND
,UB ~URFA( F
GEOTECEJNICAL
EXPLORATION
2401.
2402
2403.
2404,
2405.
2406.
2407.
2408.
2409.
2410.
2411.
<<
CLAUSE TITLE
PAGE
NO.
GENERAL
PIERS AND ABUTMENTS
PIER CAP AND ABUTMENT CAP
DIRT/BALLAST WALL,
RETURN WALL & WING WALL
TESTS AND STANDARDS OF
ACCEPTANCE
TOLERANCES IN CONCRETE
ELEMENTS
MEASUREMENTS FOR PAYMENT
RATE
529
529
530
DESCRIPTION
535
MATERIALS
535
GENERAL
REINFORCED CONCRETE
CONSTRUCTION
PRESTRF.SSED CONCRETE
CONSTRUCTION
TOLERANCES
TESTS AND STANDARDS OF
ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
535
535
GENERAL
PR! 1 IMINARY INVISTIGA I tON
DETAILED EXPLORATION
EXPLORATION FOR BRIDGE
FOUNDATIONS RESTiNG
ON ROCK
BORING
RECORDS OF BORINGS
AND TRIAL PITS
METHODS OF SAMPLING
PROCEDURE FOR
TAKiNG SAMPLES
PROTECTION, HANDLING
AND LABELLING OF SAMPLES
TESTS FOR EXPLORATION
OF SHALLOW FOUNDATIONS
OF BRIDGES
TESTS FOR EXPLORATION
FOR DEEP FOUNDATIONS OF
1RIDGES
543
531
531
531
532
532
536
538
538
539
539
~41
546
547
550
550
551
552
554
555
555
CEontents
ix
SECTION
NO.
SECTION
TITLE
CLAUSE
NO.
CLAUSE TITLE
2412.
PACE
NO.
556
EMBANKMENT AND
ITS FOUNDATIONS.
2413.
2414.
2500
RIVER TRAINING
WORK AND
PROTECTION
WORK
2501.
2502.
2503.
2504
2505
559
RATE
559
DESCRIPTION
563
563
564
566
GUIDE BUND
APRON
PITCHING/REVEThIENT
ON SLOPES
RUBBLE STONE/CEMENT
569
CONCRETE BLOCK
FLOORING OVER CEMENT
2506.
2507.
2508.
2509.
2510.
2600
EXPANSION
JOINTS
2601.
2602.
2603.
2604.
2605.
2606.
26p7.
2608.
2700
ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
DESCRIPTION
GENERAL
REQUIREMENTS
STEEL PLATE SLIDING
EXPANSICdtJOINTS
FILLER JOINTS
ELASTOMERIC SLAB
SEAL EXPANSION JOiNT
STRIP SEAL EXPANSION JOINT
TESTS AND STANDARDS OF
ACCEPTANCE
2609.
2610.
RATE
WEARING
2701.
COAT AND
2702.
APPURTENANCES 2703,
2704.
2705.
2706.
2707.
2708.
2709.
<<
CONCRETE BEDDING
DRY RUBBLE FLOORING
CURTAIN WALL AND
FLEXIBLE APRON
TESTS AND STANDARDS OF
DESCRIPTION
WEARING COAT
RAILINGS
APPROACH SLAB
DRAINAGE SPOUTS
WEEP HOLE
TESTS AND STANDARDS OF
ACCEPTANCE
MEASUREMENTSFOR PAYMENT
RATE
570
570
571
571
571
575
575
576
577
578
578
583
587
587
587
591
591
592
593
594
595
595
595
595
x
SECTION
NO.
2800
CEontents
SECTION
TITLE
CLAUSE
NO.
REPAIR OF
STRUCTuRES
2801.
2802.
2803,
2804.
CLAUSE TITLE
DES~R1PTION
GENERAL
SEALING OF CRACKS
BY INJECTION OF EPOXY RESIN
EPOXY MORTAR FOR
REPLACEMENT OF SPALLED
PAGE
NO.
599
599
599
606
CONCRETE
EPOXY BONDING OF NEW
CONCRETE TO OLD CONCRETE
CEMENT GROUTING
GUNITING/SHOTCRETE
REPLACEMENT/RECTIFICATiON
OP BEARINGS
DISMANTLING OF CONCRETE
WEARING COAT
EXTERNAL PRESTRESSING
TESTS ANDSTANDARDS OF
ACCEPTANCE
MEASUREMENTS FOR PAYMENT
RATE
609
SCOPE
MATERIALS
EXCAVATION FOR PIPE
BEDDING FOR PIPE
LAYING OF PIPE
JOINTING
BACKFILLING
HEADWALLS ANI) OTHER
ANCILLARY WORKS
621
621
2909.
OPENING TO TRAFFiC
2910.
2911.
624
624
3001.
3002.
3003.
GENERAL
RESTORATION OFRAIN.CUTS
MAINTENANCE OF EARTHF.N
SHOULDERS
BITUMINOUS WORK IN
CONNECTiON WITH
MAINTENANCE AND REPAIRS
MAINTENAINING OF CEMENT
CONCRETE ROAD
2805.
2806.
2807.
2808.
2809.
2811).
2811.
2812.
2813.
2.900
PIPE
CU1.,VEST S.
2901.
2902.
2903.
2904.
2905.
2906.
2907.
2908.
3000
MAINTENANCE
OF ROA [)
3004.
3005.
<<
609
612
614
615
616
617
617
618
621
622
622
623
623
624
624
627
627
628
629
631
xi
SECTiON
SECTION
C1.,AIJSE
NO.
HIITLE
NO.
(ELAL SE TITLF,
PAGE
NC).
A PPFEN DEC ES
APPENDIX I.
637
RIIIRRID1OIN IIIFSPFUIKAI1ONS
CODES& STANDARDS
APPENDIX
640
~\PEI.ENDI\
3.
647
APPENDIX 4.
GEIDEI.JNES ON SELECTION
OFT BE GRADE OF BFTIJMEN
648
APPENDIX 5.
6 0
APPENDIX
1 (X)i-1
655
APPENDIX
1 2oO/I~
P00/I 2
200/LI
666
661
662
663
APPI EN~DIX
500/I
A PP1EE\ iTX
I 700/I
1700/TI
665
667
APPENDIX
1800/I
18(X)/tI
1800/Ill
668
674
675
I 8(X)/IT
<<
681
General
100
General
<<
General
Section 100
101..
INTRODUCTION
These Specifications shall apply to all such road and bridge works
as are required to be excctltecl under the Contract or otherwise directed
PS
Cml
PlC
IS
100-2,
l
<<
cross-sections in Figs.
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General
General
WUJ
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0
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General
Section 100
conip~scsed
to
u iron)
125
106
(in micron)
850
*
90
75
710
600
~ 500
*
425
63
53
355
300
*
45
375
250
212
*
31.5
26.5
224
19.0
~ 16..O
13.2
11:2
9_So
*
125
106
90
75
63
53
8.00
6.70
<<
180
1St)
45
General
Section 100
5.60
4.75
400
3,35
2.80
2.36
2.00
1.70
Noses
1,40
Its
1.00
1.
2.
3.
_______________
<<
Section 100
General
105.3. The Contractor shall ensure that all actions are taken to build
in quality assurance in the planning and execution of works. The quality
assurance shall cover all stages of work such as setting out, selection
of materials, selection of construction methods, selection of equipment
and plant, deployment of personnel and supervisory staff, quality control
testing, etc. The work of building in quality assurance shall be
deemed to he covered in the scope of the work.
105.4. The Contractor shall furnish, at least 15 days in advanc.e, his
programme of commencement of item of work, the method of working
he intends to adopt for various items of work such as site clearance,
construction for embankment, sub-base, base, surfacing, culverts, bridges,
retaining walls, well-sinking, cast-in-situ piling, construction of cast-insitu prestressed concrete simply supported girders, cantilever construction
of prestressed concrete superstructure, and such other items for which
the Eagineer demands the submission of the method of working. He shall
provide information regarding the details of the method of working
and equipment he proposes to employ and satisfy the Engineer about
the adequacy and safety of the same. The sole responsibility for the
safety and adequacy of the methods adopted by the Contractor will,
however, rest on the Contractor, irrespective of any approval given by
the Engineer.
The Contractor shall he required to give a trial run of the equipment for establishing
their capability to achieve the laid clown 5peciflc.atior~and tolerances to the
satisfaction of the Engineer before commencement o~the work;
~h) All equipmcnt provided shall be of proven efficiency and shall he operated
and maintained at all times in a manner acceptable to the Engineer;
<<
(c)
(4)
Any material or equipment not meeting the approval of the Engineer shall be
removed from the site forthwith;
(e)
(1)
The Contractor shall also make available the equipment for site quality control
work as directed by the Engineer~
Section 100
General
Tender Documents.
108.3. Whereas the right-of-way to the bridge sites/road works shall
he provided to the Contractor by the Engineer, the Contractor shall
have to make his own arrangement for the land required by him for site
offices, labour camps, stores, etc.
108.4. The quarry charts enclosed with the Tender Documents
indicate the location of quarries and other sources from which naturally
occurring materials are available, for guidance of the Contractor. The
leads indicated in the said charts are only approximate. It is assumed
<<
General
Section tOO
that the. Contractor has inspected the quarries, borrow areas etc , hefore
quoting his rates for the work to assess the availability of con,stnict ion
materials in required quantity and quality.
109.
SETTING OUT
1092. The lines and levels of formation, side slopes., drainage works,
earriageways and shoulders shall he care lully set out and frequently
checked, care being taken to ensure that correct gradients and crosssections are ohtained everywhere.
109.3. In order to facilitate the setting out of the works, the centre
of the carriageway or highway rntist be accurately c ieiblished by
the Contractor and approved by the Engineer. It must theit he accurately
referenced in a manner satisfactory to the Engineer, every 50 in intervals
in plain and rolling terrains and 20 in intervals in Ii illy terra in and
in all curve poinis as directed by the Engineer, with marker pegs and
chainage hoards set in or near the fence line, and a schedule of reference
dimensions shall be prepared and supplied by the Contractor to the
Engineer. These markers shall he maintained until the works rea.ch
finished formation level and are accepted by the Engineer
line
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to
Sieetion
General
100
guarding all survey monuments, bench marks, beacons, etc. The Engineer
wtll provide the Contractor with the data necessary for setting out
of the centre line, All dimensions and levels shown on the drawings or
mentioned in documents forming part of or issued under the Contract
shall he verified by the Contractor on ihe site and he shall immediately
inform the Engineer of any apparent errors or discrepancies in such
dimensions or levels The Contractor shall, in connection with the staking
c.iut of the centre line, survey the terrain along the road and shall subniit
to the Engineer for his approval, a profile along the road centre line
and cross-sections at intervals as required by the Engineer.
<<
ti
General
SCL iUfl I
~t Doe
110.2.
are, however, unknown at the design stage, these being dictated by the
Contractors methods of working. Accordingly, the Contractors programme must take into account the period of notice and duration of
diversionary works of each body as given on the Drawings and the
Contractor must also allow for any effect of these services aad alterations upon the Works and for arranging regular nieetings with the various
hodies at the commencement of the Contract and throughout the period
of the Works. in order to maintain the required co-ordination. During
the period of the Works, the Contractor shall have no objection if the
public utility bodies vary their decisions in the execution of their proposals
in terms of programme and construction, provided that, in the opiniou
of the Engineer, the Contractor has received reasonable notice thereoF
before the relevant alterations are put in hand.
110.3. No clearance or alterations to the utility shall be carried out
unless specially orde.red by the Engineer.
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12
Section
General
100
111.6.
The Contractor shall not use or generate any materials in the works
which are hazardous to the health of persons, animals or vegetation.
Where it is necessary to use some substances which can cause injury
to the health of workers, the Contractor shall provide protective clothing
or appliances to his workers.
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13
General
Section ItS)
The (.ontraetc.ir shall provide the Engineer with a copy of the regulations
govern ir~g the. safe use of nuclear gauges he intends to employ arid
shall abide by such regulations,
111,8, The Contractor must take all reasonable steps to minimise
dust nuisanc.e during the construction of the works.
ill. 12. Compliance with the foregoing wilt not relieve the Contractor
of any responsibility for complying with the requirenients of any Highway
Authority in respect of the roads used by hi in,
112.1.
The Contractor shall at all times carry out work on the highway
in a manner creating least interference to the flow of traffic while
consistent with the satisfactory execution of the same. For all works
involving improvements to the existing highway, the Contractor shall,
in accordance with the directives of the Engineer, provide and maintain,
during execution of the work, a passage for traffic either along a part
of the existing carriageway under improvement, or along a temporar)
diversion constructed close to the highway. The Contractor shall take
prior approval of the Engineer regarding traffic arrnn~!ementsduring
construction
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Section
General
100
112.2. Passage of Traffic along a part of the Existiug Carriageway under Improvement
For widening/strengthening existing carriageway where part width
of the existing carriageway is proposed to be. used for passage of traffic,
treated shoulders shall be provided on the side on which work is not
in progress. The treatment to the shoulder shall consist of providing
atleast 150 mni thick granular base course covered with bituminous
surface dressing in a width of atleast 1.5 m and the surf.ace shall
he. n dintamed throughout the period during which traffic uses the same
to the satisfaction of the Engineer. The continuous length in which
such work shall he carried out, would he limited normally tt.500 m
a.t a place. However, where work is allowed by the Engineer in longer
stretches passing place...s atie.ast 20 m long with additional paved width
of 2.5 m shall be. provided at every 0.5 km interval.
In case of widening existing two-lane to four-lane, the additional
two lanes would he constructed first and the traffic diverted to it and
only thereafter the required treatment to the existing carriageway would
ht. carried out, However, in case where on the request of the Contractor,
work on existing two-lane carriageway is allowed hy the Engine.e.r
with traffic using part of the cx isting carriageway, stipulations as in
para ahove shall 01)131 y.
After obtaining permission of the Engineer, the treated shoulder
shall be. dismnr.ntled, the debris disposed of and the area cleared as
per the direction of the Engineer.
112.3, Passage of Traffic along a Temporary Diversion
in stretches where. it is not possible to pass the traffic on part
width of the carriageway, a temporary diversion shall be constructe.d
with 7 mu carriageway and 2..5 m.. earthen shoulders on each side (total
width of roadway 12 m) with the following provision for road crust
in the 7 in widthE
(I)
(ii)
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15
Section
Genera]
100
The Contractor shall take all necessary measures for the safety
of traffic during construction and provide, erect and maintain such barricades, including signs, markings, flags, lights and flagmen as may
he required by the Engineer for the information and protection of
traffic approaching or passing through the section of the highway
under improvement. Before taking up any construction, an agreed
phased programme for the diversion of traffic on the highway shall
be drawn up in consultation with the Engineer.
The barricades erected on either side of the carriageway/portion of
the carriageway closed to traffic, shall be of strong design to resist
violation, and painted with alternate black and white stripes. Red lanterns
or warning lights of similar type shall he mounted on the harricades
at night and kept lit throughout from sunset to sunrise.
At the points where traffic is to deviate from its normal path (whether
on temporary diversion or part width of the carriageway) the channel
for traffic shall be clearly marked with the aid of pavement markings,
painted drums or a similar device to the directions of the Engineer.
At night, the passage shall be delineated with lanterns or other suitable
light source.
One-way traffic operation shall be established whenever the traffic
is to be passed over part of the carriageway inadequate for two-lane
traffic, This shall be done with the help of temporary traftic signals
or fiagmen kept positioned on opposite sides during all hours, For
regulation of traffic, the flagmen shall be equipped with red and grec.n
flags and lanterns/lights.
On both sides, suitable regulatory/warning signs as approved by the
Engineer shall be installed for the guidance of road users. On each
approach, at least two signs shall be put up, one close to the point
where transition of carriageway begins and the other 120 m away. The
signs shall be of approved design and of reflectory type, if so directed
by the Engineer.
112$, Maintenance of Diversions and Traffic Control Devices
Signs, lights, barriers and other traffic control devices, as well as
the riding surface of diversions shall be maintained in a satisfactory
condition till such time they are required as directed by the Engineer.
The temporary travelled way shall be kept free of dust by frequent
applications of water, if necessary.
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t6
General
Section 100
10 nun
(iii
5 mm
(ia) areas
aoi cu. m.
113.2.
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17
Section 1 00
General
and greater than half of the unit shall be reckoned as one and less than
half of the unit ignored. In this regard, the source of the material shall
be divided into suitable blocks and for each block, the distance from
the centre of the block to the centre of placing pertaining to that block
shall be taken as the lead distance.
113.3. Measurement of Pavement Thickness for Payment on
Volume Basis
The finished thickness of sub-base, base and bituminous courses to
he paid on volume basis shall be computed in the following manner:
Levels shall be taken before and after construction, at grid of points
10 m centre to centre longitudinally in straight reaches but 5 m at curves.
Nornally, on two-lane roads, the levels shall be taken at four positions
transversely, at 0,75 and 2.75 m from either edge of the carriageway;
and on single lane roads, these shall be. taken at two positions
transversely, being at L25 in from either edge of the carriageway. For
multilane roads, levels shall be taken at two positions transversely
for e.ach lane at locations specified by the Engineer.
S. uitahlc references for the transverse grid lines should be left
in the form of embedded bricks on either ends or by other means so
that it is possible to locate the grid points for level measurements
alier each successive course is laid.
For pavement courses laid only over widening portions, atle.ast one
lire of levels shLill he taken on each strip of widening, or more depending
on the width .~fwidening a.s decided by the Engineer.
Notwithstanding the above, th.e measurements may he taken a.t closer
mtervals also, if SO desired by the Engineer, the need for which may
arise particularly in the case of estimation of the volume of the material
br profile. corrective cours.e (levelling course). The. average thickness
of the pavement course. in any area shall he the arithmetic mean of the
difference. of levels before and after constfliclion at all the grid points
falling in that area, provided that the thickness of finished work shall
he. limited to those shown on the drawings or approved by the Engineer
in writing.
As supplement to level measurements, the Engineer shall have the
option to take cores/make holes to check the depth of construction. The
holes made and the portions cut for taking cores shall be made good
by the Contractor by laying fresh mix/material including compacting as
required at no extra cost immediately after the measurements are recorded.
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General
Section 100
113.4.
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19
Section 100
General
General works such as setting out, clearance of site before setting out and clearance
of works after completion;
(ii)
A detailed programme for the construction and completion of the work(using CPM!
PERT techniques) giving, in addition to construction activities, detailed netwo:rk
activities for the submission and approval of materials, procurement of critical
materials and equipment, fabrication of special products/equipment and their tn~
stallation and testing, and for all activities of the Employer that are likely to affect
the progress of work, etc., including updating of all such activities on the basis
of the decisions taken at the periodic site review meetings or as dirceted
by the Engineer;
(ii) Samples of various materials proposed to Ft used on the Work for conducting
tests thereon a.s required as per the provision:s of the Contract;
(iv) Design of mixes as per the relevant Clauses of th.e Specifications giving proportions
of ingredients, sources of aggregates and binder along with accompanying trial
mites as per the relevant Clautes of these Specifications to he submitted to the.
Engineer for his approval before use on the Works;
~v) Detailed design calculations and drawings for all Temporary Works (such as form..
work, staging, centering; specislised constructional handling and launchins,
equipment and the like);
(vi) Detailed drawings for temptatcs, support and end anchorage, details for ~ restressing
e:ahle profiles, bar bending and cutting schedules for reinforcement, matrrial lists
(or fabrication of stnsctssral steel, mc;
(sir) Mill test reports for all mild and high tensile steel and. cast steel as per the relevant
provisions of the Specifications;
(sitti Testing of various finished items and materials including bitumen, cement,
concrete, bearings as required under these Specifications and furnishing test
rexsrtsfeertifieates;
(is) Inspection Reports irs respect of fo nnwork, staging, reinforcement
items of work as per the relevant Specifications;
(a)
and other
(xi) Any other item of work which is not specifically provided in the Bill of Quantities
hut which is necessary for complying with she provisions of she Contract;
(,sii) All tesnporary works, formwork and false work;
(xiii) listahlishing and running a laboratory with facilities for testing for various items
of works as specified in Section 9~)and other relevant Clauses, where there
is no separate item in the Bill of Quantities for establishing and ntnning a
laboratory;
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General
Section 100
114.3, Portions of road works beyond the Limits and/or any other
work may be got constructed by the Employer directly through
other agencies. Accordingly, other agencies employed by the Employer
may be working in the vicinity of the Works being executed by the
Contractor. The Contractor shall liaise with such agencie.s and adjust
his construction programme br the completion of work accordingly and
no claim or compensation due to any reason whatsoevcr will be
entertained on this account. The Employer will he indemnified by the.
Contractor for any claims from other agencies on this account.
115, METHODOLOGY AND SEQUENCE OF WORK
21
<<
Section
General
100
<<
22
General
Section 100
SpecifIcations
01
Executive table
(for the Engineer)
02.
Executive chair
(for the Engineer~
Make-Godrej Model
No, PCH-701 or equivalent
03.
04,
05.
Make~OodrejModel No
T-i0l or equivalent
06.
Ordinary ehair~Type
II (for all other
staff and visitors)
Make-Codrej Model
No. CITR-6 or equivalent
137.
Stool
OS
Steel Almirah
1980mm a 915mm a
485mm
Make-Oodrej Model
No.1 Storewel plain
or equivalent
09.
Steel Atmirtth
1270mm a 765 rum a
440 mm
11).
Racks
5 Tie.r
1800 mm a 900 mm x
355 mm
Made of slotted
angles and MS. Sheets
of Godrej make
Il.
Typewriter
ElectronicBilingual
(English & Rindi)
Network make or equivalent.
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23
Nos. Reqd.*
General
Section 100
S.No. Item
Specifications
Nos. Reqd.
12.
Make-Cktdrej Storewel
or equivalent
13.
Air Coolers
1 4.
Room Heaters
5.
Ceiling Pans
1400 mm sue
16.
CEompu cr with
printer
Phoroc:opier
7.
120.3.
Ownership
The sile office with all services, furniture anti fittings shall he the
property of the Employer. The land for the site office shall he provided
by the Engineer and the location shall he as indicated in the Drawings.
120.4,
Maintenance
The Contractor shall arrange to maintain the site office until the
issue. of Taking over Certificate for the complete work, Maintenance
includes the day to day upkeep of the building and the surroundings,
attending to repairs to various parts of the building, furniture, fittings,
office equipment and the connected services as and when necessary.,.
including the periodic white/colour washing of building and painting of
wood work, steel work, replacing the broken window/door/ventilator
24
<<
Section 100
General
<<
25
General
Section 100
Engineers, one from the Contractors side and another from the Engineers
side and a store for the storage of samples. The remaining space shall
be provided for the. installation of equipment, laboratory tables and
cupboards, working space for carrying out various laboratory tests,
besides a. wash basin, toilet facility and a curing tank fOr the curing
of samples, around 4m x 2m x im in size and a fume chamber. The,
furnishing in each of two offices of the Materials Engineers shall he
as provided for the Site Engineer in Table 100-2.. Wooden/concrete working table with a working platform area of about Tm x TOm shall he
provide.d against the wails, also providing wooden cupboards above and
below the working tables to store accessories such as sample moulds
etc. Atleast 4 racks of slotted angles and! MS. sheets as at SINo. ID
of Table 100-2 and atleast 6 stools for laboratory test operators as
at Sl,No 7 of Table 100-2 shall also be provided.
121.3. Laboratory Equipment
The. following items of laboratory equipment shall he provided
in the field laboratory..
26
<<
General
Section 100
121.3.1. General
(I)
1 No.
(ii)
1 No.
(iii)
1 No.
(iv)
2 Nos.
(v)
1 No.
(vi)
Thennometers:
Mercury-in-glass thermometer range
0 LO 250c
Mercury-in-steel thermometer with 30 cm
stem, range upto 300C
4 Nos.
(vii)
1 Nn,
(viii)
As required
(it)
2 sets
(4
i set
(xi)
1 set
121,3,2.
<<
1 set
(i)
Riffle Box
I No.
(ii,)
1 set
27
Sechost 100
(iii)
General
C~ompaetion Tess Equipment both 2.5 kg and 4.5 kg
rammers (1..ight and Heavy compactive efforts)
I set
I set
(v)
I set
(vi)
1 set
(vii)
I set
I set
)is)
I set
(x)
1 set
lsi)
1 set
(tii)
I set
(iv)
(viti)
121.3,3.
<<
(i)
(ii)
Riffle box
(iii)
small size
I set
1 No.
complete
I set
(iv)
(v)
2 Nos.
(vi)
3 rn straight edge
I No.
(vii)
Camber hoard
I No.
(viii)
I set
(is)
Vacuum
I set
28
I set
General
121.3.4,
Section
100
(i)
(ii)
(iii)
121,4,
Ownership
Maintenance
maintenance and.
121.7. Rate
If provide.d in the Bill of Quantities as a separate payable item,
thd~ contract unit rate for constructing and providing the field laboratory
shall include, expenses of all operations involved in construction of
the httilding including all services, fittings, fixtures, furniture and fencing
as mentioned in Clause 121.2,
The Contract unit rate for maintenance shall include expenses
towards all items of works and equipment in Clauses. .121.2 and 121.3
including power and water charges for supply from the mains and for
providing uninterrupted supply of power and water from alternate
sources in case of failure of main supply.
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29
General
Section 100
Ownership
<<
30
Section
General
100
122,4,
<<
31
Section 100
123.
General
123.1. Scope
The work covers the provision and maintenance of wireless coin
munieation systems with necessary mobile/base trans-receivers and other
accessories,
123.2,
Supply
(h)
to Not,
The Contractor shall provide the complete wireless system within
12 months from the date of commencement of work or 8 months from
the ttate. on which frequency is allotted to him by the Coy L Department,
whichever is later. FTc shall submit a guarantee for replacement of any
d,e.feclive. trans-receiver/trans-receivers during the hurrency of the. con---tract.
(c)
..
123.3. Approval
The Contractor shall. arrange to obtain all necessary statutory
approvals From various Government bodies for operating the system,. He
shall also fulfil the requirements laid down hy various Government
Departments and obtain the frequency to operate the wireless system.
123.4.
Maintenance
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32
Section 100
General
<<
3:1
(ieneral
Section 100
cars and br hard top leeps for use by the Engineer as described under
the Bill of Quantities,
124,2,
Description
The passenger cars shall be petrol or diesel driven and may he Am.
hassador or equivalent having cylinder capacity of minimum 1400 cc
The hard top jeeps shall be 4 \V Drive either petrol or diesel driven
and may be Maruti Gypsy Model MG 410, Mahindra & Mahindra leep
Model MM 540/MM~440or equivalent. The number of vehicles to h1
pm idc.d by the Contractor shall be decided hy the Engineer at vanno
limes, out of the total provision in the B ill of Quantities and md tEnted
in writing.
The Contractor shall provide within one month from the due of
order by the Engineer, vehicles as indicated above, lhe vehicless hal I
he provided and maintained unhl issue of the Taking Over (ertifitEatL
fix the complete Work. Initially, new vehicles shall he provided, in
case of vehicles of Indian make. a velt ide shall be replaced with a
new xrchiclt~after a maxim tim run of 75,001 km or two years whiche ci
is earlier, in case ot vehuEles of lbreign make approved b~the Engineer
the vehicle shall be replaced with a new vehicle after a maximum run
uI 1,00,0110 km er three Lears u~hicheveris earlier. All necessary taxes
for operating the vehie ic shall he hilly prod anti all necessary papers
,shal be pros ided as reru red hy prevailing Motor Vehicles Act tvi th
iEomprrhensivc in~urance :ov er for the vehicles. The vehicles shall he
provided da> and night ai required by the Engineer The Contractor
shall also makE as ailEd~lc. ~lnvrrs hEEivmne valid licence at such tunes and
or such duration as I nstruER d by the Engineer.
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.34
Secuon (Xi)
Ocncrat
If the Contract Works are not completed within the stipulated penod
or within the granted extended lime of completion, provision and maui
tcnance of vehicles in accordance with Clause 124.,! through 124 4 shall
be carried oot by the Contractor at his own cost and no payment shall
he made for the same. In case of any failure by the Contractor to
do so an amount of R s, 700 per clay or part thereof per vehicle sft ill
125,2. Description
The Contractor shall arrange to take colour photograph sacv
stages/facets of the worl: including interesting and no H (cat res
of the work as desired h) the Engineer. The. photograph.;; shalt he
acceptable quality and they shall he tal:en by a professior ally ci rrrrpe .en
photographer with caineri having the facility ro reeori I te U t 1
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Section 1(X)
General
photographs taken in the prints and negative. The Contractor shall supply
albums
126.1. i)escription
The work conskts of taking video films of important activities of
the work as directed by the Engineer during, the currency of the proiect
and editing them to a vidpo film of playing time not less than 60 minutes
md upto 180 minutes as directed by the Engineer. It shall contain
naiTation of thene tivities in English by a competent narrator. The
edition of the video 1dm and the script for narration shall be as approved
by the Engineer. The video cassettes shall be of acceptable quality
and the film shaL he capable of producing: colour pictures.
126.2. Measu renients for Payment
The nleaanement shall be by number of sets of edited master
cassettes each with four copies thereof.
.
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36
General
126.3.
Section 11)0
Rates
The contract unit rate shall include all expenses for making video
films with the help of a professionally competent photographer, editing,
narration and supplying the final edited master cassette aiongwiih
tour copies thereof..
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Site Clearance
200
Site Clearance
<<
Site Clearance
Section
200
Scope
20L2.
Preservatkni of Property/Amenities
Roadside trees, shrubs, any other plants, pole lines, fences, signs,
monuments, buildings, pipelines., .sewer~and all highway facilities within
or adjacent to the highway~.vhichare not to be disturbed shall be protected
from injury or damage. The Contractor shall provide and install at
his own expense, suitable safeguzuds approved by the Engineer for
this purpose.
During clearing and grubbing, the Contractor shall take all adequate
precautions against soil erosion, water pollution, etc., and where required,
undertake additional works to that effect vide Clause 306. Before start
of operations, the Contiactor shall submit to the Engineer for approval,
his work plan including the procedure to be followed for disposal of
waste materials, etc.., and the schedules for carrying out temporary
and permanent erosion control works as stipulated in Clause 306.3.
2013, Methods, Tools and Equipments
Only such methods, tools and equipment as are approved by the
Engineer and which will not affect the property to be preserved shall
be adopted for the Work. If the area has thick vegetation/roots/trees, a
crawler or pneumatic tyred dozer of adequate capacity may be used for
clearance purposes. The dozer shall have ripper attachments for removal
of tree stumps, All trees, stumps, etc., falling within excavation and
fill lines shall be cut. to such depth below ground level that in no ease
these fall within 500 mm of the subgrade. Also, all vegetation such as
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41
Section 200
Site Clearance
roadway
shall he
All excavations below the general ground level arising out of the
removal of trees, stumps, etc., shall be filled with suitable material and
compacted thoroughly so as to make the surface at these points conform
to the surrounding area.
Antli ills both above and below the ground, as are liable to collapse
and obstruct free subsoil water flow shall be removed and their workings,
which may extend to several metres, shall be suitably treated.
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42
Site Clearance
Section 20()
trees upto 300 mm in girth including removal of stumps and roots, and
trimming of branches of tmes extending above the roadway shall be
considered incidental to the clearing and grubbing operations. Removal
of stumps left over after trees have been cut by any other agency
shall also be considered incidental to the clearing and grubbing
operations.
Cutting, including removal of stumps and roots of trees of girth
above 300 mm and hackfilling to required compaction shall he measured
in ten-os of number according to the sizes given below:i)
Above
3(X) mm
to
6()0
mm
ii)
Above
6(X)
fl)
Above
to
900
mm
9(X) mm to
1800
mm
iv)
Above
mm
1800 mm
201.6.
Rates
201.6.1, The Contract unit rates for the various items of clearing
and grubbing shall be payment in full for carrying out the required
operations including full compensation for all labour, materials, tools,
equipment and incidentals necessary to complete the work, These ~vi11
also include removal of stumps of trees less than 300 mm in girth as
well as stumps left over after cutting of trees carried out by another
ag:ncy, excavation and back-filling to required density, where necessary,
and handling, salvaging, piling and disposing of the cleared materials
with all lifts and upto a lead of 1000 m.
201.6.2. The Contract unit rate for cutting (including removal of
stumps and roots) of trees of girth above 300 mni shall include
excavation and hackfilling to required compaction, handling, salvaging,
piling and disposing of the cleared materials with all lifts and upto
a lead of 1000 m.
201.6.3. Where a Contract does not include separate items of clearing
and grubbing, the sa.me shall be considered incidental to the earthwork
items and the Contract unit prices for the same shall be considered as
including clearing and grubbing operations.
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.:j 1
Section 200
Site Clearance
OTHER STRUCTURES/PAVEMENTS
21)2.1. Scope
This work shall consist of removing, as hereinafter set forth, existing
culverts, bridges, pavements, kerbs and other structures like guard~rails.,
fences, utility services., manholes, catch basins, inlets, etc.~~)which are
in place but interfere with the new construction or are not suitable to
remain in place..~,and of salvaging and disposing of the resulting materials
and back filling the resulting trenches and pits.
Existing culverts, bridges, pavements and other structures which
are within the highway and which are designated for removal, shall
be removed upto the limits and extent specified in the drawings or as
indicated by the Engineer.
Dismantling and removal operations shall he carried out with such
equipment and in such a manner as to leave undisturbed, adjacent
pavement, structures aud any other work to be left in place.
All operations necessary for the removal of any existing structurc
which might endanger new construction shall be completed pnor w.
the start of new work.
20L2.
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44
Site Clearance
Section 200
202.4.
Back-filling
Disposal of Materials
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..
di h
II
th
ot
s imE~,
Site Clearance
Section 2110
value shall he placed in neat stacks of like materials within the righ o
cThway, as directed by the Engineer with all lifLs and upto a lead of
1000
Pipe t: ulverls that are removed shall he cleaned and neatly piled
on the nght~of~way
at points designated by the Engineer ss ith all lifts
and lead upto 1000 in.
Struc tura.i steel removed from old structures shall, unless otherwise
speci bed or directed, he stored in a neat and presentable manner on
blocks in locations suitable for loading. Structures or portions thereof
which are specified in the Contract for re~erectionshall he stored in
separate ~i1e~,
Timber or lurn her from old structures which is desig naled by the
E: ng ineer as rnateri a Is to he salvaged shall have all nails and bolts rem ove. il
theretroin and shall be stored in neat piles in locations suitalElle for
loading.
nEt
202.6.
cci in
tot
en. in
ionrie
cii in
irrear ft
Nor
202.7. Rates
The Contract i nit rates for the various i teins of disinanti ing shall
paid in hill for carrying out the required operations including hill
a ipen sation for all labour, materials, tools, ec~tupnlen
t, safeguards and
neidentals necessary to complete the work. These will also include cx
.avation and back lilling where necessary to the required compac Lion
anti for handling, salvaging, piling and disposing of the cli.smantlta:l
materials within all lifts and upto a lead of 1000 rn,
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300
Earthwork, Erosion
Control and Drainage
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Soil
This shalt comprise topsoil, turf, sand, silt, loam, clay, mud, peat, black cotton
soil, soft shale or loose moomna, a mixture of these and similar material which
yields to the ordinary application of pick, spade and/or shovel, rake or oth,e.r
ordinary digging implement. Removal of gravel or any other nodular material
having dimension in any one direction not exceeding 75 mm occurring in such
strata shall be deemed to be covered under this category.
(ii)
(iii) lime concrete, stone masonry in lime mortar and brick work in lime/cement
mortar below ground level, reinforced cement concrete which may be broken
up with crow bars or picks and storw masonry in cement mortar below
ground level; and
(iv) boulders which do not require. biaating having maximum dimension in any
direction of more than 300 mm, found lying loose on the surface or embedded
in river bed, soil, talus, slope wash and terrace material of dissimilar origin.
.49
<<
and Drainage
any rock or cement concrete for the excavation of which the usc of
mechanical plant and/or blasting is required;
(ii)
(c)
Marshy Soil
This shall include soils like soft clays and pears eacavated below the original
ground level of marshes and swamps and soils excavated from other areas
requiring continuous pumpi g or bailing out of water,
301,2.2. Authority for classification The classification of excavation shall he decided by the Engineer and his decision shall be final
and binding On the Contractor. Merely the~use of explosives in excavation
will not be considered as a reason for higher classification unless blasting
is clearly necessary in the opinion of the Engineer.
301.3. Construction Operations
301.31. Seding out After the site has be.e.n cleared as per Clause
201., the. limits of excavation shall he set out hue to lines, curves, slopes,
grades and sections as shown on the drawings or a.s directed by the
Engineer., The Contractor shall provide all labour, survey instrtiments
and materials such as strings, pegs., nails, bamboos, stones, lime,, r.orl.ar,
concrete, etc.., required in connection with the setting otit of work,s and
the e.,sl.ablishment of bench marks. The Contractor shall be responsible
for the maintenance, of bench tnarks and other marks and stakes as long
.as in t.he. opinion of the Engineer, they are required for the work.
301,3.2. Stripping and storing topsoil When so directed by the.
Enginte., the topsoil existing over the siles of excavation shall be stripped
to spe.cified depths constituting Horizon A and stockpile.d at designated
locations for re-use in covering embankment slopes, cut slopes, berrns
and olher disturbed areas where re-vegetation is desired. Prior to stripping
the topsoil, all trees, shrubs etc. shall be removed along with their roots,
with approval of the Engineer.
301,3.3. Excavation General All excavations shall he carrie.d
out in conformity with the directions laid here.-in~underand in a manner
-
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50
Section 300
approved by the Engineer, The work shall be so done that the suitable
materials available from. excavation are satisfactorily utilized as decided
upon beforehand.
While planning or executing excavations, the Contractor shall take
all adequate precautions against soil erosion, water pollution etc. as per
Clause 306, and take appropriate drainage measures to keep the site
free of water in accordance with Clause 3li.
The excavations shall conform to the lines, grades, side slopes and
levels shown on the drawings or as directed by the Engineer. The
Contractor shall not excavate outside the limits of excavation. Subject
to the pennitted tolerances, any excess depth] width excavated beyond
the specified levels/dimensions on the drawings shall be made good at
the cost of the Contractor with suitable material of characteristics similar
to that removed and compacted to the requirements of Clause 305.
All debris and lose material on the slopes of cuttings shall be
removed. No backfilling shall be allowed to obtain required slopes
excepting that when boulders or soft materials are encOuntered in cut
slopes, these shall be excavated to approved depth on instructions of the
Engineer and the resulting cavities filled with suitable material and
thoroughly compacted in an approved manner..
After excavatior, the sides of excav.ated area shall be trimmed and
the area contoured to minimise erosion and ponding, allowing for natural
drainage to t4ke. place. If trees were removed, new trees shall be planted,
as directed by the Engineer. The cost of planting
he deemed to be incidental to the work.
new trees
shall
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51
Section 300
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and Drainage
Section 300
:309, excavation for these shall be carried out in proper sequence with
other works as approved by the Engineer.
All hard niaterials, such as hard moortim, rubble, etc., not intended
for use as above, shall be stacked neatly on ~peeified land as directe.d
by the Engineer svith all lifts anti lead upto 1000 m.
Unsuitable antI surplus material not intended for use within th.e lead
sieciiied above .sh.al.l also, if necessary, he transported with all lifLs anti
lead beyond initia.i 1000 m, disposed of or tised as directed by the
Engineer.
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.53
Section 300
Earthwork, Erosion
Control and
l)rainagc
Preservation of Property
by
the Engineer.
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54
Section 300
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.55
Section 300
Drainage
...
as. m.
...sq. m.
...
301.9.
as. m.
...
cu. m.
cu. m.
Rates
301,91. The Contract unit rates for the items of roadway and drain
excavation shall he payment in full for carrying out the operations
required for the individual items including full compensation for
(i)
selling out;
(ii)
(iv) dewatering;
~v) keeping the work free of water as per clause 3tl; and
(vi) all labour, materials, tools, equipment, safety measures, testing and incidentats nec~
cssary to complete the work to Specifications.
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56
achieve a
Drainage
Section 300
~pecifledslope in rock excavation, the same shall be paid for vide Clause
3015.
3019.2.
302.1. General
Blasting shall be carried out in a. manner that completes the
excavation to the. lines indicated in drawings, with the least disturbance
to adjacent material. It shall be done only with the written permission
of the Engineer. All the statutory laws, regulations, rules, etc., pertaining
to the. acquisition, transport, storage, handling and use of explosives shall
be strictly followed.
The Contractor may adopt any method or methods of blasting
consistent with the safety and job requirements. Prior to starting any phase
of the operation the Contractor shall provide information describing
pertinent blasting procedures, dimensions and notes.
The magazine for the storage of explosives shall be built to the.
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57
into the magazine which when not in use shall be kept securely
locked, No matches or inflammable material shall be allowed in the
magazine. The magazine shall have an effective lighlning conductor
The following shall be hung in the lobby of the magazine:
(a)
A copy of the relevant niles regarding safe storage hot.h itt English and in the
language with which the workers coneented are familiar.
(0)
(c)
(to
All the materials, tools and equipment used for blasting operations
shall be of approved type. The, Engineer may specify the type of
explosives to be allowed in special cases The fuse to be used in wet
locations shall he. sufficiently water-resistant as to he unaffected when
immersed in water for 30 minutes. The Tate of burning of the fuse
shall be ttniibrm and definitely known to permit such a length being
cut as will permit sti fficient time to the firer to reach safety before
explosion takes place. Ce,tonators shall he capable of giving effective
blasting of the explosives. The blasting po~vder,explosives, detonators,
fuses, etc., shall be fresh and not damaged due t.o dampness, moisture
or any other cause, They shall be inspected before use and damaged
articles shall be discarded totally a.i~dremoved from the site imrn cr1 iately.
3023.
Personnel
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58
and Drainage
Section 300
blasting
work within
When blasting is done with powder, the fuse cut to the required length
shall he inserted into the hole and the. powder dropped in. The powder
shall be. gently tamped with copper rods with rounded ends. The explo.sivc.
POwder shall then be covered with tamping material which shall be
tarnped lightly but firmly.
When blasting is done with dynamite and other hig.h explosives, dynamite cartridges shall be prepared by inserting the square cut end of
a fuse. mb the de.ton ator and finishing it with nippers at tine opc.tn entl,
line. dc.tonatnr gently pushed into the primer leaving 1/3rd of the coppe.r
tube expose.d outside. The paper of the cartridge shall then he clc.se.d
up anti securely bound with wire or twine. Th..e primer shall be. housr.d.
into the explosive.. Boreholes shall be of such size that the cartridge
can easily g.n down. The. holes shall be cleared of all debris and
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59
Scetiort 300
esplosmve inserted. The space of about 200 mmn above the charge shall
then be gently filled with dry clay, pressed home and the rest of the
tamping fOrmed of any convenient material gently packed with a wooden
rammer,
At a time, not more than 10 such charges will be. prepared and
iircd. The man in charge shall blow a siren in a recognised manner
for cautioning the people. All the people. shall then he required to move.
to safe dIstances. The charges shall be lighied by the man~in-chargeonly,
The man-in-charge shall count the number of explosions. He shall satisfy
hint selF that all the charges have been exploded before allowing the
workmen 1.0 go hack to the work site,
Alter blasting operations, the Contractor shall compact the loose rematerial below suhgrade a.nd replace the material removeti
below stmbgrade with suitable materiaL
Si LI ttal
302.5.
Misfire
with water
ness Fr ~le shall he drilled at about ~i5tl trios from the old hole and fired. This
should lrlasr the ,ld charge. Should I I trot hIatt the old charge, the procedure
shall ho repeated till the old charge is hlr.tstect
11
i lit 5451 ol ehirges of geltynire, dynamite, etc., the man-ittcharge shall gently
rrnrsve the tamping and the primer with the detortator A frssh detonator and
u mrr shall then he used to blast the charge. Altsrnattvely, the hole may hre
I eared of 10(1 mm of tarrrprng and the drreetisrrr Llten ascertained by p1wittg
a strel. itt the hole. Anorlrer hole rrr.rs their he drilled t 50mm away ,snd parallel
or it
ibis hole shtall then he ettarged and fired when thte to isfired hole shoe Id
explede.at the same time. fire man-rn-c barge shall at ortec report to the
our r,setor s office artd the Fnrtineer all eases of misfire, the ccrrrse of the sarrrs
and ahat steps were taken in ronrreetron therewith.
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60
Section 300
All overburden soil and weathered. rock along the top of the
r,.~..xeavatinn for a distance of about 5 to 15 rn beyond the. drillirrg limits,
or to the iEm.d of the excavation, as decided by Engineer shall be removed
belor.e drilling the prespliwng holes, Particular care and attention sEhaII
he di recEted to the beginning and end of excavations to ensure complete.
removal of all overburden sod and we.athere.d rock and to expose I resEh
rock to an elevation equal to the bottom of the adjacent lift of the.
lwesplittimtg holes being drilled,
S lope. holes for presplitting shall he drilled along the lin.e of the
planned slope within the specified tolerances, The drill holes shall
be not less than 60 mm nor more. than 75 mm in diameter, Drilling
opera.uotts shall be controlled by the use of proper equipment arldl
tech muque to ensure. that no hole shall deviate from the plane of the
plan neil slope by more. than 300 mm nor shall any hole deviate from
being parallel to an adjacent hole by more than two~third of the.
planned horizontal spacing between holes.
The length
of
9 ni.
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61
Srction 300
and Drainage
Auxiliary drill holes along the presplit line, not loaded or stemmed,
may be ordered by the Engineer. Except for spacing, auxiliary drill holes
shall conform to the provisions for presplit holes.
The line of production holes shall be placed inside the presplit
lines in such a manner as to avoid damage to the presplit face.
If necessary, to reduce shatter and overbreak of the presplit surface,
first line of the production holes shall be drilled parallel to
the slope line at the top of the cut and at each bench level thereafter,
the
to the presplit
303.3. Tolerances
The presplit face shall not deviate more than 300 mm from the plane
passing through adjacent drill holes, except where the character of the
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62
Section 300
303.4.
Rates
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61
Section 300
the Engineer.
The depth to which the excavation is to be carried out shall be as
shown on the drawings, unless the type of material encountered is such
a.s to require changes, in which ease the depth shall be as ordere.d
by the Engineer. Propping shall be -undertaken when any foundation
or stresse.d zone from an adjoining structure is within a line ol 1 vertica,l
to 2. horizontal from the. bottom of the excavation,
Where. blasting is to he resorted to, the same shall he carried out
in accordance with Clause 302 and all precautions indicated therein
ohserved, Where. blastitig is likely to endanger adjoining foundations
or other structures, necessary precautions such as controlled blasting,
providing rubber mat cover to prevent flying of debris etc, shall he.
taken to prevent any damage.
304.3.3. Dewatring and protection Normally, open foundations
shall he laid dry. Where water is met with in excavation due to stream
flow, seepa.ge, springs, rain or other reasons, the Contractor shall take
adequate measures such as hailing, pumping, constructing diversion
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64
dii:
tie
cii nijr;:tiE.ior
o[
or
Lire. reduircEd. t.hflsr shall Lie LEa rr
dc ILLnIEd arid (ii rstiiictid MiLl Ii.: inalEle EEL ;
is necescEay l:nr facilitatinu, construction tc.i ha carried
of the cofh::rrdarn~ shall he suirEh as
for thi corOnictieri sni:i irirspr;. toni and
el i(i.iLni~riny equ.rpincno. ccc.., nude
it
iii: iEViIiEEiEE.tir,
Tlti~~.niiiEiiiEd
IF
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65
Section 3t~.t
of all soft and loose material., cleaned and cut to a firm surface either
level and stepped as directed by the Engineer, All seams shall be cleaned
out and filled with cement mortar or grout to the satisfaction of the
If the depth of fill required is more than I .5m above the top of
the footing, filling upto 1.5m above top of footing shall be done with
lean concrete (1:3:6 nominal mix) followed by boulders grouted with
cement.
When foundation piles are used, the excavation of each pit shall
be substantially completed before beginning pile-driving operations
therein. After pile driving operations in a given pit are completed, all
loose and displaced materials therein shall be removed to the elevation
of the bottom of the footings.
304.3.5. Slips and slip-outs : If there are any slips or slip-outs in
the excavation, these shall be removed by the Contractor at his own
cost.
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Section 300
setting out;
(ii)
construction of necessary cofferdams, cribs, sheeting, shoring and bracing and their
subsequent removal;
(iii) removal ofalt togs, stumps, grubs and other deleterious matter and obstructions,
for placing the foundations including trimming of bottoms of excavations;
(iv) fotmdation sealing, dewatering including pimping when no separate provision for
it is made in the Contract;
(v)
backfilling, clearing up the site and disposal of all surplus material within all lifts
and leads upto 1000 m or as otherwise specified; and
(vi) alt labour, materials, tools, equipment, safety measures, diversion of traffic and
incidentals necessary to complete the work to Specification.
EMBANKMENT CONSTRUCTION
305.1. General
305.1.1. Description : These Specifications shall apply to the
construction of embankments including subgrades, earthen shoulders and
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67
(h)
Cc
Cd
Clay having liquid limit eacceding 70 and plasticity index exceeding 45 and
(11
Materials wills
salts resulting in
leaching in
thc embankment.
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68
]~5~
itt
Section 3(X)
ill c~id nan ft ttol exceed 75 mm when he int; placed in the embank tnert
and. 50 rnni when placed in the suhgrade. However, the Engineer may
hi discretion Permit the use of maieriai coarser than this also if he
:Eltts [tedthat the same will not present any difficulty as regards the
a:.: EE tit Itt of fill material and its compactton to the requirements of
: ~pecifi,caiions, the maximum particle siie shall not he more than
c ~ ii nil
I I he compacted layer thickness.
c
305. 2,1.5. OrcI manly, ortly the materials sEatisfying the density
ttten U; g iv ert mn Table 3(X)i shall be employed for the construct]on
te e nit bank men t and the subgrade.
~i
id liL
si[
ii..
is
ii
(1
md eari.hcn
lie t.i/ier5e (ls,sckfil
0 it t:.iltle is net applicable for lightweight fill sssateciat e.g cinder, ft~ash
[he Ertc sneer etemy relax these rel:Iutrclments at his disc retton taking into account
its exists Lilsi lit
5 stE materials for cssitsrnsctton sand other relevant itsce~srs.
1.115
ILtOLt
design dEeR
at
diii
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69
Section 300
as---
-.
The work shall be so planned and executed that the best available
materials are saved for the subgrade and the embankment portion just
below the subgrade.
305.2,2.2. Borrow materials Where the materials are to be
obtained from designated borrow areas, the location, size and shape of
these areas shall be as indicated by the Engineer and the same shall
not be opened without his written permission. Where specific borrow
areas are not designated by the Employer/the Engineer, arrangement for
locating the source of supply of material for embankment and subgrade
as well as compliance to environmental requirements in respect of
excavation and borrow areas as stipulated, from time to time by the
Ministry of Environment and Forests, Government of India and the local
bodies, as applicable, shall be the sole responsibility of the Contractor.
Borrowpits along the road shall be discouraged. If permitted by the
Engineer, these shall not be dug continuously. Ridges of not less than
8 m width should be left at intervals not exceeding 300 m. Small drains
shall be cut through the ridges to facilitate drainage. The depth of
the pits shall be so regulated that their bottom does not cut an imaginary
line having a slope of 1 vertical to 4 horizontal projected from the
edge of the final section of the bank, the maximum depth in any case
being limited to 1.5 m. Also, no pit shall be dug within the offset width
from the toe of the embankment required as per the consideration of
stability with a minimum width of 10 m.
Haulage of material to embankments or other areas of fill shall
proceed only when sufficient spreading and compaction plant is operating
at the place of deposition.
No excavated acceptable material other than surplus to requirements
of the Contract shall be removed from the site. Should the Contractor
be permitted to remove acceptable material from the site to suit his
operational procedure, then he shall make good any consequent deficit
of material arising therefrom.
Where the excavation reveals a combination of acceptable and unacceptable materials, the Contractor shall, unless otherwise agreed by
the Engineer, carry out the excavation in such a manner that the
acceptable materials are excavated separately for use in the permanent
works without contamination by the unacccptable materials. The
acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the
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70
Section 300
1,
2.
3.
Not allowed
Not less than 90
The values of maximum thy density and optimum moisture content obtained
in accordance with IS: 2720 (Part 7) or (Part 8), as the case may be, appropriate
for each of the fill materials he intends to~use
(ii)
A graph of density plotted against moisture content from which each of the
values in (I) above of maximum dry density and optimum moisture content were
determined.
(iii)
The Dry density-moisture content .CBR relationships for light, intermediate and
heavy compactive efforts (light corresponding to IS: 2720 (Part 7), heavy
corresponding to IS: 2720 (Part 8) and intermediate in-between the two) for
each of the fill materials he intends to use in the subgrade.
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71
ic.attr so
niL 10 cause daniac 10 the works, crops or any
property. [)i ie 0 any negligence on the part of the Contractor,
nucEh iI1ifl1aL~E LEalised, it shall be the sole responsih~Iityol the
1 IC re]pair/Iestore U to e.rkEEinal condition or compensate
LiL1flW~c ii, his own COSt.
ci
?~
LIIi,
LEmi:mnkrnent
under
water, Clause
[ii In
..;irIl{P
be eIE)nsL.rueted
~.,I IELHe
B5 10
15~...I
.~1...r..:sp1ler; 1
IrL,
..iIt
~LlhiIt IIitt
~,lI:r(rL:~. and
l]llr~,,E,.o:r,:1, ~ltere (he dilferenee between the suhc;rade level (top of the
.~vibrradeOil which pi.tvement rests t and ground level is less, than U.S
round dc.ie.s not have 97 per cent relative compaction
It rlEi,i
pr..~cI
ri ihLJpLIE1Ar,it level
density
30O~2,the
ground
1.~ic li.iosened
0.5asrn given
below intheTable
subgrade
level, wateretEl
all ii LEcU It piaEted mu I ayers in aciEEordance witlt Clauses 305,3.5 and 3053.6
I El riot less than 97 per cent of dry dens,ity as given in Talle 3002.
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h.Lrthl~IITk
l)rainage
Secliorl
.itx:
,in the ent haru k nue n t foundation shall he removed and replaced by
approve il irtaterials lairl in layers to the required degree of compaction.
ntban k.rtie n t or sEubgrade work shall not proceed until the fouttdttt~
tons fur sin bank men lJsuhg rrtde have he.eit inspected by tltc Engineer
er Lau.i sl:LIIE liEtry i:nttd itiOn and approved.
undati on tre attnent specified for crnhankments especially high
reittny on suspect foundations as revealed by horchole
sha llhe LEarned out iru a rrtanne.r and to the depth as desinsd by
the entElund t:tn ~, hich ait emhankmnent is to he huilt
at cr1 IfI~.. .Erts.Fte.I tel types a.) to (I.) in Clause 3052.1, at least 500
inasi be rerrioved and replaced by aceclELthlc
~atEbrinkntentconstruction comnlencrt,s,
Fri
Hi
Eli..
i.
itt
.j~~q
e,t,..tL.~, Ftu... hsLtt Lhrlrtugitl5 compacted to dir: s
.5 ..ttI tI ttt L,.Fie 1001 curl cot approved by the Engineer. built
ted
tsr
ii . i~I
.hail
10
Ku,
Ito
to tEontrttcnce.tneot of compaction; if fr:aud tsr
iL .0 cc rr:H l,,ttets, the satttiEr .rltall he made good. Wltere water
is Os .,trlLlrEri in sttch rEr.lrtstrutEtLons, water shall he. sprinkled
t,tti.:er f;ttcd .tit.h sprinkler capable of applying
F, :n lv .rLtlt a sun crollahie rate of flow to variable widths of sunia:e
an, fleer.:Iin,e,. The water shall he added unifbnnly arid
:
ml:, eti use, I hy hiading, disc inc or harrowing until a uotfonn
,:..IJttE
s.c eut d.tlE,tained tltrottghottt. the depth of the la,,er.
Er
<<
I [aLEtrt:trt.
.Sltneiri eirt:Eutrtslances tuise, where. owing to wet weather,
hIts notrtt,rtt LEontertt eEtnno~be reduced to the required am.iuot by the
i;tOc.:riurC~ t..ttittpctet ittnw tEnEk shall he suspended.
73
Section 300
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74
Earthwork,
Section 300
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75
Section 300
Drainage
under
Special Conditions
305.4] Earthwork for widening existing road embankmenu
When art existing embankment and/or subgrade is to be widened
and its slopes are steeper than 1 vertical on 4 horizontal, continuous
horizontal benches, each at least 300 mm wide, shall be cut into the
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76
Section 300
old slope for easuring adequate bond with the fresh embankment/subgrade
material to be added. The material obtained from cutting of benches
could be utilized in the widening of the embankmeni/subgrade. However,
when the existing slope against which the fresh material is to be placed
is flatter than 1~vertical on 4 horizontal,the slope surface may only be
ploughed or scarified instead of resorting to benching.
Where the width of the widened portions is insufficient to permit
the use of conventional rollers, compaction shall be carried out with
the help of small vibratory rollers/plate compactor~powerrammers or
arty other appropriate equipment approved by the Engineer. End dumping
of material from trucks for widening operations shall be avoided except
in difficult circumstances when the extra width is too narrow to permit
the movement of any other types of hauling equipment.
305.4.2. Earthwork for embankment and subgrade to be placed
against sloping ground Where an embankment/subgrade is to be
placed against sloping ground, the latter shalt be appropriately benched
or ploughed/scarified as required in Clause 305.4,1 before placing the
embankrnent/subgrade material. Extra earthwork involved in benching or
dtie to ploughing/scarifying etc. shall be considered incidental to the work.
For wet conditions, benches with slightly inward fall and subsoil
drains at the lowest point shall be provided as per the drawings,
before the till is placed against sloping ground.
Where the Contract requires construction of transverse subsurface
drain at the cut~llllinterface, work on the same shall be carried out to
Claose 309 in proper sequence with the embankment and suhgrade work
as approved by the Engineer.
305.4.3. Earthwork over existing road surface
Where the
embankment is to be placed over an existing road surface, the work shall
he earned out as indicated below
(ii
If the existing road surface is of granular or bituminous type and lies within
1 in of the new subgradc level, the same shatl be scarified to a stepth of 50 mm
or more if specified, so as to provide ample bond between the old and new material
ensuring that at least SOt) mm portion below the top of new suhgracle level
is compactesl to the desired density.
(ii)
If the existing road surface is of cement concrete type and lies within I m
of the new subgrade level the same shall be removed completely.
(iii) If she level difference between the existing road surface and the new formation
level is snore than tm, the existing surface shall be petmitted to stay in place
without any modification.
<<
77
Section 3(X)
<<
Drainage
Section 300
<<
79
Ear hwnrk,
ntaterial, which is unacceptable for use in the fill being surcharged, lying
below formation level, the ContracEtor shall remove the unacceptable
material and dispose it as per direction of the Engineer. I-Ic shall
then bring the resultant level up to formation level with acceptable
material,
<<
80
Section 300
The measurement of fill material from borrow areas shall be the difference between the net quantities of compacted fill and the net
quantities of suitable material brought from roadway and drainage
excavation. For this purpose, it shall be assumed that one cu,m. of
suitable material brought to site from road and drainage excavation
forms one cu.m. of cbmpacted fill and all buiking or shrinkage shall
be ignored.
Construction of embankment under water shall be measured in
Cu,m.
Construction of high embankment with specified material and in
specified manner shall be measured in cu.m.
Stripping including storing and reapplication of topsoil shall be measured in cu.m.
Work involving Loosening and recompacting of ground supporting
embankment/subgrade shall be measured in cu. m.
Removal of unsuitable material at embankmentisubgrade foundation
and replacement with suitable material shall be measured in cu.m.
Scarifying existing granular/bituminous road surface shall be measured in square metres.
Dismantling and removal of existing cement concrete pavement
shall be measured vide Clause 202.6,
Filter medium and backfill material behind abutments, wing walls
and other retaining structures shall be measured as finished work in
position in cu.m.
305.9. Rates
305.9.1. The Contract unit rates for the items of embankment ~nd
subgrade construction shall be payment in full for carrying out the
required operations including full compensation for
(1)
(ii)
Setting
Out;
81
<<
Section 300
(xi) All labour, materials, tools, equipnent and incidentals necessary to complete the
work to the Specifications;
(xii) Dewatering; and
(xiii) Keeping the embankment/completed formation free of water as per Clause 311.
<<
82
305.9.9. Clause 305A..6 shall apply as regards Contract unit rate for
construction of embankment under water.
305.9.10. Clause 305.4.7 shall apply as regards Contract unit rate
for construction of high embankment. It shall include cost of instrumentation, its monitoring and settlement period, where specified in the
Contract or directed by the Engineer.
306. SOIL EROSION AND SEDIMENTATION CONTROL
3061. Description
This work shall consist of measures as shown on plans or as
directed by the Engineer to conirol soil erosion, sedimentation and water
pollution, through use of berms, dikes, sediment basins, fibre mats,
mulches, grasses, slope drains, and other devices.
306.2. Materials
All materials shall meet commercial grade standards and shall be
approved by the Engineer before being used in the work.
3063. Construction Operations
Prior to the start of the relevant construction, the Contractor shall
submit to the Engineer for approval his schedules for carrying out
temporary and permanent emsion/sedimentation control works as are
applicable for the items of clearing and grubbing, roadway and drainage
excavation, embankipent/subgrade constructio~i,bridges and other structures across water courses, pavement courses and shoulders. He shall also
submit for approval his proposed method of erosion/sedimentation control
on service road and borrowpits and his plan for disposal of waste
materials. Work shall not be started until the erosion/sedimentation control
schedules and methods of operations for the applicable construction have
been approved by the Engineer.
The surface area of erodible earth material exposed by clearing and
grubbing, excavation, borrow and fill operations shall be limited to the
extent practicable. The Contractor may be directed to provide immediate
permanent or temporary erosion and sedimentation control measures
to prevent soil erosion and sedimentation that will adversely affect
construction operations, damage adjacent propeEties, or cause contamination of nearby streamS or ether water cotu~es, lakes, reservoirs
etc. Such work may involve the construction of temporary berms, dikes,
<<
83
Section 300
<<
84
Earthwork,
Section 300
306.5. Rates
The Contract unit rate for different items of soil erosion, sedimentation and pollution control works shall be payment in full for carrying
out all required operations including full compensation for all laboui,
tools, equipment and incidentals to complete the works to the Specifications.
307. TURFING WITH SODS
307.1. Scope
This work shall consist of furnishing and laying of the live sod of
perennial turf forming grass on embankment slopes, verges (earthen
shoulders) or other locatiOns shown on the drawings or as directed by
the Engineer. Unless otherwise specifled, the work shall be taken up
as soon as possible following construction of the embankment, provided
the season is favourable for establishment of the sod.
307.2. Materials
The sod shall consist of dense, well-rooted growth of permanent and
desirable grasses, indigenous to the locality where it is to be used, and
shall be practically free from weeds or other undesirable matter. At the
time the sod is cut, the grass on the sod shall have a length of
approximately 50 mm and the sod shall have been freed of debris.
Thickness of the sod shall be as uniform as possible, with some 5080 mm or so of soil covering the grass roots depending on the
nature of the sod, so that practically all the dense root system of the
grasses is retained in the sod strip. The sods shall be cut in rectangular
strips of uniform width, not less than about 250 mm x 300 mm in size
but not so large that it is inconvenient to handle and transport these
<<
85
Section 3(X)
without damage. During wet weather, the sod shall be allowed to dry
sufficiently to prevent rearing during handling and during dry weather
shall be watered before lifting to ensure its vitality and prevent the
droppmg of the soil in handling.
307.3, Construction Operations
307.3,1. Preparation of the earth bed : The area to be sodded
shall have been previously constructed to the required slope and
cross section. Soil on the area shall be loosened, freed of all stones
larger than 50 mm size, sticks, stumps and any undesirable foreign
matter, and brought to a reasonably fine granular texture to a depth
of not less than 25 mm for receiving the sod.
Where required, topsoil shall be spread over the slopes. Prior to
placing the topsoil, the slopes shalt be scarified to a depth which, after
settlement, will provide the required nominal depth shown on the plans.
Spreading shall not be done when the ground is excessively wet.
Following soil preparation and top soiLing, where required, fertilizer
and ground limestone when specified shalt be spread uniformly at the
rate indicated on the plans. After spreading, the materials are incorporated
in the soil by discing or other means to the depths shown on the plans.
307.3.2. Placing the sods : The prepared sod bed shall be moistened
to the loosened depth, if not already sufficiently moist, and the sod
shall be placed thereon within approximately 24 hours after the same
had been cut. Each sod strip shall be laid edge to edge and such that
the joints caused by abutting ends are staggered. Every strip, after it
is snugly placed against the strips already in position, shall be lightly
tamped with suitable wooden or metal tampers so as to eliminate
air pockets and to press it into the underlying soil.
On side slopes steeper than 2 (horizontal) to I (vertical), the laying
of sods shall be started from bottom upwards. At points where water
may flow over a sodded area, the upper edges of the sod strips shall,
be turned into the soil below the adjacent area and a layer of earth placed
over this followed by its thorough compaction.
307.33. Staking the sods: Where the side slope is 2 (horizontal)
to 1 (vertical) or steeper and the distance along the slope is more than
2 m, the sods shall be staked with pegs or~nails spaced approximately
500 to 1000 mm along the longitudinal axis of the sod strips, Stakes
shall be driven approximately plumb through the sods to be almost
flush with them.
<<
86
Section 300
307.3.4. Top dressing: After the sods have been laid in position,
the surface shall be cleaned of loose sod, excess soil and other foreign
material. Thereafter, a thin layer of topsoil shall be scattered over the
surface of top dressing and the area thoroughly moistened by sprinkling
with water.
307.3.5. Wateri~igand maintenance : The sods shall be watered
by the Contractor for a period of at least four weeks after laying.
Watering shall be so done as to avoid erosion and prevent damage
to sodded areas by wheels of water tanks.
The Contractor shall erect necessary warning signs and barriers,
repair or replace sodded areas failing to show uniform growth of
grass or damaged by his operations and shall otherwise maintain
the sod at his cost until final acceptance.
307.4. Measurements for Payment
Turfing with sods shall be measured as finished work in square
metres.
307.5. Rate
The Contract unit rate for turfing with sods shall mean payment in
full for carrying out all the required operations explained above including
compensation for
(i)
furnishing all the materials to be incorporated in the Works with all leads and
lifts; and
(ii)
all labour, tools, equipments and incidentals to complete the work in accordance
with these Specificaons.
as per
<<
Seeds: The seeds shall be of approved quality and type suitable for the soil
on which these are to be applied, and shall have acceptable purity and germination
to requirements set down by the Engineer.
87
Section 300
Fertilizer shall consist of standard commercial materials and conform to the grade
specified. Organic manure shall be fully puirefied organic maser such as cow
dung.
Mulching materials shall consist of straw, hay, wood shavings or sawdust,
and shall be delivered dry. They shall be reasonably free of weed seed and such
foreign materials as may detract from their effectiveness as a mulch or be
injurious so the plant growth.
B.
Topsoil: Topsoil shall not be obtained from an area known to have noxious weeds
growing in it. If treated with herbicides or sterilents, it shall be got tested
by appropriate ~griculturalauthority to determine the residual in the soil. Topsoil
shall not contain less than 2 per cent and more than 12 per cent organic matLer.
C.
D.
Netting: Jute netting shall be undyed jute yam woven into a uniform open weave
with approximate 2.5 cm square openings.
Geonetting shall he made of uniformly extruded rectangular mesh having mesh
opening of 2 cm x 2 cm. The colour may be black or green. It shall weigh
not less than 3.8 kg per 1000 sq. m.
<<
88
Drainage
Section 300
<<
89
Section
300
<<
90
Section 300
309.3.2. Materials
A.
R,
PIpe
Perforated pipes br the drains may be ofmetatlasbestos cement/
cement concretelPVC, and unperforated pipes of vitrified claylccment concrete/
asbestos cement. The type, size and grade of the pipe to be used shall be
as specified in the Contract. In an case, however, shall the internal diameter
of the pipe be less than 100 mm. Holes for perforated pipes shall be on one
half of the circumference only and conform to the spacing indicated on the
drawings. Size of the holes shall not ordinarily be greater than half of ~
size of the material surrounding the pipe, subject to being minimum 3 mm and
maximum 6 mm. l)~~
stands for the size of the sieve that allows 85 per cent
of the material to pass through it.
Backfill materIal
particles of free draining sand-gravel material or crushed stone and shall be free
of organic material, clay balls or other deleterious matter Unless the Contract
specifies any particular gradings for the backfill material or requires these to
be designed on inverted filter criteria for filtration and permeability to the approval
of the Engineer, the backfill material shall be provided on the following lines:
(i)
Where the soil met with in the trench is of fine grained type (e.g.. silt,clay
or a mixture *hereot),the backfill material shall conform to Class I grading
set out in-Table 300-3.
(ii)
Where the soil met with in the trench is of coarse silt to medium sand
or sandy type, the backfill material shall correspond to Class 11 grading
of Table 300-3.
(iii) Where soil met with in the trench is gravelly sand, the backfill material
shall correspond to Class III grading of Table 300-3.
53mm
45 mm
26.5mm
22,4 mm
11.2 mm
5.6 mm
2.8 mm
1,4 mm
710 micron
355 micron
l80micron
90 micron
<<
Class I
Class H
Class III
100
97.100
100
95-100
58-100
48-100
28-54
20-35
20-60
4-32
100
92-100
83-100
59-96
35-80
0-10
0-5
6-18
14-40
3-15
2-9
0-5
0-4
91
0-3
Section 300
<<
92
Section 300
<<
93
Section 300
63mm
37.5 mm
100
19mm
45-100
25-80
8-45
0-10
0-5
9.5 rum
3.35 mm
600 micron
150 micron
75 micron
TypeB
100
85-100
0-20
0-5
<<
All surfaces below carriageway, laybyes, footways and hard shoulders shall,
after reinstatement of any soft areas to the required Specifications be well cleaned
and freed of mud and slurry.
94
Section 300
The formation shall, wherever necessary, be regulated and trimmed to the requirements of Clause 505.3.9 with motor grader.
(d)
The trimmed formation shall be rolled by one pass of smooth wheeled roller
of 80 to 100 kN weight after spraying requisite amount of water, if required,
before the commencement of rolling.
Where the completed formation is not immediately covered with subbase or road base material, its moisture content shall be maintained
to prevent cracking in the formation by suitable measures as approved
by the Engineer. The entire work of surface treatment of formation shall
be deemed as incidental to the work of sub-base/base course to be
provided on the subgrade and as such no extra payment shall be made
for the same.
311. WORKS TO BE KEPT FREE OF WATER
311.1. The Contractor shall arrange for the rapid dispersal of water
collected/accumulated on the earthwork or completed formation during
construction or on the existing roadway or which enters the earthwork
or any other item of work from any source, and where practicable, the
water shall be discharged into the permanent outfall of the drainage
system. The arrangements shall be made in respect of all earthwork
including excavation for pipe trenches, foundations or cuttings.
311.2. The~Contractor shall provide, where necessary, temporary
water courses, ditches, drains, pumping or other means for maintaining
the earthwork free from water. Such provisions shall include carrying
out the work of forming the cut sections and embankments in such
manner that their surfaces have at all times a sufficient minimum
crossfall and, where practicable, a sufficient longitudinal gradient to
enable them to shed water ,and prevent ponding.
The works involved in keeping the earthwork or any other item
of works free of water shall be deemed as incidental to the respective
item of work and as such no separate payment shall be made for
the s~me.
312. WATER COURSES AT CULTERTS
312.1, Excavation carried out in the diversion, enlargement,
deepening or straightening water courses at culverts, where necessary,
shall include the operations such as clearing, grubbing, removal of
vegetation, trimming of slopes, grading of beds, disposal of excavated
<<
95
Section 300
materials, pumping, timbering etc. necessary for dealing with the flow
of water.
3 12.2. The beds and sloping sides of water courses shall, where
shown on the Drawings, be protected against the action of water by
rubble paving to form a flat or curved surface as indicated. The
protection shall consist of large smooth faced stones or of blocks of
precast concrete. Stones for rubble paving shall be roughly dressed
square. No stone shall be less than 255 mm in depth nor less than
0.02 cu. m. in volume and no rounded boulders shall be used. After
completion of construction of culverts, temporary diversion of watercourse, if any, shall be closed and water course restored for flow through
the culvert as per the direction of the Engineer.
312.3. Measurements for Payment
The work for water courses at culverts as stated above shall be
measured in terms of units specified in the Bill of Quantities for respective
items. The temporary diversion of channel to facilitate construction of
culverts, its closure and restoration to original water course shall be
considered incidental to the work of construction of clverts and no
extra payment shall be made for the same.
312.4. Rates
The Contract unit rates for di:fferent items for water courses at
culverts shall be payment in full for carrying out all j~equiredoperations
including full compensation for all cost of materials, laboUr, tools,
equipment and other incidentals to complete the work to the Specification,
313. CONSTRUCTION OF ROCKFILL EMBANKMENT
313.1, Scope
In normal circumstances, the embankment should not be constructed
with rockfill material. However, where specifically permitted by the Engineer because of imperative economic or technical reasons, construction
of rockfill embankments shall be in accordance with th~lines, grades
and cross-sections as shown in drawings or as directed by the Engineer.
Rockfill shall not be used at least for a depth of 500 mm below
the formation level. There sho~ildbe a minimum of 500 mm thick earthen
cushion over the rocklill.
313.2. Material
The size of rock pieces used in rockfihl embankments shall be
such that they can be deposited in layers so as to suit the conditions
-
<<
96
Section 300
<<
97
400
Sub-Bases, Bases (NonBituminous) and Shoulders
<<
Section 400
401.1. Scope
This work shall consist of laying and compacting well-graded material
on prepared subgrade in accordance with the requirements of these Specifications. The material shall be Laid in one or more layers as sub-base
or lower sub-base and upper sub-base (termed as sub-base hereinafter)
as necessary according to lines, grades and cross-sections shown
on the drawings or as directed by the Engineer.
401.2. Materials
401.2.1. The material to be used for the work shall be natural sand,
moorum, gravel, crushed stone, or combination thereof depending upon
the grading required. Materials like crushed slag, crushed concrete, brick
metal and kankar may be allowed only with the specific approval of
the Engineer. The material shall be free from organic or other deleterious
constituents and conform to one of the three gradings given in Table
400-1.
While the gradings in Table 400-1 are in respect of close-graded
granular sub-base materials, one each for maximum particle size of 75
mm, 53 mm and 26.5 mm, the corresponding gradings for the coarsegraded materials for each of the three maximum particle sizes are
given at Table 400-2. The grading to be adopted for a project shall be
as specified in the Contract.
401.2,2. Physical requirements: The material shall have a 10 per
cent fines value of 50 kN or more (for sample in soaked condition)
when tested in compliance with BS:812 (Part Ill). The water absorption
value of the coarse aggregate shall be determined as per IS 2386 (Part
3); if this value is greater than 2 per cent, the soundness test shall
be carried Out on the material delivered to site as per IS : 383.
For Grading II and Ill materials, the CBR shall be determined at
the density and moisture content likely to be developed in equilibrium
conditions which shall be taken as being the density relating to a
uniform air voids content of 5 per cent.
<<
101
Section 400
SUB-BASE MATERIALS
IS Sieve
Designation
75.0mm
53.0 mm
26.5 mm
9.50 mm
4.75 mm
2.36 mm
0.425 mm
0.015 mm
CBR Value (Minimum)
Grading H
G rading HI
100
80-100
55-90
100
70-100
100
35-65
25-55
20-40
10-25
3-10
50-80
40-65
30-50
3-10
65-95
50-80
40-65
20-35
3-10
30
25
20
15-25
75.0 mm
53.0 mm
26.5 mm
9.50 mm
4,75 mm
2.36 mm
0.425 mm
0.075 mm
CBR Value (Minimum)
Nate
100
Grading II
Gm ding III
55-75
100
50-80
100
10-30
15-35
25-45
<10
<10
<10
30
25
20
The material passing 425 micron (0.425 mm) sieve for all the three gradings
when tested according to IS
2720 (Pail 5) shafi have liquid limit and plasticity
index not more than 25 and 6 per cent respectively.
<<
102
Section 400
hydraulic controls suitable for initial adjustment and for maintaining the
required slope and grade during the operation or other means as approved
by the Engineer.
When the sub-base material consists of combination of materials mentioned in Clause 401.2.1, mixing shall be done mechanically by the mixin-place method.
Manual mixing shall be permitted only where the width of laying
is not adequate for mechanical operations, as in small-sized jobs. The
equipment used for mix-in-place construction shall be a rotavator or
similar approved equipment capable of mixing the material to the desired
degree. If so desired by the Engineer, trial runs with the equipment
shall be carried out to establish its suitability for the work.
mechanical
or other approved means like disc harrows, rotavators until the layer
is uniformly wet.
Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not exceed 100 mm, a smooth wheeled roller of
80 to 100 kN weight may be used. For a compacted single layer upto
225 mm the compaction shall be done with the help of a vibratory roller
of minimum 80 to 100 kN static weight with plain drum or pad footdrum or heavy pneumatic tyred roller of minimum 200 to 300 kN weight
having a minimum tyre pressure of 0.7 MN/m2 or equivalent capacity
roller capable of achieving the required compaction. Rolling shall
commence at the lower edge and proceed towards the upper edge
longitudinally for porthns having unidirectional crossfall and super-.
103
<<
Section 400
<<
making arrangements for traffic to Clause 112 except for initial treatment to verges,
shoulders and construction of diversions;
104
Section 400
furnishing all materials to be incorporated in the work including all royalties, fees,
rents where necessary and all leads and lifts;
(iii) all labour, tools, equipment and incidentals to complete the work to the Speci.
fications;
(iv) carrying out
(v)
<<
Section 400
IS Sieve designation
26.5 mm
100
5.6 mm
80
<<
106
Section 400
<<
107
Section 400
<<
108
Section 400
friable. No traffic of any kind shall ply over the completed sub-base
unless pepnitted by the Engineer.
402.4. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements
of Clause 902.
Control on the quality of materials and works shall be exercised
by the Engineer in accordance with Section 900.
402.5. Strength
When lime is used for improving the subgrade, the soil-lime mix
shall be tested for its CBR value. When lime stabilised soil is used
in a sub-base, it shall be tested for unconfined compressive strength
(UCS) at 7 days. In case of variation from the design CBR/UCS, in situ
value being lower, the pavement design shall be reviewed based on the
actua.l CBR/UCS values. The extra pavement thickness needed on
account of lower CBR/UCS value shall be constructed by the Contractor
at his own cost.
402.6. Arrangements of Traffic
During the period of construction, arrangement of traffic shall be
maintained in accordance with Clause 112.
402.7, Measurements for Payment
Stabilised soil sub-base shall be measured as finished work in position
in cubic metres.
402.8. Rates
The Contract unit rate for lime stabilised soil sub-base shall be
payment in full for carrying out the required operations including full
compensation for all components listed in Clause 401.8 (i) to (v).
403.
CEMENT TREATED SOIL SUB-BASE/BASE
403.1. Scope
This work shall consist of laying and compacting a sub-base/base
course of soil treated with cement on prepared subgrade/sub-base, in accordance with the requirements of these Specifications and in conformity
with the lines, grades and cross-sections shown on the drawings or as
directed by the Engineer.
403.2. Materials
403.2.1. Material to be stabilised: The material used for cement
<<
109
Section 400
treatment shall be soil including sand and gravel, laterite, ,kankar, brick
aggregate, crushed rock or slag or any combination of these. For use
in a sub-base course, the material shall have a grading shown in Table
400-4; it shall have a uniformity coefficient not less than 5, capable of
producing a well closed surface finish, For use in a base course, the
material shall be sufficiently well graded to ensure a well-closed surface
finish and have a grading within the range given in Table 400-4. If
the material passing 425 micron sieve is plastic, it shall have a liquid
limit not greater than 45 per cent and a plasticity index not grater than
20 per cent determined in accordance with IS:2720 (Part 5). The physical
requirements for the material to be treated with cement for use in a
base course shall be same as for Grading I Granular Sub-base, Clause
401.2.2.
403.2.2. Cement: Cement for cement stabilisation shalt comply with
the requirements of IS: 269, 455 or 1489.
Table 400-4. GRADING LIMITS OF MATERIAL FOR STABILISATION
WITH CEMENT
IS Slave size
Base
FIner than:
53.0mm
37.5 mm
19.0 mm
9.5 mm
4.75 mm
600 micron
100
95
45
35
100
95-100
45-100
25
X
300 micron
75 micron
25-100
8-65
5-40
0-10
35-100
<<
110
Section 400
26.5 mm
100
5.6 mm
80
<<
111
Section 400
403.5. Strength
Control on the quality of materials and works shall be exercised
by the Engineer in accordance with Section 900.
Cement treated soil sub-base /base shall be tested for the unconfined
compressive strength (UCS) value at 7 days, actually obtained in situ.
In case of variation from the design UCS, in situ value being on lower
side, prior to proceeding with laying of base/surface cotfrse on it,
the pavement design shall be reviewed for actual UCS value. The extra
pavement thickness needed on account of lower UCS shall be constructed
by the Contractor at his own cost.
403.6. Arrangements for Traffic
During the period of construction, arrangement of traffic shall be
maintained in accordance with Clause 112.
403.7~ Measurements for Payment
Stabilised soil sub-base! base shall be measured as finished work
in position in cubic metres.
403.8. Rates
The Contract unit rate for cement treated soil sub-base/base with
pretreatment with lime if required shall be payment in full for carrying
out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v).
404. WATER BOUND MACADAM SUB-BASFJBASE
404.1. Scope
404.1.1. This work shall consist of clean, crushed aggregates mechanically interlocked by rolling and bonding together with screening,
binding material where necessary and water laid on a properly prepared
subgrade/ sub-base/ base or existing pavement, as the case may be
and finished in accordance with the requirements of these Specifications
and in close conformity with the lines, grades, cross-sections and thickness
as per approved plans or as directed by the Engineer.
404.1.2. It is, however, not desirable to lay water bound macadam
on an existing thin black topped surface without providing adequate
drainage faciljty for water that would get accumulated at the interface
of existing bituminous surface and water bound macadam.
<<
112
Section 400
404.2. Materials
40&2.I. Coarse aggregates : Coarse aggregates shall be either
crushed or broken stone, crushed slag, overburnt (Jhama) brick aggregates
or any other naturally occurring aggregates such as kankar and laterite
of suitable quality. Materials other than crushed or broken stone and
crushed slag shall be used in sub-base courses only. If crushed gravel!
shingle is used, not less than 90 per cent by weight of the gravel!
shingle pieces retained on 4.75 mm sieve shall have at least two fractured
faces. The aggregates shall conform to the physical requirements set
forth in Table 400-6. The type and size range of the aggregate shall
be specified in the Contract or shall be as specified by the Engineer.
if the water absorption value of the coarse aggregate is greater than
2 per cent, the soundness test shall be carried out on the material deLivered
to site as per IS : 2386 (Part 5).
404.2.2. Crushed or broken stone: The crushed or broken stone
shall be hard, durable and free from excess flat, elongated, soft
and disintegrated particles, dirt and other deleterious material.
TABLE 400.6. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR
WATER BOUND MACADAM FOR SUB.BASE,BASE COURSES
Test
1.
Test Method
Requirements
IS :2386
(Part-4)
IS: 2386
(Part-4) or
IS:5640**
Flakiness and
IS:2386
Elongation
Indices (Tetal)
(Part-i)
Los Angeles
Abrasion value
Or
Aggregate
Impact value
2.
Combined
***
*
two tests.
Aggregates like brick metal, kankar, laterite etc. which gel softened in presence of waler
shall be tested for Impact value under wet conditions in accordance with IS: 5640.
The requirement of flakiness index and elongation index shall be enforced only in the
case of crushed broken stone and crushed slag.
404.2.3. Crushed slag : Crushed slag shall be made from aircooled blast furnace slag. It shall be of angular shape, reasonably uniform
in quality and density and generally free from thin, elongated and
soft pieces, dirt or other deleterious materials. The weight of crushed
slag shall not he less than ii.2 kN per l11~and the percentage of ~lossy
<<
113
Section 400
Sub-Bases, Bases
material shall not be more than 20. It should also comply with the
following requirements:
(i)
Chemical stability
(ii)
Sulphur content
Size Range
1.
90 mm to 45 mm
2.
3.
IS Sieve
Designatktn
Per cent by
weight passing
125
mm
90
rum
63
mm
45
mm
22.4 mm
63 mm to 45 mm
53 mm to 224 mm
90
63
53
45
22.4
mm
mm
mm
mm
mm
63
53
45
22.4
11.2
mm
mm
mm
mm
mm
100
90-100
25-60
0-15
0-5
100
90-100
25.75
0-15
0-5
100
95-100
65-90
0-10
0.5
100 mm while for
<<
114
Section 400
and Shoulders
Size of
Screenings
IS Sieve Designation
13.2 mm
13.2
11.2
5.6
180
mm
mm
mm
micron
100
95-100
15-35
0-10
11.2 mm
11.2
5.6
180
mm
mm
micron
100
90-100
15-35
Size
Range
Compacted Loose
thickness
Qty.
Stone Screening
Grading
ClassI..
ficalion
& Size
Grading
Cfassiticatlon
& Size
Loose
Qty.
For. WBM
Sub-base!
base course
(Loose
quantity)
90 mm to 100 mm
45 mm
Not
uniform
030 to
Grading 2
63 mm to 75 mm
45 mm
-do-
0.22 to
0.24 &
-do-
-do-
-do-
Type B 0.20 to
11.2 mar 0.22 sn
-do-
-do-
Grading 3
53 mm to 75 mm
22.4 mm
-do-
-do-
-do-
-do-
Grading I
<<
-do-
115
0.18 to
0.21 mt
0.32 rn1
Section 400
<<
116
Section 400
<<
117
Section
400
<<
Sub-Bases, Bases
Section 400
accompanied by dry rolling and brooming with mechanical brooms, handbrooms or both. In no case shall the screenings be applied so fast and
thick as to form cakes or ridges on the surface in such a manner as
would prevent filling of voids or prevent the direct bearing of the roller
on the coarse aggregate. These operations shall continue until no more
screenings can be forced into the voids of the coarse aggregate.
The spreading, rolling, and brooming of screenings shall be carried
out in only such lengths of the road which could be completed within
one days operation.
404.3.6. Sprinkling of water and grouting : After the screenings
have been applied, the surface shall be copiously sprinkled with water,
swept and rolled. Hand brooms shall be used to sweep the wet
screenings into voids and to distribute them evenly. The sprinkling,
sweeping and rolling operation shall be continued, with additional
screenings applied as necessary until the coarse aggregate has been
thorougl.ly keyed, well-bonded and firmly set in its full depth and a
grout has been formed of screenings. Care shall be taken to see that
the base or subgrade does not get damaged due to the addition
of excessive quantities of water during construction.
In case of lime treated soil sub-base, construction of water bound
macadam on top of it can cause excessive water to flow down to the
lime treated sub-base before it has picked up enough strength (is still
green) and thus cause damage to the sub-base layer. The laying of
water bound macadam layer in such cases shall be done after the subbase attains adequate strength, as directed by the Engineer.
40&3.7. Application of binding material: After the application
of screenings in accordance with Clauses 404.3.5 and 404.3.6. the binding
material where it is required to be used (Clause 404.2.7) shall
be applied successively in two or more thin layers at a slow and
uniform rate. After each application, the surface shall be copiously
sprinkled with water, the resulting slurry swept in with hand brooms,
or mechanical brooms to fill the voids properly, and rolled during
which water shall be applied to the wheels of the rollers if necessary
to wash down the binding material sticking to them. These operations
shall continue until the resulting slurry after filling of voids, forms a
wave ahead of the wheels of the moving roller.
404.3.8. Setting and drying: After the final compaction of water
bound macadam course, the pavement shall be allowed to dry overnight.
Next morning hungry spots shall be filled with screenings or binding
<<
119
Section 400
<<
120
Section 400
<<
12t
Section 400
the top layer shall be treated with a penetration coat of binder described
in Clause 4053.2.
405.3.2. Application of penetration coat over the top layer:
Before the application of the penetralion coat, the surface shall be cleaned
of dust, dirt and other foreign matter, using mechanical broom or any
other equipment specified by the Engineer. Dust removed in the process
shall be blown off with the help of compressed air.
The binder shall be heated to the temperature appropriate to the
grade of bitumen used and sprayed on the dry surface in a uniform manner
a~the rate of 25 kg per 10 m2 area in terms of the residual bitumen
with the help of either self-propelled or towed bitumen pressure
sprayer with self-heating arrangement and spray nozzle capable of
spraying bitumen at specified rates and temperatures so as to provide
a uniform, unbroken spread of bitumen. Excessive deposits of binder
caused by stopping or starting of the sprayer or through leakage or
any other reason shall be suitably corrected.
Immediately after the application of binder, the key aggregates,
in a clean and dry state shall be spread uniformly on the surface at
the rate of 0,13 m3 per 10 m2 area, preferably by means of a mechanical
gritter, capable of spreading aggregate uniformly at specified rates
or otherwise manually with the approval of the Engineer, so as
to cover the surface completely. Immediately after the application of the
key aggregates, the entire surface shall be rolled to Clause 506.3.8.
405.4. Surface Finish and Quality Control of Works
The surface finish of construction shall conform to the requirements
of Clause 902.
Control on the quality of material and works shall be exercised by
the Engineer in accordance with Section 900.
405.5. Arrangements for Traffic
During the period of construction, arrangement of traffic shall be
done as per Clause 112.
405.6. Measurements for Payment
Breaking the existing cement concrete pavement slabs, crushing and
recompacting the slab material as sub-base/base course shall be measured
as a single item in terms of the volume of sub-base/base laid in position
in cubic metres.
122
<<
Section 400
square
405.7.!. The Contract unit rate for crushed cement concrete subbase/base course shalL be payment in full for carrying out the
required operations including full compensation for:
(0
treatment to
(ii) breaking the cement csiricrete slabs, crushing, sieving and recompacting the
slab material as suh-base)base course;
(iii)
all labour, tools, equipment and incidentals to complete the work to the
Specifications; and
(iv)
carrying out
where directed.
405.7.2. The Contract unit rate for penetration coat shalt be payment
in full for carrying out the required operations including full
compensation for all components listed in Clause 504.8.
406. WET MIX MACADAM SUB-BASE/BASE
406.1. Scope
This work shalt consist of laying and compacting clean,
crushed, graded aggregate and granular material, premixed with water,
to a dense mass on a prepared subgrade/sub-base/base or existing
pavement as the case may be in accordance with the requirements
of these Specifications. The material shall be laid in one or more layers
as necessary to lines, grades and cross-sections shown on the approved
drawings or as directed by the Engineer.
Aggregates
<<
123
Section 400
TABLE 400-10.
2.
*
**
Test
*Los Angii
Abrasion value
or
*Aggregate
tmpact value
Combined Flakiness and
Elongation indices (Total)
TestMethod
IS: 2386 (Part-4)
Requirements
40per cent (Max,)
MACADAM
tS Sieve Designation
53.00
45.00
2650
22.40
lt.20
4.75
236
600.00
75.00
iiiiii
mm
mm
mm
mm
mm
mm
micron
micron
100
95-100
60-80
40-60
25-40
15-30
8-22
0-8
Materials finer than 425 micron shall have Plasticity Index (P1) not
exceeding 6.
The final gradation approved within these limits shall be wefl graded
from coarse to fine and shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve or vice versa.
406.3. Construction Operations
406.3.1. Preparation of base: Clause 404.3.1. shall apply.
406.3,2. Provision of lateral confinement ofaggregates : While constructing wet mix macadam, arrangement shall be made for the lateral
<<
124
Section 400
(ii)
The screed shall have tamping and vibrating arrangement for initial compaction
to the layer as it is spread without ruuing or otherwise marring the surface
profile.
<<
125
Section 400
<<
126
Section 40()
Shoulders
crossfall. In no case should the use of unmixed material be permitted
<<
127
Section 400
<<
128
Section 400
<<
129
Section
4(X)
(iii) For
407.7. Rate
The Contract unit rate for shoulder (hard/paved/earthen with brick
or stone block edging), island and median construction shall be payment
in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (1) to (v) as applicable.
The rate for brick/stone block edging shall include the cost of sand
cushion.
408. CEMENT CONCRETE KERB AND KERB WITH
CHANNEL
408.1. Scope
This work shall consist of constructing cement concrete kerbs and
kerbs with channel in the central median and/or along the footpaths
or separators in conformity with the lines, levels and dimensions as
specified in the drawings.
408.2. Materials
Kerbs and kerb with channel shall be provided in cement concrete
of Grade M20 in accordance with Section 1700 of these Specifications.
<<
130
Section 400
<<
131
Section 400
(a)
Cast-in-situ cesnent concrete of Grade M20 as per Section 1700 of the Specifications.
(b)
Precast cement concrete blocks/tiles of Grade M20 as per Section 1700 of the
specifications. The minimum thickness of the cement concrete block/tile shall
be 25 mm and minimum size shall be 300 mm x 300 mm.
(c)
Natural stone slab cut and dressed from stone of good and sound quality, uniform
in texture, free from defects and at least equal to a sample submitted by the
Contractor and approved by the Engineer. The minimum thickness of the
natural stone slab shall be 25 mm and minimum size shall be 300 mm x 300
mm.
<<
132
Shoulders
Section 400
following
(a) Minimum 150 mm thick,compacted granular sub-base materialas per Clause 401
(b)
the Specifications.
Minimum 25 mm thick cement concrete of Grade M 15.
of
<<
Section 400
rolling to form a firm, stable base. The aggregate shall conform to the grading
and quality requirements shown in Tables 400-12 and 400-13.
At the option ofthe Contractor, thegrading for either 53 mm maximum
size or 37.5 mm maximum size shall be used, except that once a grading is
selected, it shall not be changed without the Engineers approval.
TABLE 400.12. AGGREGATE GRADING REQUIREMENTS
Sieve size
63
mm
100
45
mm
87-lOG
tOO
22~4 mm
5O~85
90-tOO
5.6 mm
25-45
35-55
710
micron
10-25
10-30
90
micron
2-9
2-9
TABLE 400-13. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR
CRUSHER-RUN MACADAM BASE
Test_-~
4Los Angeles
Abrasion value
or
*Aggregate
Impact value
2.
Combined
Flakiness and
Elongation Indices (Total)
Test Method
IS :2386
(Part-4)
Requirements
40 maximum
IS :2386
(Part.4) or
IS : 5640
30rnaxirnum
IS :2386
(Pan-i)
30maximum***
3.
**W~t~.
absorption
IS: 2386
(Part-3)
2per cent
Maximum
4,
liquid Limit of
material passing 425 micron
IS : 2720
(Part-5)
5.
Plasticity Index
ofmaterial passing 425 micron
IS :2720
(Part-5)
~
~
134
<<
Section 400
<<
135
Section 400
<<
136
500
Base and Surface Courses
(Bituminous)
<<
Section 500
Section 500
501.1. Scope
This work shall consist of preparing an existing granular or blacktopped surface to specified lines, grades and cross-sections in advance
of laying a bituminous course. The work shall be performed on such
widths and lengths ~s shown in applicable drawing and consist of
scarifying and re-laying the granular base course and/or scarifying the
existing surface, filling of potholes, sealing of cracks and/or application
of a profile corrective course (levelling course) as necessary.
501,2. Materials
501.2.1. For scarifying and re-laying the granular surface
The materials used shall be coarse aggregates salvaged from scarification
of the existing granular base course supplemented by fresh coarse
aggregates and screenings so that aggregates and screenings thus
supplemented correspond to Clause 404: Water Bound Macadam or
Clause 406: Wet Mix Macadam, as the case may be.
501.2.2. For patching potholes and seating cracks: For patching
potholes, approved material having same specification as that of
profile corrective course shall be used. For sealing small cracks
finer than 3 mm, a fog seal conforming to Section 3000 shall be applied
while larger cracks wider than 3 mm shall be treated with an emulsion
slurry seal, conforming to Clause 516.
501.2.3. For profile corrective course: Aprofile corrective course
(levelling course) is essentially a pavement base material course for correcting the existing pavement profile which has either lost its shape
or has to be given a new shape to meet the requirement of specified
lines, grades and cross-sections.
It shall be differentiated from the strengthening course or other
type of structural pavement course needed for upgrading as a remedial
measure against inherently deficient and/or distressed pavement. It is
meant to remove the irregularity in the existing road profile only.
501.2.4. Profile corrective course and its application: The type
of material for profile corrective course shall be as shown on the
drawing. If it is to be laid as part of the overlay/strengthening course,
the profile corrective course material shall be of the same specification
as that of the overlay/strengthening course. However, if provided as a
<<
139
Section
500
separate layer, it may be of the same specification as the layer over which
it is to be laid or intermediate between underlying and overlying layers,
as shown on the Drawing.
(i)
Wherever isolated high spots projecting over the pavement surface do exist, the
same shalt be cut by milling machine or any other approved method, to minimise
the profile corrective course requirensenL If, in the proceas,the bottom layer gets
disturbed, the local area shall be cut and filled with profile corrective course
mate ral
(ii)
Where the maximum profile corrective course thickness works out to be not more
than 40 mm, it shall be done as an integral part of the overlay course. In other
cases, the profile corrective course shall be provided as a separate layer a5pting
such construction procedures and using such equipment as may be appropriate
to the specified type of material and thickness of the course to be provided.
<<
140
Section 500
<<
141
Section 500
Base
LIFTS
(A)
EXISTING LAYER
C~tRECT METHOD
EXISTING
(B)
LAYER
2~
3INCORRECT METHOD
Note Profile corrective course matenat so ne rn accordance with the tilt Inicieness
Fig. 500-LMethods for providing corrective course for short sags and depressions
<<
142
C)
C)
a
a
Cl
0
td)
Ha
&
a
U
a
0 U
~
C
CO
B
E41
Section 500
Section 500
<<
Section 500
(iii) Preparation of the exposed surface/existing surface including filling of pot holes,
all cleaning operations and application of tack coat;
(iv) All labour, tools, equipment and incidentals necessary to complete the work
to the Specifications; and
(v)
Carrying out the work in part widths of road where directed by the Engineer.
501.7.3. The contract unit rate for sealing cracks by applying fog
seal shall be inclusive of providing all materials and tools arid plant
and carrying out the work. The contract unit rate for sealing cracks
by providing emulsion slurry seal shall be as set forth in Clause 516.9.
502. PRIME COAT OVER GRANULAR BASE
502.1., Scope
This work shall consist of application of single coat of low
viscosity liquid bituminous material to an absorbent granular surface
preparatory to any superimposed bitUminous treatment or construction.
502.2. Materials
502,2.1. The choice of a bituminous primer shall depend upon the
porosity characteristics of the surface to be primed as classified in IRC:
16. These are
(i)
Surfaces of low porosity; such as wet mix macadam and water bound macadam,
(ii)
Low porosity
Medium porosity
High porosity
Kinematic Viscosity
of Primer at 60~C
(Centistokes)
( kg)
30-60
70.140
250-500
6 to 9
9 to 12
12 to 15
<<
145
Section 500
<<
146
Courses (Bifliminous)
Section 500
<<
147
Section 500
502.8. Rate
The contract unit rate for prime coat shall be payment in full for
carrying out the required operations including full compensation for all
components listed in Clause 401.8 (i) to (v) and as applicable
to the work specified in these Specifications.
<<
148
Section 500
Quantity of liquid
bituminous mater1i~in
kg per 10 sq. m. area
i)
ii)
2.0 to 2.5
2.5 to 3.0
2.5 to 3.0
3.5 to 4.0
3.0 to 3.5
laid bituminous course if the
subsequent bituminous course is overlaid the same day without opening it to traffic.
<<
149
Section 400
penetration grade (30/40 to 80/100) as per IS:73. The actual grade of bitumen
to be used shall be decided by the Engineer appropriate to the region, traffic,
rainfall and other environmental conditions, Guidelines on selection of the
grade of bitumen are given in Appendix-4.
504.2.2. Aggregates
504.2.2.1. The aggregates shall consist of crushed stone, crushed
gravel/shingleor other stones. They shall be clean, strong, durable, of fairly
cubical shape and free from disintegrated pieces, organic or other deleterious
matter and adherent coating. If crushed shingle/gravel is used, not less than
90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve
shall have at least two fractured faces. The aggregates shall preferably be
hydrophobic and of low porosity. If hydrophilic aggregates are to be used,
thebitumen shall preferably be treated with anti~strippingagents of approved
quality in suitable dose as per Appendix-5. The aggregates shall satisfy the
physical requirements set forth in Table 500.3.
TABLE 500.3.
S,No,
Test
Test Method
Requirement
5 IS:2386(Part..4)
40per cent Maximum
1.
Los Angeles Abrasion Value
2.
Aggregate Impact Value5
IS:2386 ~Part-4)
30 per cent Maximum
3.
Flakiness and Elongation55
IS:238$(Part-1)
30 per cent Maximum
Indices (Total)
4.
Coating and Stripping of
AASI ITO T 182
Minimum retained
Bitumen Aggregate Mixtures
coating 95 percent
5.
Soundness
IS:23 86 (Part-5)
(i) Loss with Sodium
12 per cent Maximum
Sulphate 5 cycles
(ii) Loss with Magnesium
IS per cent Maximum
Sulphate 5 cycles
6
Waterabsorptian
IS:2386(Patt-3)
ZpercentMaximum
*
Aggregates may satisfy requIrements 01 eitfler at the two tests.
~
To determine this combined proportion, the flaky stone from a representative
sample should first be separated out. Flakiness index is weight of flaky stone
<<
Section 500
i)
ii)
iii)
iv)
Note
Quantity ef liquId
bItuminous material In
kg per 10 sq. m. area
2.0 to 2.5
2.5 to 3.0
2.5 to 3.0
3.5 to 4,0
3.0 to 3.5
There is no need to apply a tack coat on a freshly laid bituminous course if the
subsequent bituminous course is overlaid the same day without opening it to traffic.
<<
149
(Bituminous)
Section 500
45.0
26.5
22.4
11.2
5.6
2.8
90.0
mm
mm
mm
mm
mm
mm
micron
GradIng 2
100
75.100
100
60-95
75.100
50-85
20-40
5-20
0-5
30.55
15-35
5.20
0-5
<<
151
Section 500
The plant shall have coordinated set or essential units capable of producing
sxsifonn mix as per the job mix formula.
(b)
cold aggregate feed system with minimum 4 bins having belt conveyor arrangement for initial proportioning of aggregates from each bin in the required quantities.
In order to have free flow of fines from the bin, it is advisable to have
vibrator fitted on bin to intenninently shake it,
(c)
Belt convryers below each bin shoold have variable speed drive motors. There
should be electronic load sensor on the main conveyer for measuring the flow
of aggregates.
(d)
Dryer unit with burner capable of heating the aggregate to the required temperature.
without any visible unbumt fuel or carbon residue on the aggregate and reducing
the moisture content of the aggregate to the seecified minimum.
(e)
(f)
(g)
(h)
A suitable built-in dust control system for the dryer to contain/recycle permissible
fines into the mix. It should be capable of preventing the exhaust of fine dust
into atmosphere for environmental control wherever so specified by the Engineer.
(i)
(j)
Every hot mix plant should be equipped with siren or horn so that the operator
may use the same before starting the plant every time in the interest of safety
of staff.
(i)
Gradation control unit having minimum four deck vibratory screens for accurate
sizing of hot aggregate and storing them in separate bins. This unit should be
fully covered to reduce the maintenance cost and for better environmental
condition.
(ii)
from
(iii) Paddle mixer unit shall be capable of prodlicing a homogeneous mix withuniform
coating of all particles of the mineral aggregate with binder.
<<
152
Section 500
(i)
Gradation control unit having vibratory screens for accurate sizing of hot
aggregate and storing them in separate bins. This unit should be fully covered
to reduce the maintenance cost and for better environmental condition.
(ii)
(iii) Paddle mixer unit shall be capable of producing a homogeneous mix with
uniform coating of all particles of the mineral aggregate with binder.
D
(i)
(ii)
Belt conveyers below each bin should have variable speed drive motors. There
should be electronic load sensor on the main conveyer for measuring the flow
of aggregate.
(a)
<<
153
Section 500
(b)
(c)
The machine shall have a hydraulically extendable screed for appropriate width
requirement.
(d)
The screed shall have tamping and vibrating arrangement for initial compaction
so the layer as it is spread without rutting or otherwise marring the surface.
It shall have adjustable amplitude and variable frequency.
(e)
The
that
The
and
(I)
(g)
(h)
The paver shall be capable of laying either 2.5 to 4.0 m width or 4.0 to 7.0
m width as stipulated in the Contract.
(i)
<<
54
Courses (Bituminous)
Section 500
The roller shall move at a speed not more than 5 km/h. Rolling
shall be done with care to avoid unduly rougheniitg of the pavement
surface.
Rolling of the longitudinal joints shall be done immediately
behind thr paving operation. After this, the rolling shall commence at
the edges and progress towards the centre longitudinally except that
on ~uperelevated and uni-directional cambered portions, it shall
progress from the lower to the upper edge parallel to the centre line
of the pavement.
The initial or break.down rolling shall be done with 80 100 kN
static weight smooth wheel roller (3 wheels or tandem), as soon as it
is possible to roll the mix without cracking the surface or having the
mix pick up on the roller wheels, The second or intermediate rolling
shall follow the break-down rolling with vibratory roller of 80 to 100
kN static weight or pneumatic tyred roller of 150 to 250 kN weight,
with minimum 7 wheels and minimum tyre pressure of 0.7 MPa as closely
as possible to the paver and be done while the paving mix is still at
a temperature that will result in maximum density. The final rolling shall
be done while material is still workable enough for removal of roller
marks, with 60 80 kN tandem roller. During the final rolling, vibratory
system shall be switched ofL The joints and edges shall be rolled with
a 80 to 100 kN static roller.
When the roller has passed over the whole area once, any high
spots or depressions which become apparent shall be corrected by
removing or adding mix material. The rolling shall then be continued
till the entire surface has been rolled to 95 per cent of the average
laboratory density (obtained from Marshall specimens compacted as
defined in Table 500-10), there is no crushing of aggregates and all
roller marks have been eliminated. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the
preceding pass. The roller wheel shall be kept damp if necessary to
avoid bituminous material from sticking to the wheels and being picked
up. In no case shall fuel, lubricating oil be used for this purpose, nor
excessive water poured on the wheels.
Rolling operations shall be completed in every, respect before the
temperature of the mix falls below 100C.
Roller(s) shall not stand on newly laid material while there is a
risk that surface will be deformed thereby. The edges along and
transverse of the bituminous macadam laid and compacted earlier shall
-
<<
155
I-
Section 500
Making arrangements for traffic to Clause 112 excex for initial treatment to verge,
shoulders and construction of diversions;
(ii)
Preparation of base except for laying of profile corrective course but including
filling of potholes;
Carrying
<<
The rate shall cover the provision.of bitumen at 3.25 per cent of weight of
total mix, with the provision that the variation of quantity of bitumen will be
asseased and the payment adjusted as per the rate of bitumen quoted.
156
Section 500
The roller shall move at a speed not more than 5 km/h. Rolling
shall be done with care to avoid unduly roughenir~gof the pavement
surface.
Rolling of the longitudinal joints shall be done immediately
behind thr paving operation. After this, the rolling shall commence at
the edges and progress towards the centre longitudinally except that
on ~uperelevated and uni-directional cambered portions, it shall
progress from the lower to the upper edge parallel to the centre line
of the pavement.
The initial or break-down rolling shall be done with 80 100 kN
static weight smooth wheel roller (3 wheels or tandem), as soon as it
is possible to roll the mix without cracking the surface or having the
mix pick up on the roller wheels. The second or intermediate rolling
shall follow the break-down rolling with vibratory roller of 80 to 100
kM static weight or pneumatic tyred roller of 150 to 250 kM weight,
with minimum 7 wheels and minimum tyre pressure of 0.7 MPa as closely
as possible to the paver and be done while the paving mix is still at
a temperature that will result in maximum density. The final rolling shall
be done while material is still workable enough for removal of roller
marks, with 60 80 kN tandem roller. During the final rolling, vibratory
system shall be switched off. The joints and edges shall be rolled with
a 80 to 100 kN static roller.
When the roller has passed over the whole area once, any high
spots or depressions which become apparent shall be corrected by
removing or adding mix material. The rolling shall then be continued
till the entire surface has been rolled to 95 per cent of the average
laboratory density ~obtainedfrom Marshall specimens compacted as
defined in Table 500-10), there is no crushing of aggregates and all
roller marks have been eliminated. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the
preceding pass. The roller wheel shall be kept damp if necessary to
avoid bituminous material from sticking to the wheels and being picked
up. In no case shall fuel, lubricating oil be used for this purpose, nor
excessive water poured on the wheels.
Rolling operations shall be completed in every, respect before the
temperature of the mix falls below 100C,
Roller(s) shall not stand on newly laid material while there is a
risk that surface will be deformed thereby. The edges along and
transverse of the bituminous macadam laid and compacted earlier shall
-
<<
155
Courses (Bituminous)
Section 500
<<
157
Section 500
For 50 mm compacted
for 75 mm compacted
thickness
thickness
IS Steve
Design.
Coarse
Aggregate
Aggregate
Key
Coarse
Aggregate
Key
Aggregate
100
atlon
63
53
mm
mm
45 mm
26.5 mm
22.4 mm
132 mm
11.2 mm
5.6mm
2.8 mm
100
37-72
58-82
100
2-20
50-75
5-25
0-5
0-5
5-27
100
50-75
5-25
0-5
0-5
50 mm
75 mm
Binder
run bitumen
Straight
Coarse
Aggregate
Key
Aggregate
50 kg
68 kg
0.60 cu.m.
0.90 cu.m.
0.15 en. m.
0.18 cc. m.
<<
158
Section 500
(Bituminous)
<<
159
Section 500
<<
160
Base
Section 500
500-3. The coarse and key aggregates for built-up spray grout shall
conform to the grading given in Table 500-7.
TABLE 500-7. GRADING REQUIREMENTS OF COARSE AND KEY GGREGATES
FOR BUILT-UP SPRAY GROUT
Per cent by weight passing the Sieve
IS Sieve
Designation
Coarse Aggregate
53.0 mm
26.5 mm
22.4 mm
tOO
40-75
13.2 mm
5.6 mm
0-20
2.8 mm
0-5
Key Aggregate
lOt)
40-75
0-20
0-5
<<
161
Scction 5(X)
Base
<<
162
Section 5(X)
allowing any traffic over it, The seal coat in such cases shall be
considered incidental to the work and shall not be paid for
separately.
506.6. Arrangements for Traffic
During the period of construction, atrangement of traffic shall be
done to Clause 112.
506.7. Measurements for Payment
Built-up spray grout shall be measured as finished work in square
metres.
506.8. Rate
The cutract unit rate for built-up spray grout shall be payment in
full for caying out the required operations including full compensation
for all components listed in Clause 504.8 (i) to (vi).
597. DENSE BITUMINOUS MACADAM
507.1. Scope
This work shall consist of construction in a single course of 50
to 100 mm thick base/binder course to the following Specifications on
a previously prepared base.
507.2. Materials
507.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration
Grade S 65 or A 65 (60/70) as per Indian Standard Specifications for
Paving Bitumen IS: 73. In case of non- availability of bitumen of
this grade, S 90 (80/100) grade bitumen may be used with the approval
of the Engineer. Guidance to selection of the grade of bitumen may
he taken from Appendix-4.
507.2,2. Coarse aggregates : The coarse aggregates shall consist
of crushed stone, crushed gravel/shingle or other stones. They shall be
clean, strong, durable, of fairly cubical shape and free from disintegrated
pieces, organic or other deleterious matter and adherent coating. The
aggregates shall preferably be hydrophobic and of low porosity. If
hydrophilic aggregates are to be used, the bitumen shall be treated with
antistripping agents of approved quality in suitable doses. The aggregates
shall satisfy the physical requirements set forth in Table 500-8.
If crushed gravel/shingle is used, not less than 90 per cent by weight
ol the gravel/shingle pieces retained on 4.75 mm sieve shall have at
least two fractured faces. The portion of the total aggregate passing
<<
163
Base and
Section 500
Surface
Courses (Bituminous)
4.75 mm sieve shall have a sand equivalent value of not less than 50 when
tested in accordance with the requirement of IS: 2720 (Part-37).
The plasticity index of the fraction passing the 425 micron sieve shall
not exceed 4.
TABLE 500.5. PHYSICAL REQITIREMENTS OF AGGREGATES FOR DENSE
UtTUMINOUS MACADAM
S.No,
Tess Method
Requirement
Test
15~2386~Part4)
2.
IS:2386(Pars-4)
15:2386 (Pan-i)
30perceat Maximum
30 per cent Maximum
tt
3.
Flakiness
and Elongauon
Indices (loial)
AASItTO T 182
Minimum retained
coating 95 per cent
5,
Scsindness
(i) Inst with Sodium
Sulphate
(ii)
l,o.ss with Magncsium
Sulphate
IS:2386(Pan-5)
S cycles
5 cycles
Water ahsoption
15:2386 (l5art-3)
5.
*
**
507.2.3. Fine aggregates: Fine aggregates shall be the Fraction passirtg 2.36 mm sieve and retained on 75 micron sieve, consisting of crusher-run
screening, gravel, sand or a mixture of both. These shall he clean, hard,
durable, ttncoated, dry and free from any injurious, soft or flaky pieces and
organic or other deleterious suhstances.
507.2.4. Filler: Filler shall consisl of finely divided mineral matter
such as rxk dust, hydraled lime or cement as approved by the Engineer.
The filler shall be graded within the following limits
tS Sieve
601) micron
3(X) micron
75 micron
100
95-1(X)
85-100
The filler shall be free from organic impurities and have a Plasticity
Index not greater than 4. The Plasticity Index requirement shall not apply if
filler is cement or lithe. When the coarse aggtregate is gravel,
-
164
<<
Section 500
BITUMINOUS MACADAM
Sieve Designation
37.5
26.5
13.2
4,75
2.36
mm
mm
mm
mm
mm
300
micron
75
micron
100
90-100
56-80
29-59
19-45
5-17
1-7
The aggregate mix, as used in work, shall not vaty from the low limit on one
sieve to the high limit on the adjacent sieve but shall be well graded.
507.3.
Mix Design
S.No. Description
Requirements
1.
2.
2-4
3.
3-5
4.
10 per cent
5.
65-75
6.
12 per cent
<<
165
Section 500
(ii)
(a)
(b)
(iii) A
single definite percentage passing each sieve for the mixed aggregate;
(iv) The results of tests enumerated in Table 50010 as obtained by the Contractor;
(v)
While working out the job mix formula, the Contractor shall ensure
that it is based on a correct and truly representative sample of the
materials that will actually be used in the work and that the mix and
its different ingredients satisfy the physical and strength requirements
of these Specifications.
Approval of the job mix formula shall be based on independent
testing by the Engineer for which samples of all ingredients of
the mix shall be furnished by the Contractor as required by the
former.
The approved job mix formula shall remain effective unless and
until modified by the Engineer. Should a change in the source of
materials be proposed, a new job mix formula shall be established
and got approved from the Engineer before actually using the
materials.
507.3,4. Permissible variation from job mix formula: It shall
be the responsibility of the Contractor to produce a uniform mix
conforming to the approved job mix formula subject to the
permissible variations of the individual percentages of the various
ingredients in the actual mix from the job mix formula to be used within
the limits as specified in Table 500-Il. These variations are intended
to apply to individual specimens taken for quality control tests vide
Section 900.
<<
166
Courses (Bituminous)
Section 500
0f Ingredients
Permissible variation
by weight of total
mix-in per cent
Aggregate passing
2.
3.
4.
5.
6.
7.
8,
8
7
6
S
4
2
0.3
10C
<<
167
Section 500
true to the delineating lines parallel to the centre line of the road.
Longitudinal and transverse joints shall be offset by at least 250 mm
from those in the lower courses and the joint on the top most layer
shall not be allowed to fall within the wheel path. All lransverse joints
shall be cut vertically to the full thickness of the previously laid mix
with asphalt cutter and the surface painted with hot bitumen before
placing fresh material. Longitudinal joints shall be preferably hot joints.
Cold longitudinal joints shall he properly heated with joint heater to
attain a suitable temperature of about 80Cbefore laying of adjacent
material.
-
507.4.6. Rolling : After spreading the mix by paver, it shall be thoroughly compacted by rolling with a set of rollers moving at a speed
not more than 5 km/h, immediately following close to the paver.
Generally the initial or breakdown rolling shall he done with 80-100
kN static weight smooth-wheeled roller. The intermediate rolling shall
be done with 80 -100 kM static weight vibratory roller or with a
pneumatic tyred roller of 150-250 kM weight having a tyre pressure of
at least 0.7 MPa. The finish rolling shall be done with 60 8OkN weight
smooth wheeled tandem roller. All the compaction operations, i.e.,
breakdown roiling and intermediate rolling can be accomplished by using
vibratory tandem roller of 80-100 kN static weight. During initial
breakdown rolling and finish rolling, no vibratory compaction shall be
resorted to. The exact pattern of rolling shall be established after
trial compaction as approved by the Engineer. Any displacement occurring
as a result of reversing of the direction of a roller or from any other
cause shall be corrected at once as specified and/or removed and made
good. The rollers shall not be permitted to stand on pavement which
has not been fully compacted and where temperature is still more than
70C.Necessary precautions shall be taken to prevent dropping of
oil, grease, petrol or other foreign matter on the pavement either when
the rollers are operating or standing.
The wheels of roller shall be kept moist to prevent the mix from
adhering to them. But in no case shall fuel/lubricating oil be used
for this purpose nor excessive water poured on the wheels, Rolling
shall commence longitudinally from edges and proceed towards the
centre, except that on superelevated and unidirectional cambered
portions, it shall progress from the lower to upper edge parallel to
the centre line of the pavement. The roller shall proceed on the fresh
material with rear or fixed wheel leading so as to minimise the
<<
168
Section 500
pushing of the mix and each pass of the roller shall overlap the
preceding one by half the width of the rear wheel.
Rolling shall be continued till the density achieved is at least 98
per cent of that of laboratory Marshall specimen (compacted as defined
in Table 500-10) and all roller marks are eliminated. Skin patching of
an area that has been rolled, will not be permitted. Rolling operations
shall be completed in all respects before the termperature of the mix
f~.illsbelow 100C.
507.5. Opening to Traffic
Traffic may be allowed after completion of the final rolling when
the mix has cooled down to the surrounding temperature. The Dense
Bituminous Macadam shall be provided with an appropriate wearing
course as early as possible prior to regular opening to normal traffic and!
or impending rain.
507.6. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements
of Clause 902.
Control on the quality of materials and works shall be exercised by
the Engineer in accordance with Section 900.
507.7. Arrangements for Traffic
During the period of construction, arrangements for the traffic shall
be done to Clause 112,
507.8. Measurements for P~~~ne~t
Dense Bituminous Macadam shall be measured as finished work
in cubic metres or tonnes as directed by the Engineer.
507.9. Rate
The contract
<<
169
Section 500
508.
SURFACE DRESSING
Normal size or
stone chipplngs
1.
13.2 mm
2.
11.2 mm
TABLE 500-13.
S.No.
Type
1.
2.
<<
Specifications
or construction
Binder
Stone
chlppings
18.0 kg
015 cu.m.
10.0 kg
0.10 cu.m.
70
Section 500
<<
171
Section 500
than one-third of the track made in the preceding pass. While rolling
is in progress, additional chippings shall be spread by hand in
necessary quantities required to make up irregularities. Rolling shall
continue until all aggregate particles are firmly embedded in the
binder and present a uniform closed surface.
508.1.3.6. Application of second coat of surface dressing
Where surface dressing in two coats is specified, the second coat shall
he applied immediately after laying of the first coat. The construction
operations for the second coat shall be the same as described in
Clauses 508.1.3.3 to 508.1.3.5.
508.1.4. Opening to traffic : Traffic shall not be permitted to run
on any newly surface dressed area until the following day. in special
circumstances, however, the Engineer may open the road to traffic
immediately after rolling, but in such cases traffic speed shall be limited
to 16 km per hour till the following clay.
508.1.5. Surface finish and quality control of work: The surface
finish of construction shall conform to the requirements of Clause 902.
Control on the quality of materials and works shall be exercised by
the Engineer in accordance with Section 900.
508.1.6. Arrangements for traffic : During the period of
construction, arrangement of traffic shall be done as per Clause 112.
508.1.7. Measurements for payment: Each coat of surface dressing
shall be measured as finished work in square metres.
508.1.8. Rates: The contract unit rate for each coat of surface
dressing shall be payment in full for carrying out the required
operations including full compensation for all components listed it
Clause 504.8 (i) to (vi).
508.2. TwoCoat Surface Dressing Using Cationic Bitumen
Emulsion
508.2.!, Scope
508.2.1.1. This work shall consist of two-coat surface dressing, each
coat consisting of a layer of cationic bitumen emulsion binder sprayed
on a base prepared previously, followed by a cover of stone aggregate,
properly roiled to form a wearing course to the requirements of these
Specifications.
508.2.1.2. It shall, however, not be applicable to a single coat
surface dressing using cationic bitumen emulsion.
<<
172
Section 500
508.2.2. Material
508.2.2.1. Binder: The binder shall be a Cationic type bitumen
emulsion of Rapid Setting ~RS)grade complying with 1.5. 8887 and
having bitumen content 60 per cent minimum by weight.
508.2.2.2. Aggregate
(A)~General Requtrements: Clause 508.1.2.2. shall apply except the size requirement
which shall be as given in Table 500-14. Wet aggregates can be used for surface
dressing with Cationic bitumen emulsions and when aggregates are dusty, they
should be cleaned by washing or by sprinkling water copiously. If the road
surface is thy, a light sprinkling with waler shall be done.
(B)
Size: The aggregates shalt conform to the size given in Table 500-14,
Ior second coat-6.7 mm size Passing 9.5 mm sieve and retained on 2.36 mm sieve.
(C) QuantIties of Materials: The quantities of materials used for this work shalt
be as given in Table 500-15.
TABLE 50045. REQUIREMENTS OF MATERIALS USING BITUMEN
EMULSION
12 to 14 kg
0.10 so 0.12 cu.m,
16 to 18 kg
0.06 to 0.08 cu.m.
<<
173
Section 500
508.2.3.5.
Second coat
(A) rune interval : The second coat of surface dressing shall be applied on the
same day as the Isrst coat but at least not earlier than one hour after finishing
the rolling of the first coat.
(B) Application of emulsion: Traffic shall not be allowed on the first coat before
the appi ication of second coat. If the aggregates of the first coat appear to
be loose and unbonded - in few spots, the same shall not be disturbed.
[he Caliortic bitumen emulsion for secoqd coat shall be sprayed by mechanical
sprayer or in exceptional cases by using pouring can with the approval of the
Engineer, taking care not to disturb the first layer while walking over it.
(C) Application of aggregate: Immediately after the application of emulsion, 6.7
mm size aggregates shall be spread uniformly by mechanical means to cover
the whole surface evenly.
(II)
Rolling: Rolling shall start soon after spreading the aggregates and all
operations carried out as per Clause 508.2.3.4 (C) to achieve a uniform closed
surface.
(E) Finishing: After one pass of the roller, depressions shall be filled with
6.7 mm size aggregate. If excess of aggregate is found in isolated spots, the
bigger size aggregates shall be removed to give a uniform surface. Finish
rolling on the next day helps to give a firm surface.
<<
174
Section 500
<<
175
Section 500
508.3.2. Materials
508.3.2.1. Bind~r:The binder shall be straight run bitumen of
a suitable grade appropriate to the region, traffic and other environmental
conditions and as directed by the Engineer and conforming to
IS:73.
508.3.2,2. Aggregates : The aggregaS shall conform to Clause
504.2.2. They shall conforni to the quality requirements of Table 5(X)3 except that the water absorption shall be restricted to maximum of
I per cent. The Stone Polishing Value as measured by BS 812 (Part114) shall not be less than 55.
The size of the aggregates shall be .in accordance with Table
500-12.
508.3.2.3. Quantities of materials: The quantities of materials used
for this work shall be as specified in Tables 500-12 and 500-13.
508.3.2.4. Precoating: The aggregates shall be precoated with 0.75
to 1.00 per cent of their weight with binder and shall not be precoated
simultaneously with the surface dressing operation. The precoated aggrcgates shall be allowed to cure for at least one week so that they become
non-sticky to facilitate easy spreading like normal uncoated aggregates.
The aggregates, free of dust or fine parlicles shall be preheated to
160Cfor pr~coatingand then mixed with bitumen binder (0.75 to
1.00 per cent hy weight of aggreg~fte) heated to its application
temperature. The aggregates and binder shall be thoroughly mixed in
a mixer of approved type till the aggregates are uniformly coated.
508.3.3. Construction operations
508.3.3.1 Weather and seasonal limitations: Clause 504.3.1
shall apply.
508.3.3.2. Preparation of base: Clause 508.1.3.2 shall apply.
508.3.3.3. Application of binder: After deducfing the binder quantity
consumed in precoating aggrega~e~[or:.first coat in terms of para
508.3.2.4 from the quantities spn:sfiecl in Table 500-13, remaining
binder of first coat shall be heated to 150-165Cand sprayed on the
clean and dry surface in a uniform manner preferably with the help of
mechanical sprayers having self-heating arrangement, bitumen, pressure
pump anti spray nozzle bar capable of spraying bitumen uniformly at
tha4xates and temperatures specified above. Excessive deposits of binder
caused by stoppage or starting of sprayer or through leakage or any
other reason shall be corrected before stone chip~ingsare spread.
<<
176
Base
Section 500
<<
177
Section 500
(Bituminous)
509.1.2. Materials
509.1.2.1. Binder: The binder shall be bitumen of a suitable grade
appropriate to the region, traffic, rainfall anl other environmental conditions, as directed by the Engineer and satisfying the requirements
of IS 73, 217, 454 or other approved cuthack as applicable. Guidance
in this regard may be taken from Appendix 4.
-
2 OF ROAD
QUANTITIES OF MATERIAlS REQUIRED FOR 10 m
SURFACE FOR 20 mm THICK OPEN-GRADED PREMIX CARPET
USING BITUMEN
0.18m5
(b)
0.09s&
Total
0.27&
9.5 kg
(b)
5.1 kg
Total
14.6 kg.
<<
178
Courses (Bituminous)
Section 500
509.1,3.3. Tack coat : A tack coat complying with Clause 503, shall
be applied over the base preparatory to laying of the carpet.
509.1.3.4. Preparation of premix: Hot mix plant of appropriate
capacity and type shall be used for the preparation of mix material.
The hot mix plant shall have separate dryer arrangement for heating
aggregates and pugmill for mixing aggregates and binder.
The temperature of binder at the time of mixing shall be in the
range of 150C to 163C and that of the aggregates in the range of
1550 C to 163C provided that the difference in temperature between
the binder and aggregates at no time exceeds 14C. Mixing shall be
thorough to ensure that a homogeneous mixture is obtained in which all
particles of the aggregates are coated uniformly and the discharge
temperature of mix shall be between 130C and 160C.
The mix shall be immediately transported from the mixer to the
point of use in suitable vehicles or wheel barrows. The vehicles
employed for transport shall be clean and the mix being transported
covered in transit if so directed by the Engineer.
509.13.5. Spreading and rolling: The mixed material shall be
spread by suitable means. As soon as sufficient length of bituminous
material has been laid, rolling shall commence with 80-100 kN rollers,
preferably of smooth wheel tandem type, or other approved equipment.
Rolling shall begin at the edge and progress toward the centre
longitudinally, except that on the superelevated and uni-directional
cambered portions, it shall progress from the lower to upper edge
parallel to the centre line of the pavement.
When the roller has passed over the whole area once, any high
spots or depressions which become apparent shall be corrected by
removing or adding premixed materials. Rolling shall then be continued
until the entire surface has been rolled to compaction and all the roller
marks eliminated. In each pass of th~roller, preceding track shall be
overlapped uniformly by at least 1/3 width. The roller wheels shall be
kept damp to prevent the premix from adhering to the wheels and being
picked up. In no case shall fuel/lubricating oil be used for this purpose.
Excess use of water for this purpose shall be avoided.
Rollers shall not stand on newly laid material while there is a risk
that it will be deformed thereby. Rolling operations shall be completed
in every respect before the temperature of the mix falls below l000C,
<<
179
Section 500
The edges along and transverse of the carpet lai,d and compacted
earlier shall be cut to their full depth so as to expose fresh surface which
shall be painted with a thin surface coat of appropriate binder before
the new mix is placed against it.
509.1.3.6. Seal coat: A seal coat conforming to Clause 513 shall
be applied to the surface immediately after laying the carpet.
509.1.4. Opening to traffic: No traffic shall be allowed on the road
tilt the seal coat has been laid. After the seal coat is laid, the road
shall be opened to traffi~according to Clause 513.4.
509.1.5. Surface finish and quality control of work: The surface
finish of construction shall conform to the requirements of Clause
902. Control on the quality of materials and works shall be exercised
by the Engineer in accordance with Section 900.
509.1.6. Arrangements for traffic: During the period of construclion, arrangement of traffic shall be done to Clause 112.
509.1.7. Measurements for payment: Open graded premix carpet
shall be measured as finished work in square metres.
509.1.8. Rate: The contract unit rate for open-graded premix carpet
shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 504.8.
509.2. 20mm Thick Premix Carpet using Cationic Bitumen Emul..
sion
.509.2.1. Scope: This work shall consist of laying and compacting
an olen graded premix carpet of 20mm thickness with Cationic bitumen
emulsion placed on a previously prepared base in accordance with the
requirements of these Specifications to serve as a wearing course.
509.2.2. Materials
509,2.2.1. Binder: The binder shall be Cationic bitumen emulsion
of Medium Setting (MS) grade complying with IS: 8887 and having
bitumen content 60 per cent minimum by weight. For liquid seal coat
MS grade can be used, but it is preferable to use Rapid Setting (RS)
grade of Cationic bitumen emulsion. However, for premix seal coat Stow
Setting (SS) grade Cationic bitumen emulsion shall be used.
509.2.22. Coarse aggregates : C!ause 509.1.2.2. shall apply. Aggregates should be cleaned by washing or by spriniding water copiously.
The coarse aggregates shall satisfy the quality requirements set forth
<<
180
Section 500
in Table 500-3, except that the water absorption value shall be limited
to a maximum of I per cent. Stripping value is not to be considered
unless directed by the Engineer. Water absorption up to 2 per cent may
be permitted in exceptional cases only.
509.2.2.3. Fine aggreg~tes~Fine aggregates for seal coat shall
be crushed stone chips or coarse sand, clean, uncoated and free from
clay, dust and other deleterious matter.
509.2.3. Quantities of materials required: The materials shall
be proportioned as per quantities given in Tables 500-17 and 500-18.
TABLE 500.17. QUANTITIES OF AGGREGATES FOR 10 nsa AREA
(A) Prembi Carpet
(a)
0.18 m
0.09 in
TABLE 500.18.
(i)
(ii)
0.06 rn~
QUANTITIES OF BINDER
(B)
0.06 m
2.0 to 2.5 kg
2.5 to 3.0 kg
2.5 to 3.0 kg
(a)
3.5 to 4.0 kg
(b)
2.5 to 4.0 kg
20 to 23 kg
12 to 14 kg
(b)
10 to 12 kg
509.2.3,1. Aggregates
509.2.4. Construction operations
509.2.4.1. Weather limitations: Cationic bitumen emulsions shall
<<
181
Section500
(Bituminous)
<<
182
Courses (Bituminous)
Section 500
required to fill
should be
<<
183
Section 500
(Bituminous)
<<
184
Section 500
100
13.2 mm
11.2 mm
100
88.100
5.6 mm
52-88
31-52
2.8 mm
14-38
5-25
0.5
0.5
90
micron
<<
185
Section 500
<<
186
Section 500
CONCRETE
IS Sieve
Designation
22.4 mm
13.2 mm
11.2 mm
100
88-100
5,6 mm
2.8
710
355
180
90
Note:
42-64
22-38
11-24
7-18
5-13
3-9
mm
micron
micron
micron
micron
Grading_3
Grading_2
100
100
85-100
70-92
42-64
22-38
11-24
7-18
5-13
3-9
79-100
68-90
33.55
22-38
6-22
4-14
2-9
0-5
Grading 1 shall be adopted for 25 mm compacted thickness and Grading 2/3 for
higher thicknesses.
REQUIREMENTS OF SEMI-DENSE
BITUMINOUS CONCRETE MIX
2.
3.
4.
5.
6.
<<
500-21.
(VFB)
13.15
(for 13.2 mm max size)
11-13
(for 22.4 mm max size)
65-75
Not less than 4.0 per cent
Notet : 1.
2.
At bus stops, parking areas and roundabouts near minimum flow value should
be adopted.
3.
Attempt should be to have well graded aggregates and the per cent voids in
the mix closer t.o the lower limit.
187
Section 500
Base and
S,No.
Description of ingredient
I.
2.
3.
4.
5.
6.
7.
8.
PennSslble jariatlon by
weight ci total mix In
percentage
8
7
6
5
4
2
0.3
10C
<<
188
Section 500
<<
189
Section 500
AGGREGATES
15 Sieve Designation
26.5
19
9.5
4.75
2.36
300
75
Per cent
100
mm
mm
mm
mm
mm
micron
micron
90-100
56-80
35-65
23-49
5-19
2-8
Description
2.
CONCRETE
MIX
Requirements
3.
4.
5.
Per cent
Per cent
Per cent
filled by
6.
7.
8.
2-4
3-5
<<
190
Section 500
percentages of various ingredients in the actual mix from the job mix
formula may be within the limits as specified in Table 5O0~l1. These
variations are intended to apply to individual specimens taken for quality
control tests vide Section 900.
512.4. Construction Operations
512.4.1. Weather and seasonal limitations: Clause 504.3.1 shall
apply.
512.4.2. Preparation of base: The base on which bituminous
concrete is to be laid shall be prepared, shaped and conditioned to the
specified levels, grade and crossfall (camber) in accordance with Clause
501 or as directed by the Engineer.
The surface shall be thoroughly swept clean free from dust and
foreign matter using mechanical broom and dust removed by mechanical
means or blown off by compressed air. In portions where mechanical
means cannot reach, other approved method shall be used.
512.4.3. Tack coat: A tack coat complying with Clause 503 shall
be applied over the base.
512.4.4. Preparation of mix: Clause 5074.4 shalt apply.
512.4.5. Spreading: Clause 507.4.5 shall apply.
512,4.6. Rolling: Clause 5074.6 shall apply.
512.5. Opening to Traffic
Traffic may be allowed immediately after completion of the final
rolling when the mix has cooled down to the surrounding temperature.
512.6. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the
requirements of Clause 902.
Control on the quality of materials and works shalt be exercised by
the Engineer in accordance with Section 900.
512,7. Arrangements for Traffic
During the period of construction, arrangement of traffic shall be
done to Clause 112.
512.8. Measurements for Payment
Bituminous concrete shall be measured as finished work in cubic
metres or tonnes as provided in the Contract.
<<
191
.__#---
Section 500
512.9.
.-.
-.
.-
513.2. Materials
<<
192
Section 500
<<
193
Section 500
<<
194
Section 500
Standard size
of aggregates
Designation of sieve
through which the
aggregates shall
wholly pass
Designation of
sieve on which
the aggregates
shall wholly be
retained
(i)
75 mm
106 mm
(ii)
63mm
90mm
53mm
(iii)
45 mm
53 mm
26.5 mm
(iv)
26.5 mm
45 mm
22.4 mm
(v)
22.4 mm
26.5 mm
13.2 mm
63 mm
(Vi)
13.2 mm
22.4 mm
11.2 mm
(vii)
11.2 mm
13.2 mm
6.7 mm
(viii)
6.7 mm
11.2 mm
2.8 mm
514.3. Stacking
1. Coarse Aggregates
Only the aggregates satisfying the Specification requirements shall
be conveyed to the roadside and stacked. Each size of aggregate shall
be stacked separately. Likewise, materials obtained from different quarry
sources shall be stacked separately.
2. Fine Aggregates : As given in relevant Specifications.
The aggregates shall be stacked entirely clear of the roadway on
even ground, or platform prepared in advance for the purpose by the
Contractor at his own cost and in a manner that permits of correct and
ready measurement. Materials shall not be stacked in locations liable
to inundation or floods.
The dimensions of the stacks and their location shall be as approved
by the Engineer. Where the material is improperly stacked, the Engineer
shall have the right to order complete re-stacking of the materials to
specifications at the cost of the Contractor.
Mineral filler shall be supplied in dry state in bags or other suitable
containers approved by the Engineer and shall be protected from
weather dampness, etc., so as to prevent deterioration in quality.
-
<<
195
Section 500
One test for each specified property for every five tonnes,
subject to a minimum of one test for each consignman.
Standard size
of aggregates
1.
75 mm and 63 mm
123
2.
45 mm and 26.5 mm
10.0
3.
4.
Fine aggregate
5.0
5.0
Unless otherwise directed, measurements shall not be taken until sufficient materials for use on the road have been collected and stacked.
Immediately after measurement, the stacks shall be marked by white
wash or other means as directed by the Engineer.
Mineral filler as delivered at site of works shall be measured in
tonnes.
514.6.
Rates
The contract unit rates for different sizes of coarse aggregates, fine
aggregates and mineral filler shall be payment in full for collecting,
conveying and stacking or storing at site of works including full
compensation for
(i)
(ii)
(iii) all labour, tooIs..equipi~entsand incidentals to complete the work to the Speci.
fications.
<<
196
Base and
Section 500
Characteristic
Requirement
Method of tests
1.
20 to 40
IS; 1203
2.
50C to 90C
IS; 1205
3.
Ductility at 27C(Minimum)
10 cm
15: 1208
4.
3 per cent
IS: 1212
5.
Solubility in CS
99 per cent
IS; 1216
2 (Minimum)
<<
197
Section
500
TABLE 500.28.
S.No.
Type of work
1.
Wearing course
for pavement
& bridge deck
Thickness
of Finished
Course (mm)
Percentage
of Coarse
Aggregates
(a)
2.5-40
(a)
30-40
(b)
41.50
(b)
40-50
Grading of Coarse
Aggregates
Passing
ts. Sieve
Percentage
19 mm
13.2 mm
2.36 mm
100
88-96
0-5
IS. Sieve
Passing
2.36
IS. Seive
Retained
mm
600
micron
Percentage
by Weight
0.25
600
micron
212
micron
5-35
212
micron
75
micron
10-20
75
micron
30-50
14-17
Bitumen Binder
<<
198
(Bituminous)
Section 500
Engineer in writing at least 20 days before the start of the work, the
job mix formula proposed to be used by him for the work, indicating
the source and location of all materials, proportions of all materials such
as binder and aggregates, single definite percentage passing each sieve
for the mixed aggregates and results of the tests recommended
in various Tables and Clauses of this Specification.
515.4. Construction Operations
515.4.1. Weather and seasonal limitations: Clause 504.3.1 shall
apply.
515.4.2. Preparation of the base: The base on which bitumen mastic
is to be laid shall be prepared, shaped and conditioned to the specified
levels, grade and crossfall (camber) in accordance with Clause 501 or
as directed by the Engineer. In case of a cement concrete base, the
surface shall be thoroughly swept and scraped clean and free of dust
and other deleterious matter. Under no circumstances shall bitumen
mastic be spread on a base containing a binder which will soften under
high application temperatures. if any such spots or area are there,
the same shall be cut out and repaired before the bitumen mastic is
laid.
515.4.3. Tack coat : A tack coat as per Clause 503 shall be applied
on the base or as directed by the Engineer:
515.4.4. Preparation of bitumen mastic : Preparation of bitumen
mastic consists of two stages. The first stage shall be mixing of filler
and fine aggregates and then heating the mixture to a temperature of
170Cto 200C~
Required quantity of bitumen shall be heated to 170C
to 180C and added to the heated aggregate. They shall be mixed and
cooked in an approved type of mechanically agitated mastic cooker for
some time till the materials are thoroughly mixed. Initially the filler
alone is to be heated in the cooker for an hour and then h~iJfthe quantity
of binder is added. After heating and mixing for some time, the tine
aggregates and the balance of binder are to be added and further cooked
for about one hour. The second stage is incorporation of coarse
aggregates and cooking the mixture for a total period of 3 hours. During
cooking and mixing, care shall be taken to ensure that the contents
in the cooker are at no time heated to a temperature exceeding
200C.
In case where the material is not required for immediate use it shall
be cast into blocks with filler, fine aggregates and binder, weighing
about 25 kg each. These blocks when required to be used, have to
<<
199
Section 500
Base
IS. Sieve
Retained
236
600
212
75
600
212
75
Percentage by weight
.
Minimum
mm
micron
micron
micron
micron
micron
micron
Bitumen Content
Maximum
0
4
8
25
22
30
18
45
14
17
<<
200
Base
Section 500
<<
201
Section 500
Courses (Bituminous)
516.2. Materials
The materials for slurry seal immediately prior to mixing shall
conform to the following requirements:
516.2.1. Emulsified bitumen : The emulsified bitumen shall
be a Cationic rapid setting type as approved by the Engineer, conforming
to the requirements as per IS: 8887. It shall be capable of producing
a slurry as would develop early resistance to traffic and rain and is
sufficiently stable to permit mixing with the specified aggregates,
without breaking during the mixing and laying processes. If approved
by the Engineer, a slow setting emulsion may be used.
516.2.2. Water: Water shall be of such quality that the bitumen will
not separate from the emulsion before the slurry seal is in place of work.
516.2.3. Aggregates: The aggregates shall be crushed igneous
rock, limestone or slag and may be blended, if required, with clean, sharp,
naturally occurring sand free from silt, clay or other tine material to
produce a grading as given in Table 500-31. It shall meet the requirements
of the film stripping test (-IS: 6241) and suitable amount and type of
anti-stripping agent added, as may be i~eeded.
TABLE 500-31. AGGREGATES GRADING FOR SLURRY SEAL
Sieve size
<<
4.75 mm
100
3.35 mm
80-100
100
2.36 mm
75-100
95-100
1.18 mm
55-90
70-95
600
micron
35-70
55-75
300
micron
20-45
30-50
150
micron
10-25
10-30
75
micron
5-15
5-15
202
Section 500
516.3. Proportioning
The mixed material shall consist of aggregates, water and emulsified!
bitumen (about 180-250 litres per tonne of dry aggregates) and where
necessary, Portland cement as an additive. The proportion of the additive
(portland cement) shall not normally exceed 2 per cent by weight of
dry aggregates. The precise proportion of each constituent should be
selected by laboratory tests and trials.
516.4. Mixing
The various constituents shall be weighed in the needed proportions
and mixed in a mechanical mixer so that all particles of the aggregates
are uniformly coated and the slurry is of such consistency as can
be satisfactorily laid. It shall be a semi-fluid, homogeneous mass with
no emulsion run-off.
516.5. Site Preparation
The pavement surface shall be suitably prepared by removing any
loose material, dust and vegetation after patching up any potholes, depressions etc. All manhole covers, inspection covers and gully gratings
should be masked.
516.6. Laying
If required, a tack coat shall be applied. The rate of spread of tack
coat shall depend on the surface to be treated: for bituminous surfaces,
at the rate of 0.15 to 0.30 litreWsq.m. and for concrete surfaces at
the rate of 0.4 to 0.6 litres/sq.m. Spreading shall be carried out by
mechanical means. Spreading shall not be undertaken when the ground
temperature falls below 4Cor wher the surface contains standing water.
The slurry shall be spread at a rate such that the cover of aggregates
(dry mass equivalent ) is 4-6 kg! sq.m. for 3 mm thick work and 24 kg/sq.m. for 1.5 mm thick work.
The slurry shall be rolled by a pneumatic tyred roller having an individual wheel load between 7.5 and 15.0 kN making at least six
passes or as may be directed by the Engineer. Rolling shall commence
as soon as the slurry has set sufficiently to ensure that rutting or
excessive movement will not occur. Adequate steps shall be taken to
avoid damage by traffic until such time that the mixture has cured
sufficiently so that the slurry seal will not adhere to and be picked
up by the tyres of vehicles.
<<
203
Section 500
<<
204
Section 500
<<
205
Section 500
<<
206
Base and
Section 500
with the job mix formula and strictly controlled. All overheated and
carbonized mixture, shall be rejected.
.Mixing shall be thorough to ensure that a homogeneous mixture is
obtained in which all particles of the mineral aggregates are coated uniformly.
Any tipper causing excessive segregation of materials by its spring
suspension or other contributing factors or that showing undue delays
shall be removed from the work until such conditions are corrected.
517.5.2. Spreading: The mix transported from the hot mix plant to
the site shall be spread by means of a self-propelled mechanical paver
with suitable screeds capable of spreading, tamping and finishing the mix
to specified grade, lines and crosssection. Paver Finisher shall have the
essential features as spelt out in Clause 504.3.5. However, in restricted
locations and in narrow width where the available equipment cannot
be operated in the opinion of the Engineer, he may permit manual laying
of the mix.
Mixes with a temperature of less than 120 Cshall not be put into
paver spreader.
Longitudinal joints and edges shall be constructed true to the centre
line of the road. Longitudinal and transverse joints shall be offset by
at least 250 mm from those in the lower courses and the joints on
the top most layer shall not be allowed to fall within the wheel path.
All transverse joints shall be cut vertically to the full thickness
of the previously laid mix with pneumatic cutter and the surface painted
with hot bitumen before placing fresh material. Longitudinal joints
shall be preferably hot joints. Cold longitudinal joints shall be properly
heated with joint heater to attain a suitable temperature of about 80 C
before laying of any adjacent material.
517.5.3. Compaction: Clause 507.4.6 shall apply.
517.5.4. Opening to traffic: Traffic may be allowed after completion
of the final rolling when the mix has cooled down to the surrounding
temperature.
517.6. Surface Finish and Quality Control
The surface finish of construction shall conform to the requirements
of Clause 902.
Control on the quality of materials and works shall be exercised by
the Engineer in accordance with Section 900.
<<
207
Section 500
517.7.
During
be done to
517.8.
(ii)
(iii) All labour, tools, equipment, plant and incidentals to complete the work
to the Specification;
(iv) Cariying
(v)
<<
out the
work
208
Concrete Pavement
600
Concrete Pavement
<<
Concrete Pavement
Section 600
IS
IS :
IS
269
455
1489
<<
211
Concrete Pavement
Section 600~
of deleterious materials shall not exceed the requirements set out in IS:
383. In case the Engineer considers that the aggregates are not free from
dirt, the same may be washed and drained for at least 72 hours before
batching, as directed by the~Engineer.
601.2.3.2. Coarse aggregate: Coarse aggregate shall consist of clean,
hard, strong, dense, non-porous and durable pieces of crushed stone or
crushed gravel and shall be devoid of pieces of disintegrated stone, soft,
flaky, elongated, very angular or splintery pieces. The maximum size of
the coarse aggregate shall be 25 mm. The coarse aggregate shall comply
with Clause 602.2.4.2.
601.2.3.3. Fine aggregate: The fine aggregate shall consist of clean,
natural sand or crushed stone sand or a combination of the two and shall
conform to IS: 383. Fine aggregate shill be free from soft particles, clay,
shale, loam, cemented particles, mica, organic and other foreign matter,
The fine aggregate shall comply with Clause 602.2.4,3.
601.2.3.4. The coarse and fine aggregates may be obtained in either
of the following manner:
(i)
In separate nominal sizes of coarse and fine aggregates and mixed Logether
intimately before use,
(ii)
Separately as 25 rem nominal single size, 12.5 mm nominal size graded aggregates
and fine aggregate of crushed stone dust or sand or a combination of these two.
26.50
19.00
9.50
4.75
600.00
75.00
mm
mm
mm
mm
micron
micron
100
80-100
55.75
35-60
1045
0-8
601.2.4. Water: Water used for mixing and curing of concrete shall
be clean and free from injurious amounts of oil, salt, acid, vegetable
matter or other substances harmful to the finished concrete. It shall meet
the requirements stipulated in IS : 456.
601.2.5. Storage of materials: All materials shall be stored in
accordance with the provisions of Clause 1014 of these Specifications and
<<
1,,
Concrete Pavement
Section 600
<<
213
Concrete Pavement
Section 600
shall be got approved from the Engineer and demonstrated in the trial
length construction.
601.4. Subgrade
The subgrade shall conform to the grades and cross sections shown
on the drawings and shall be uniformly compacted to the design strength
in accordance with these Specifications and Specification stipulated in
the Contract. The lean concrete subbase shall not be laid on a subgrade
softened by rain after its final preparation; surface trenches and soft
spots, if any, must be properly back-filled and compacted to avoid any
weak or soft spot. As far as possible, the construction traffic shall be
avoided on the prepared subgrade. A day before placing of the sub-base,
the subgrade surface shall be given a fine spray of water and rolled with
one or two passes of a smooth wheeled roller after a lapse of 2-3 hours
in order to stabilise loose surface. If Engineer feels it necessary, another
fine spray of water may be applied just before placing sub-base.
6013. Construction
601.5.1. General: The pace and programme of the lean concrete subbase construction shall be matching suitably with the programme of
consi~ruction of the cement concrete pavement Over it. The sub-base
shall be overlaid with cement concrete pavement only after 7 days after
sub-base construction.
601.5.2. Batching and mixing: The batching plant shall be capable
of proportioning the materials by weight, each type of material being
weighed separately in accordance with Clause 602.9.3.2. The cement
from the bulk stock shall be weighed separately from the aggregates. The
capacity of batching and mixing plant shall be at least 25 per cent higher
than the proposed capacity for the laying arrangements. The batching
and mixing shall be carried out preferably in a forced action central
batching and mixing plant having necessary automatic controls to ensure
accurate proportioning and mixing. Other types of mixers shall be permitted subject to demonstration of their satisfactory performance during
the trial length. The type and capacity of the plant shall be got approved
by the Engineer before commencement of the trial length. The weighing
balances shall be calibrated by weighing the aggregates, cement, water
and admixtures physically either by weighing with large weighing machine or in a weigh bridge. The accuracy of weighing scales of the
batching plant shall be within 2 per cent in the case of aggregates
and 1per cent in the case of cement and water.
<<
214
Concrete Pavement
Section 600
<<
215
Section 600
Concrete Pavement
the final finishing of the same shall not exceed 90 minutes when the
concrete temperature is above 25 and below 30 degree Celsius and
120 minutes if less than 25 degree Celsius. This period may be reviewed
by the Engineer in the light of the results of the trial run but in no case
shall it exceed 2 hours. Work shall not proceed When the temperature
of the concrete exceeds 30 degree Celsius. If necessary, chilled water
or addition of ice may be resorted to for bringing down the temperature.
It is desirable to stop concreting when the ambient temperature is above
35C. After compaction has been completed, roller shall not stand on the
compacted surface for the duration of the curing period except during
commencement of next days work near the location where work was
terminated the previous day.
601.5.5.3. Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 kN static weight are considered to be suitable for rolling
dry lean concrete. In case any other roller is proposed, the same shall be
got approved from the Engineer, after demonstrating its performance,
The number of passes required to obtain maximum compaction depends
on the thickness of the lean concrete, the compactibility of the mix, and
the weight and type of the roller etc., and the same as well as the total
requirement of rollers for the job shall be determined during trial run
by measuring the in-situ density and the scale of the work to be
undertaken.
601.5.5.4. In addition to the number of passes required for compaction
there shall be a preliminary pass without vibration to bed the lean concrete
down and again a final pass without vibration to remove roller marks
and to smoothen the surface.
Special care and attention shall be exercised during compaction near
joints, kerbs, channels, side forms and around gullies and manholes.
In case adequate compaction is not achieved by the roller at these points,
use of plate vibrator shall be made, if so directed by the Engineer.
601.5.5.5. The final lean concrete surface on completion of compaction and immediately before overlaying, shall be well closed, free from
movement under roller and free from ridg~s,low spots, cracks, loose
material, pot holes, ruts or other defects. The final surface shall be
inspected immediately on completion and all loose, segregated or defective areas shall be corrected by using fresh lean concrete material
laid and compacted as per Specification. For repairing honeycombed
surface, concrete with aggregates of size 10 mm and below shall be
spread and compacted. It is necessary to check the level of the rolled
<<
216
Concrete Pavement
Section 600
surface for compliance. Any level/thickness deficiency should be corrected after applying concrete with aggregates of size 10 mm and below
after roughening the surface. Similarly the surface regularity also should
The initial curing shaH be done by spraying with liquid curing compound. The
curing compound shall be white pigmented or transparent type with water retention
indea of 90 per cent when tested in accordance with BS 7542. Curing compound
shall be sprayed immediately after rolling is complete. As soon as the curing
compound has loss its tackiness, the surface shall be covered with wet hessian for
three days.
(b)
<<
217
Section 600
Concrete Pavement
<<
218
Section 600
Concrete Pavement
<<
219
Concrete Pavement
Section 600
269.
(ii)
8112.
IS
12269.
If the soil around has soluble salts like sulphates in excess of 0.5 per
cent, the cement used shall be sulphate resistant and shall conform to IS:
12330.
Guidance may be taken from IS: SP: 23, Handbook for Concrete
Mixes for ascertaining the minimum 7 days strength of cement required
to match with the design concrete strength. Cement to be used may
preferably be obtained in bulk form. If cement in paper bags are
proposed to be used, there shall be bag-splitters with the facility to
separate pieces of paper bags and dispose them of suitably. No paper
pieces shall enter the concrete mix. Bulk cement shall be stored in
<<
220
Concrete Pavement
Section 600
<<
221
Section
600
Concrete Pavement
from dirt, the same may be washed and drained for at least 72 hours
before batching as directed by the Engineer.
602.2.4.3. Fine aggregate: The fine aggregate shall consist of clean
natural sand or crushed stone sand or a combination of the two and
shall conform to IS : 383. Fine aggregate shall be free from soft
particles, clay, shale, loam, cemented particles, mica and organic and
other foreign matter. The fine aggregate shall not contain deleterious
substances more than the following
Clay lumps
Coal and lignite
Material passing IS Sieve No. 75 micron
602.2.5. Water: Water used for mixing and curing of concrete shall
be clean and free from injurious amount of oil, salt, acid, vegetable
matter or other substances harmful to the finished concrete. It shall meet
the requirements stipulated in IS: 456,
602.2.6. Mild steel bars for dowels and tie bars : These shall
conform to the requirements of IS : 432, IS : 1139 and IS : 1786 as
relevant. The dowel bars stiall conform to Grade S 240 and tie bars to
Grade S 415 of l.S.
602.2.7. Premoulded joint filler: Joint tiller board for expansion
joints which are proposed for use only at some abutting structures like
bridges and culverts shall be of 20-25 mm thickness within a tolerance
of 1.5 mm and of a firm compressible material and complying
with the requirements of IS:1838, or BS Specification Clause No. 2630
or Specification for Highway Works, Vol. I Clause 1015. It shall be 25
mm less in depth than the thickness of the slab within a tolerance of
3 mm and provided to the full width between the side forms. It shall
ke in suitable lengths which shall not be less than one lane width. Holes
to accommodate dowel bars shall be accurately bored or punched out to
give a sliding fit on the dowel bars.
602.2.8. Joint sealing compound: The joint sealing compound shall
be of hot poured, elastomeric type or cold polysulphide type having
flexibility, resistance to age hardening and durability. If the sealant
is of hot poured type it shall conform to AASHTO M282 and cold applied
sealant shall be in accordance with BS 5212 (Part 2).
602.2.9. Storage of materials: All materials shall be stored in
accordance with the provisionsof Clause 1014 of the Specifications and
other relevant IS Specifications. All efforts must be made to store the
materials in proper places so as to prevent their deterioration or
<<
222
Concrete Pavement
Section 600
<<
223
Section 600
Concrete Pavement
<<
224
Section 600
Concrete Pavement
<<
225
Section 600
Concrete Pavement
Deviations of the filler board in the case of expansion joints from the intended line
of the joint shall not be greater than 10mm.
(ii)
The best fit straight line through the joint grooves as constructed shall he
not more than 25 mm from the intended line of the 3oInL
(iii) Deviations of the joint groove from the best fit straight line of the joint shall not be
greater than 10 miii
(iv) Transv~rsejoints on each tide of the longitudinal joint shall be in line with each
other and of the same type and width, Transverse joints shall have a sealing
groove which shall be sealed in compliance with Clause 602.11.
<<
226
Section 600
Concrete Pavement
the line of the joint within the tolerances given in Clause 602,6.2. l~and
at such depth below the surface as will not impede the passage of the
finishing straight edges or oscillating beams of the paving machines. The
adjacent slabs shall be completely separated from each other by providing
joint filler board. Space around the dowel bars, between the sub-base
and the filler board shall be packed with a suitable compressible material
to block the flow of cement slurry.
602.63. Transverse construction joint: Transverse construction
joints shall be placed whenever concreting is completed after a days work
or is suspended for more than 30 minutes. These joints shall be provided
at the regular location of contraction joints using dowel bars. The joint
shall be made butt type. At all construction joints, steel bulk heads shall
be used to retain the concrete while the surface is finished. The surface
of the concrete laid subsequently shall conform to the grade and cross
sections of the previously laid pavement. When positioning of bulk heaW
stop-end is not possible, concreting to an additional 1 or 2 m length may
be carried out to enable the movement of joint cutting machine so that
joint grooves may be formed and the extra 1 or 2 rn length is cut out
and removed subsequently after concrete has hardened.
602.6.4. Longitudinal joint
602.6.4.1. The longitudinal joints shall be saw cut as per details of
the joints shown in the drawing. The groove may be cut after the final set
of the concrete. Joints should be sawn to at least 1/3 the depth of the slab
5 mm as indicated in the drawing.
602.6.4.2. Tie bars shall be provided at the longitudtnai joints as
per dimensions and spacing shown in the drawing and in accordance with
Clause 602.6.6.
602.6.5. Dowel bars
602.6.5.1. Dowel bars shall be mild steel rounds in accordance with
Clause 602.2.6 with details/dimensions as indicated in the drawing and
free from oil, dirt, loose rust or scale. They shall be straight, free of
irregularities and burring restricting slippage in the concrete. The sliding
ends shall be sawn or cropped cleanly with no protrusions outside the
normal diameter of the bar. The dowel bar shall be supported on
cradles/dowel chairs in pie-fabricated joint assemblies positioned prior
to the construction of the slabs or mechanically inserted with vibration
into the plastic concrete by a method which ensures correct placement
of the bars besides full re-compaction of the concrete around the dowel
bars.
<<
227
Concrete Pavement
Section 600
(ii)
All bars in ajount shall be within 3mm per 300mm length of bar
(b)
(c)
(d)
Cradles supporting dowel bar shall not extend across the line of joint i.e. no
steel bar of the cradle assembly shaH be continuous across the joint.
Two-thirds of the number of bars of any assembly tested shall not deflect more
than 2 mm per 300 mm length of bar
(ii)
in
For expansion joints, the deflection of the top edge of the fillet board shall be not
greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
face of the joint filler board and disuibuted over a length of 600mm by means
of a bar or timber packing, at mid depth and midway bet wean individual fixings,
or 300 mm from either end of any length of filler board, if a continuous fixing
is used. The residual deflection after removal of the load shall be not more than
3 mm.
(ii)
The joint assembly fixings to sub-base shall not fail under the l.3kN load applied
for testing the rigidity of the assembly but shall failbe~orethe load reaches 2.6
kN.
(iii) The fixings for contraction joint shall not fail under 1.3 kN load and shall fail
before the load readies 2~6kN when applied over a length of 600 mm
means
of a bar or limber packing placed as near to the level of the line of fixings as
practicable.
<<
228
Section 600
Concrete Pavement
(iv) Fixings shall be deemed to fail when there is displacement of the assemblies by
more than 3 mm with any foms of fixing, under the test load. The displacement
shall be measured at the nearest part of the assembly to the centre of the bar or
timber packing.
Four bars shall be taken at random from stock and without any special preparation
shall be covered by sheaths as required in this Clause. The ends of the dowel
bars which have been sheathed shall be cast centrally into concrete specimens
150 x 150 a 600 mm, made of the same mix proportions to be used in the
pavement, but with a maximum nominal aggregate size of 20 mm and cured in
accordance with IS: 516. At 7 days a tensile load shall be applied to achieve a
movement of the bar of at least 0,25 trim. The average bond stress to achieve
this movement shall not be greater than 014 MPa.
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Section 600
Cemcrete
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Concrete Pavement
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231
Section 600
Concrete Pavement
day before the day of construction of slab. Any deficiencies noted by the
Engineer shall be rectified by the Contractor who shall then re-apply for
approval of the affected stakes. Work shall not proceed until the Engineer
has given his approval. It shall be ensured that the stakes and guidewires
are not affected by the construction equipment when concreting is in
progress.
602.9. Construction
602.9.1. General: A systems approach may be adopted for construction of the pavement, and the Method Statement for carrying out the
work, detailing all the activities including indication of time-cycle,
equipment, personnel etc., shall be got approved from the Engineer
before the commencement of the work. The above shall include the type,
capacity and make of the batching and mixing plant besides the hauling
arrangement and paving equipment. The capacity of paving equipment,
batching plant as well as all the ancillary equipment shall be adequate
for a paving rate of atleast 300 m in one day.
602.9.2. Batching and mixing: Batching and mixing of the concrete
shall be done at a central batching and mixing plant with automatic
controls, located at a suitable place which takes into account sufficient
space for stockpiling of cement, aggregates and stationary water tanks.
This shall be, however, situtated at an approved distance, duly
considering the properties of the mix and the transporting arrangements
available with the Contractor.
602.9.3. Equipment for proportioning of materials and paving
602.9.3.1. Proportioning of materials shall be done in the batching
plant by weight, each type of material being weighed separately. The
cement from the bulk stock may be weighed separately from the
aggregates and water shall be measured by volume. Wherever properly
graded aggregate of uniform quality cannot be maintained as envisaged
in the mix design, the grading of aggregates shall be controlled by
appropriate blending techniques. The capacity of batching and mixing
plant shall be at least 25 per cent higher than the proposed capacity of
the laying/paving equipment.
602.9.3.2. Batching plant and equipment:
(1) General- The batching plant shall include minimum four bins,
weighing hoppers, and scales for the fine aggregate and for each
size of coarse aggregate. If cement is used in bulk, a separate
scale for cement shall be included. The weighing hoppers shall
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232
oncrete Pavement
Section 600
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233
Section 600
Concrete Pavement
<<
23.4
Concrete Pavement
Section 600
shall not exceed 120 minutes when concrete temperature is less than 25C
and 90 minutes when the concrete temperature is between 25Cto 30C.
Truck~ltippersdelivering concrete shall not run on plastic sheeting nor
shall they run on completed slabs until after 28 days of placing the
concrete. The Paver shall be capable of paving the carriageway as shown
in the drawings, in a single pass and lift.
602.9.4.3. Where fixed form payers are to be used, forms shall be
fixed in advance as per Clause 602.8. of the Specifications. Before any
paving is done, the site shall be shown to the Engineer, in order to verify
the arrangement for paving besides placing of dowels, tie-bars etc., as per
the relevant Clauses of this Specification. The mixing and placing of
concrete shall progress only at such a rate as to permit proper finishing,
protecting and curing of the pavement.
602.9.4.4. En all cases, the temperature of the concrete shall be
measured at the point of discharge from the delivery vehicle.
602.9.4.5. The addition of water to the surface of the concrete to
facilitate the finishing operations will not be permitted except with the
approval of the Engineer when it shall be applied as a mist by means
of approved equipment.
602.9.4.6. If considered necessary by the Engineer, the paving
machines shall be provided with approved covers to protect the surface of
the slab under construction from direct sunlight and rain or hot wind.
602.9.4.7. While the concrete is still plastic, its surface shall be brush
textured in compliance with Clause 602.9.8 and the surface and edges
of the slab cured by the application of a sprayed liquid curing membrane
in compliance with Clause 602.9.9. After the surface texturing, but before
the curing compound is applied, the concrete slab shall be marked with
the chainage at every 100 m interval.
602.9.4.8. As soon as the side forms are removed, edges of the slabs
shall be corrected wherever irregularities have occurred by using fine
concrete composed of one part of cement to 3 parts of fine chips and
fine aggregate under the supervision of the Engineer.
602.9.4.9. If the requirement of Clause 902.4. for surface regularity
fails to be achieved on two consecutive working days, then normal
working shall cease until the cause of the excessive irregularity has been
identified and remedied.
602.9.5, Construction by fixed form paver
602.9.5.1. The fixed form paving train shall consist of separate
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Section 600
Concrete Pavement
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Concrete Pavement
Section 600
<<
237
Section 600
Concrete
Pavement
once for each days paving and wherever the Engineer considers it
necessary at times after construction as under:
Five individual measurements of the texture depth shall be taken
at least 2 m apart anywhere along a diagonal line across a lane width
between points 50 m apart along the pavement. No measurement shall
be taken within 300 mm of the longitudinal edges of a concrete slab
constructed in one pass.
602.9.8.4. Texture depths shall not be less than the minimum required when measurements are taken as given in Table 600-2 nor greater
than a maximum average of 1.25 mm.
TABLE 600.2. Texture Depth
Time of Test
Number of
Measurements
Required
Texture Depth (mm)
Specified
Tolerance
Value
An average of
5 measurements
1.00
025
An average of
5 measurements
1.00
0.25
-035
Concrete Pavement
Section 600
602.9.9.2. The curing compound shall not react chemically with the
concrete and the film or membrane shall not crack, peel or disintegrate
within three weeks after application. Immediately prior to use, the curing
compound shall be thoroughly agitated in its containers. The rate of
spread shall be in accordance with the manufacturers instructions checked
during the construction of the trial length and subsequently whenever
required by the Engineer. The mechanical sprayer shall incorporate an
efficient mechanical device for continuous agitation and mixing of the
compound during spraying.
602.9.9.3. In addition to spraying of curing compound, the fresh
concrete surface shall be protected for at least 3 hours by covering the
finished concrete pavement with tents as described in Clause 602.7.2,
during adverse weather conditions as directed by the Engineer. After
three hours, the pavement shall be covered by moist hessian and the same
shall then be kept damp for a minimum period of 14 days after which
time the hessian may be removed. The hessian shall be kept continuously
moist. All damaged/tom hessian shall be removed and replaced by new
hessian on a regular basis.
602.9.9.4. The Contractor shall be liable at his expense to replace
any concrete damaged as a result of incomplete curing or cracked on a
line other than that of a joint.
602.10. Trial Length
602.10.1. The trial length shall be constructed at least one month in
advance of the proposed start of concrete paving work. At least one
month prior to the construction of the trial length, the Contractor shall
submit for the Engineers approval a detailed method statement giving
description of the proposed materials, plant, equipment and construction
methods. All the major equipments like paving train, batching plant,
tippers etc., proposed in the construction are to be approved by the
Engineer before their procurement. No trials of new materials, plant,
equipment or construction methods, nor any development of them shall
be permitted either during the construction of trial length or in any
subsequent paving work, unless they form part of further, approved
trials. These trial lengths shall be constructed away from the carriageway but with at least a subbase layer below it.
602.10.2. The Contractor shall demonstrate the materials, plant,
equipment and methods of construction that are proposed for concrete
paving, by first constructing a trial length of slab, at least 60 m but not
more than 300 m long for mechanised construction and at least 30 m long
<<
239
Section 600
Concrete Pavement
for hand guided methods. If the first trial is unsatisfactory, the Contractor
shall have to demonstrate his capability to satisfactorily construct the
pavement in subsequent trials.
602.10.3 The trial length shall be constructed in two parts over a
period comprising at least part of two separate working days, with a
minimum of 30 m constructed each day for mechanised construction and
a minimum of 15 m on each day for hand guided construction. The trial
length shall be constructed at a similar rate (speed, around lm/hr) to that
which is proposed for the main work.
602.10.4. Transverse joints and longitudinal joints of each type that
are proposed for dowel-jointed unreinforced concrete slabs in the main
work shall be constructed and assessed in the trial length. If in the trial
length the construction of expansion joint and longitudinal joint is not
demonstrated, the first 2 expansion joints and at least the first 150 m
of longitudinal construction joint for mechanised paving in the main
work, shall be considered as the trial length for these joints.
602.10.5. The trial length shall comply with the Specification in all
respects, with the following additions and exceptions:
602.10.5.1. Surface levels and regularity
(i)
In checking for compliance with Clause 903.5 the levels shall be taken at intervals
at the locations specified in this Clause along any line or lines parallel to the
longitudinal centre line of the trial length.
(ii)
602.10.5.2. Joints
(iii) Alignment, of dowel bars shall be inspected as described in Clause 602.10.7 in any
two consecutive transverse joints. If the position or alignment of the dowel bars
at one of these joints does not comply with Clause 602.6.5, ii that joint remains
the only one that does not comply after the next 3 consecutive joints of the same
type have been inspected, then the method of placing dowels shall be deemed
to be satisfactory. In order to check sufficient joints for dowel bar alignment
without extending the trial length unduly, the Contractor may, by agreement with
the Engineer, construct joints at more frequent joint intervals than the normal
spacing required in the Contract.
(iv) If there are deficiencies in the first expansion joint that is constructed as a trial, the
next expansion joint shall be a trial joint. Should this also be deficient, further tziai
expansion joints shall be made as pars of the trial length which shall not form part
of the permanent works, unless agreed by the Engineer.
<<
240
Concrete Pavement
Section 600
602.10.53. Density
(v)
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Section 600
Concrete Pavement
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Concrete Pavement
Section 600
<<
243
Section 600
Concrete Pavement
longer than the safe heating period, as specified by the manufacturer. The
dispenser shall he cleaned out at the end of each day in accordance with
the manufacturers recommendations and reheated m4terial shall not be
used.
602.11.3.3. Cold applied sealants with chemical formulation like
polysulphide may be used. These shall be mixed and applied within the
time limit specified by the manufacturer. If primers are recommended
they shall be appLied neatly with an appropriate brush. The Movement
Accommodation Factor (MAF) shall be more than 10 per cent.
602.11.3.4. The sealants applied at contraction phase of the slabs
would result in bulging of the sealant over and above the slab. Therefore,
the Contractor in consultation with the Engineer, shall establish the right
temperature and time for applying the sealant. Thermometer shall be
hung on a pole in the site for facilitating control during the sealing
operation.
602.11.3.5. Sealant shall be applied, slightly to a lower level than
the slab with a tolerance of 5 2 mm.
602.11.3.6. During sealing operation, it shall be seen that no air
bubbles are introduced in the sealant either by vapours or by the
sealing process.
602.11.4. Testing of applied sea lants: Manufacturers certificate
shall be produced by the Contractor for establishing that the sealant is not
more than six months old and stating that the sealant complies with the
relevant standard as in Clause 602.2.8. The samples shall meet the
requirement of AASHTO M 282 for hot applied sealant or BS 5212: (Part2) for cold applied sealant.
602.12. Measurement of Texture Depth Sand Patch Method
602.12.!. The following apparatus shall be used:
-
(i)
(ii)
A nat wooden disc 64 mm diameter with a hard rubber disc, 1.5 mm thick, stuck
to one face, the reverae face being provided with a handle
(iii)
Dry natural sand with a rounded particle shape passing a 300 micmn 15 sieve and
nctained on a 150 micron 15 sieve.
<<
244
Concrete Pavement
Section 600
striking off the sand level with the top of the cylinder. The sand shall
be poured into a heap on the surface to be treated. The sand shall be
spread over the surface, working the disc with its face kept flat in a
circular motion so that the sand is spread into a circular patch with the
surface depressions filled with sand to the level of peaks.
602.12.3. The diameter of the patch shall be measured to the nearest
5 mm. The texture depth of concrete surface shall be calculated from
3l000/(DxD) mm where D is the diameter of the patch in mm.
602.13. Opening to Traffic
No vehicular traffic shall be allowed to run on the finished surface
of a concrete pavement within a period of 28 days of its construction
and until the joints are permanently sealed. The road may be opened to
regular traffic after completion of the curing period of 2~ days and after
scaling of joints is completed including the construction of shoulder,
with the written permission of the Engineer.
602.14. Tolerances for Surface Regularity, Level, Thickness
and Strength
The tolerances for surface regularity, level, thickness and strength
shall conform to the requirements given in Clause 903.5. Control of
quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.
602.15. Measurements for Payment
602.15.1. Cement Concrete pavement shall be measured as a finished work in square metres with specified thickness. The volume to be
paid for will be calculated on the basis of thickness and plans shown on
the project drawings and adjusted for the deficiency in thickness. No
additional payment shall be made for extra thickness of the slab. The full
payment will be made to this item after 28 days strength of the concrete
is found to be satisfactory.
The unit for measurement for concrete pavement shall be the cubic
metre of concrete placed, based on the net plan areas for the specified
thickness shown on the Drawings or directed by the Engineer. The rate
shall include all provisions of this Specification and shall include the
provision of all materials including polythene film, concrete, stock piling,
mixing, transport, placing, compacting, finishing, curing together with all
formwork, and including testing and submission of test certificates and
records. No deduction shall be made in measurement for openings
provided that the area of each is less than 0.5 sq. m. The unit rate
<<
245
Section &00
Concrete Pavement
as entered in the Bill of Quantities shall also include the full costs
of contraction, expansion, construction, and longitudinal joints, It shall
also incLude joint filler, keys, caulking rod, deboding strip, sealant
primer, joint sealant, dowel bar and tie rod.
602.15.2, Pavement thickness
All precautions and care shall he taken to construct pavement
having uniform thickness as called for on the plans.
Thickness of the cement concrete pavement shall be calculated on the
basis of level data of the cement concrete pavement and the underlying
sub-base taken on a grid of 5 m x 3.5 m or 6.25 m x 3.5 m, the former
measurement being in longitudinal direction.
A days work is considered as a ~lot for calculating the average
thickness of the slab. In calculating the average thickness, individual
measurements which are in excess of the specified thickness by more than
10 mm shall be considered as the specified thickness plus 10 mm.
Individual areas deficient by more than 25 mm shall be verified by
the Engineer by ordering core cutting and if in his opinion the deficient
areas warrant removal, they shall be removed and replaced with concrete
of the thickness shown on the plans.
When the average thickness for the lot is deficient by the extent
shown in Table 600.3, the Contract unit price will be adjusted as per this
TabLe,
TAIILE 600.3. PAYMENT ADJUSTMENT FOR DEFICIENCY IN THICKNFSS
Deficiency in the average
thickness of days work
Upto5mm
6.10mm
11-15mm
16.20mm
21-25mm
100
87
81
75
70
<<
246
Seaion 600
Concrete Pavement
602.16. Rate
The Contract unit rate for the construction of the cement concrete
shall be payment in fuLl for carrying out the operations required for
the different items of the work as per these Specifications including
full compensation for all labour, tools, plant, equipments, testing and
incidentals to complete the work as per Specifications, providing all
materials to be incorporated in the work including all royalties, fees,
storage, rents where necessary and all leads and lifts.
603. ROLLED CEMENT CONCRETE BASE
603.1. Scope
603.1.1. The work shall consist of construction of rolled concrete
base course for cement concrete pavement in accordance with the
requirements of these Specifications and in conformity with the lines,
grades and cross sections shown on the drawings or as directed by the
Engineer. The work shall incLude furnishing of all plant and equipment,
material and Labour and performing all operations in connection with
the work, as approved by the Engineer.
603.1.2. The design parameters of rolled cement concrete base course
viz,, width, thickness, grade of concrete, details of joints, if any, etc. shall
be as stipulated in the contract drawings.
603.2. Materials
603.2.1. Source of materials: The Contractor shall indicate to the
Engineer the source of all materials to be used in the lean concrete work
with relevant test data sufficiently in advance and the approval of the
Engineer for the same shall be obtained at least 60 days before the
scheduled commencement of the work. If the Contractor later proposes
to obtain the materials from a different source, he shall notify the
Engineer for his approval at least 60 days before such materials are to
be used.
t~03.2.2.Cement: Any of the following types of cement may be used
with prior approval of the Engineer.
(i)
IS
(ii)
IS
455
IS
1489
<<
247
Section 600
Concrete Pavement
mixed together
(ii)
37.5 mm
19.0 mm
9.5 mm
4.75 mm
600 micron
75 micron
<<
100
80.100
55-80
35-60
10-35
0-8
248
Section 600
Concrete Pavement
603.2.4. Water: Water used for mixing and curing of concrete shall
be clean and free from injurious amount of oil, salt, acid, vegetable
matter or other substances harmful to the finished concrete. It shall meet
the requirements stipulated in IS: 456.
603.2.5. Storage of materials: All materials shall be stored in
accordance with the provisions of Clause 1014 of these Specifications,
and other relevant IS Specifications. All efforts must be made to store
the materials in proper places so as to prevent their deterioration or
contamination by foreign matter and to ensure their satisfactory quality
and fitness for the work. The storage place must also permit easy
inspection, removal and storage of materials. All such materials even
though stored in approved godowns must be subjected to acceptance test
immediately prior to their use. The requirement of storage yard specified
in lause 602.2.9 shall be applicable.
603.3, Proportioning of Materials for the Mix
603.3.1. The mix shall be proportioned with a maximum aggregate:
cement ratio of 15.1. After the approval of all the materials to be used
in the concrete, the Contractor shall submit the mix design based on
weighed proportion of all ingredients for the approval of the Engineer.
The mix design shall be submitted at least 30 days prior to the paving
of trial length and design shall be done based on the laboratory trials
using approved materials and methods. The water content shall be
adjusted to the optimum as per Clause 603.3.2. for facilitating compaction by rolling. The target mean strength for the design mix as well as
acceptance Speciflcation of concrete shall be in accordance with Clause
903.5.2. The mix design shall be based on the flexural strength of
concrete.
603.3.2. Moisture content: The right amount of water for the rolled
concrete in the main work shall be decided for ensuring full compaction
under rolLing and shall be assessed at the time of rolling the trial length.
Too much water will cause the concrete to be picked up on the
wheels of the roller and too little will lead to inadequate compaction, a
low in-situ strength and an open textured surface. The optimum water
content shall be determined in accordance with Clause 603.7. and
demonstrated by rolling during trial length construction; and the optimum
moisture content and degree of compaction shall be got approved by
the Engineer. While laying, in the main work, the rolled concrete shall
have a moisture content between the optimum and optimum + 2 per cent,
<<
249
Concrete Pavement
Section 600
keeping in view the effectiveness of compaction achieved and to compensate for evaporation losses.
603.3.3. Cement content: The minimum cement content in the
rolled concrete shall not be less than 150 kg/cuff. of concrete. If this
mininium cement content is not suflicient to produce concrete of the
specified strength, it shall be increased as necessary without additional
compensation under the Contract.
603.3.4. Concrete strength: The flexural strength as specified shall
be the governing criteria for approval of the mix, While designing the mix
in the laboratory, correlation between flexura! and compressive strengths
of concrete shall be established on the basis of tests on samples for use
at a later date to verify the in situ flexural strength of rolled concrete
through testing of cores.
At least a batch of two beam and cube specimens, one each for 3 day
and 7 day strength testing shall be cast for every 100 cum or part thereof
of concrete placed during construction. On each days work not Less than
four beams and four cubes shall be made.
A ratio between the 3 and 7 day strengths shall be established for
the mix to be used. This will help in assessing the fall in strength,
if any in advance so that corrective action can be taken for the future
work.
603.4. Subgrade
The subgrade shall conform to the grades and cross sections shown
on the drawings and shall be uniformly compacted to the design strength
in accordance with these Specifications and the Specification stipulated
in the Contract. The rolled concrete base shall not be laid on a subgrade
softened by rain after its final preparation; any surface trenches, soft spots
etc., must be properly back-filled and compacted to avoid any weak or
soft spot. As far as possible, the construction traffic shall be avoided on
the prepared subgrade. A day before placing of the sub-base, the subgrade
surface shall be given a fine spray of water and rolled with one or two
passes of a smooth wheeled roller after a lapse of 2-3 hours in order to
stabilise the loose surface. If the Engineer feels it necessary, another
fine spray of water may be applied just before placing the base course.
603.5. Construction
Clause 601.5 shaLl apply.
<<
250
Concrete
Section 600
Pavement
<<
251
Section 600
Concrete Pavement
<<
252
Geosynthetics
700
Geosynthetics
<<
Geosynthetics
Section 700
701. GEOSYNTHETICS IN ROAD AND BRIDGE WORKS
701.1 Scope
This specification covers the various applications of Geosynthetic materials in road and bridge works including supplying and laying as per
special provisions.
Geosynthetic is a general classification for all synthetic materials
used in geotechnical engineering application. It includes geotextiles,
geogrids, geonets, geomembranes and geocomposites.
(1)
Geotextile : Any permeable textile natural or Synthetic, used with fotmdation, soil,
rock, earth, or any other geoteclasical engineering related material. In the present
chapter, ii is related to synthetic material only.
(ii)
(iii) Geonets : These are net made of polymeric material used for drainage of
foundation, soil, rock, earth or any other geotechnical engineering related material.
(iv) Geomembrane : An essentially impermeable membrane of polymeric material
used with foundation, soil, rock, earth or any other geotechnical engineering related
material, to control fluid migration.
(v)
<<
Section 700
Geosynthetics
256
<<
Geosynthetics
Section 700
Application Area
Geosynthetlcs
Involved
Functions for
Performance
GT,
GO,
GT
GC,
CIT
GT
GT,
KS
Note
S
R
F
D
B
~
I.
2.
3.
4.
5.
6.
7.
GT
GG
GC
ON
=
=
=
=
geotextile
geogrid
geocomposite
geonet
GO
GT
ON
GC
=
=
=
=
=
R
F, S
D, F, 5, B
F,S
B, It, S
B, R, 5
separation
reinforcement
filtration
drainage
barrier
<<
Sustain a load of not less than 10 kN/m at break and have a minimum failure strain
257
Section 700
Geosynthetics
of 10 per cent when determined in accordance with BS:6906 (Part 1) or shall have
a grab tensile strength more than 0.4 kN/m and grab elongation corresponding to
this limit in accordance with ASTM D 4632.
(b)
Soil with 50 per cent or less particles by weight passing IS sieve 75 microns,
apparent opening size less than 0.6 mm.
(ii) Soil more than 50 per cent particles by weight passing IS sieve 75 microns,
apparent opening size less than 0.927 mm.
The test should be as per TF 25 # 6
(c)
allow water to flow through it at right angles to its principal plane, in either
direction at a rate of not less than 10 litres/m2/sec. under a constant head of water
of 100 mm, determined in accordance with BS:6906 (Part 3) or ASTM D 4491 or
as stated in the design drawing. The flow rate determined in the test shall be
corrected to that applicable to a temperature of 15Cusing published data on
variation in viscosity of water with temperawre.
(d)
(e)
702.2.4. The composite drain shall have a flow rate through each face
of the drain of more than 75 per cent of the value specified in sub-Clause
702.2.3 (c), determined by direct measurement of the cOmposite drain
using BS:6906 (Part 3). The composite drain shall have values of longterm in-plane flow rates as stated in the design drawing.
702.3. InstaHation
702.3.1. The installation of fin drains shall be as per the design
drawings. Where fin drains are assembled on site, the assembly area shall
be clean and dry and free of any wind-borne pollutants. No geotextile or
core material shall be exposed to daylight (or any source of ultraviolet
radiation) for a period exceeding a cumulative total of 50 hours. Whei~e
fin drains are laid in trench, the bottom of the trench shall be free of
irregularities and shall be brought to the required level. Rock and other
hard protrusions shall be removed and any excess cut in the trench bottom
filled and compacted back to the required grade with suitable excavated
or imported material as directed by the Engineer. Fin drains shall be
capable of being jointed longitudinally or laterally into pipe~systeinsor
chambers for inflow and outflow purposes. Joints parallel to the direction
of flow and any exposed edged shall be protected from the ingress of soil
by a geotextile wrapping with a minimum overlap of 150 mm or other
measures as agreed by the Engineer.
702.4. Narrow filter drains consisting of a porous or perforated pipe
<<
258
Section 700
Gcosynthetics
<<
259
Section 700
Geosynthetics
<<
260
Section 700
Geosynthetics
<<
261
Section 700
Geosynthe tics
Vibratory roller having a weight per metre width of roll not exceeding 13(X) kg.
with total weight not exceeding 10,000 kg.
(ii)
<<
Geosynthetics
Section 700
transportation costs and storage of the same as per special provisions. The
rate shall also include cost of laying of the reinforcing elements including
all overlaps, jointing or stitching, heat bonding or extension.
Rate for facia fixing shall include cost of joints, all necessary
temporary formwork, scaffolding and all lifts and leads, if any, as shown
in the drawing, unless otherwise specified to the treated separately along
with foundation or slope/wall kerb at the top of slope or wall. Rate for bed
block and capping beam shall include all items of excavation, concrete,
reinforcing steel, formwork, labour and equipment.
Rate for soil fill shall include compaction as desired in requisite layers
through mechanical means, cost of hire or labour for plant operations,
dressing and levelling slopes, including special measures for edge
reinforcements as shown in the drawing.
704. GEOSYNTHETICS FOR HIGHWAY PAVEMENTS
704.1. Scope
This work shall consist of laying geosynthetic materials over existing
biuturninous surface, including preparation of surface and joining,
stitching or overlapping of geosynthetic fabric etc., as part of highway
pavement strengthening in layers as shown on drawings.
704.2. Paving Fabrics
704.2.1. Description : This work shall consist of furnishing and
placing as asphalt/bitumen overlay textile (paving fabric) beneath a
pavement overlay or between pavement layers to provide a water resistant
membrane and crack retarding layer.
704.3. Material Requirements
704.3.1. Paving rabric: The paving fabric will be a nonwoven heat
set material consisting of at least 85 per cent by weight polyolefins,
polyesters or polyarnides. The paving fabric shall be resistant to chemical
attack, rot and mildew and shall have no tears or defects which will
adversely alter its physical properties. The fabric shall be specifically
designed for pavement applications and be heat bonded only on one side
to reduce bleed-through of tack coat during installation. The fabric shall
meet the physical requirements of Table 704-2. Heavy duty paving fabrics
should be used in areas experiencing unusually high impact forces or
heavy loads such as airport runways and taxiways:
<<
263
Section 700
Geosynthetics
Table 704.2. PhysIcal Requirements.Pavlng Fabrics
Tensile Strength
36.3
ASTM D 4632
Elongation
50
ASTM D 4632
Asphalt Retention
10
Melting Point
150
ASTM D 276
Surface Texture
I-lest bonded on
one side only
Visual Inspection
Notes
1.
2.
All numerical values represent minimum average roll values (average of test
results from any sampled roll in a lot shall meet or exceed the minimum values) in
weaker principal direction, Lot shall be sampled according to ASTM D 4354,
Practice for Sampling of Geosynthetics for Testing.
3.
704.3.2. Tack Coat: The tack coat used to impregnate the fabric and
bond the fabric to the pavement shall be a paving grade Bitumen of 80100 penetration. A cationic or anionic emulsion may be used as approved
by the engineer. The use of cutbacks or emulsions which contain solvents
shall not be used.
704.4. Construction and Installation Requirements
704.4.1. Shipment and storage: The paving fabric shall be kept dry
and wrapped such that it is protected from the elements during shipping
and storage. At no time shall the paving fabric be exposed to ultraviolet
light for a period exceeding fourteen days. Paving fabric rolls shall be
stored in a manner which protects them from the elements. If stored
outdoors, they shall be elevated and protected with a waterproof cover~.
The paving fabric shall be labeled as per ASTM D 4873, Guide for
identification, storage, and handling of geotextiles.
704.4.2. Weather limitations: Minimum air and pavement temperature shall be at least 10Cand rising for placement of bitumen and shall
be at least 15C and rising for placement bitumen emulsion. Neither
bitumen tack coat nor paving fabric shall be placed when weather
conditions, in the opinion of the engineer, are not suitable.
<<
264
Section 700
Geosynthetics
<<
265
Section 700
Geosynthetics
<<
266
c;eosynthetics
Section 700
Colour
Mechanical
Properties
BLack
:
Stands/Fabric
Form
Life
7053. Construction
705,3.1. Assembly: Gabion and mattress boxes shall be assembled in
situ, on a level surface. After fabrication is done in situ they shall be
correctly filled in layers in dense packed state.
The bottom, sides and end panels shall be erected after removal of all
kinks, kept in an upright position to form rectangular boxes by joining the
sides with connectors of 40 mm x 6 mm size, or by ring staples. The top
corners shall be tie tensioned from sides to keep it erect for filling. For
gabions of 600 mm or more height, suitable cross internal ties shall be
placed in layers of 300 mm connecting opposite sides in lateral braces tied
with polymer braids of ultra-violet stabilised variety so as to ensure
protection against bulging of the gabions during filling with stones.
705.3.2. Construction and installation : The filling of the gabion/
mattress shalt be done by hand in layers so as to minimise viods and
achieve specified density. The stones in contact with the surface of the
geogrids/geonets shall be placed in such a way that their sharp edges are
kept turned inside so that they do not damage the material of the geogrids/
geonets. The opposite panels of the boxes shall be firmly secured with
lateral ties to withstand the design forces. The bottom of the gabion mesh
shall be secured in a key type excavation for preventing slide. The space
between the gabion and earthen sides shall be filled with sand and the
filling compacted, In most of the cases design shall be supplemented with
a Layer of geotextile under the gabion/mattress to prevent migration of
fines.
705.3.3. Laying boulder apron in crates : Mattresses of minimum
height 300 mm shalt be used. The typical size of a single continuous unit
shall be I m x 5 m size with baffles at 1 m centres. The size of boulders
shall be at least 100 mm or double the size of the aperture whichever is
<<
267
Section 700
Geosynthetics
larger. The density of boulder filling shall be as stated in the drawing and
the specific gravity of stones not less than 2.65. Methodology of laying
boulders shall be as peg Clause 2503.3. Gabions if placed in the apron
shall be of size 1 m x 5 m in plan with height at least 600 mm, with baffles
in 1 m centres.
Gabions or mattresses made with polymer geogrids/geonets shall
always be laid in situ and shall not be performed, filled and transported
to be dropped in deep waters. Where depth of water is low or dry bed is
available, the boxes shall be filled in situ. In streams or water body having
running boulders in the bed, the gsbions/mattresses shall be armoured with
placement of loose large boulders alongside the gabion wall to protect
against impact hit of stray boulders.
Stakes or keying shall always be provided in the founding recess,
where the gabion be located, especially in case the ground is assessed to
be sloping or yielding type.
705,3.4. Groynes or spurs with crates : Groynes or spurs of gravity
retaining variety shall be constructed using geogrid/geonet gabions placed
in a stable configuration one over the other to form a well. They shall be
filled in situ on a shallow depth of water or dry bed with firm founding
and level strata. The provision of a layer of geotextile/geocomposite shall
be made while placing the structure if resting over a bed of fine soil to
prevent passage of fines and sinking.
705.3.5. Measurements for payment : The fabric of geotextile/
geocomposite shall be measured in sq. metres,, of plan area of actual use
(as per drawing).
The connecting rods or polymer braids shall be measured in metres.
Ring staples shall be measured in number provided per linear metre.
The boulder fill shall be measured in cubic metres.
The excavation for keying of gabions in the ground trenches shall be
measured in cubic metres.
The backfilling in side trenches shall be deemed part of the
excavation work.
705.3.6. Rate : The cost of Geosynthetic material for fabrication of
(iabions(Mattresses shall be all inclusive of supply, transportation and
storage.
The contract rate per cubic metre of crate fill shall Consist of cost of
boulders and their transportation.
<<
268
Section 700
Geosynthetics
<<
ztt
800
Traffic Signs, Markings
and Other Road
Appurtenances
<<
Section 800
801.1. General
801.1.1. The colour, configuration, size and location of all traffic
signs for highways other than Expressways shall be in accordance with the
Code of Practice for Road Signs, IRC: 67 or as shown on the drawings.
For Expressways, the size of the signs, letters and their placement shall
be as specified in the Contract drawings and relevant Specifications. In
the absence of any details or for any missing details, the signs shall be
provided as directed by the Engineer,
801.1.2. The signs shall be either reflectorised or non-refiectorised as
shown on the drawings or as directed by the Engineer. When they are
of reflectorised type, they shall be of retro-reflectorised type and made
of encapsulated lens type reflective sheeting vide Clause 801.3, fixed
over aluminium sheeting as per these Specifications.
801.1.3. In general, cautionary and mandatory signs shall be fabricated through process of screen printing. In regard to informatory signs
with inscriptions, either the message could be printed over the reflective
sheeting, or cut letters of non-reflective black sheeting used for the
purpose which must be bonded well on the base sheeting as directed by
the Engineer.
801.2. Materials
The various materials and fabrication of the traffic signs shall
conform to the following requirements:
801.2.1, Concrete : Concrete shall be of the grade shown on the
Contract drawings or otherwise as directed by the Engineer.
801.2.2, Reinforcing steel : Reinforcing steel shall conform to
the requirement of IS:l786 unless otherwise shown on the drawing.
801.23. Bolts, nuts, washers: High strength bolts shall conform to
IS : 1367 whereas precision bolts, nuts, etc., shah conform to IS: 1364.
801.2.4. Plates and supports: Plates and support sections for the
sign posts shall conform to IS: 226 and IS: 2062 or any ot!~errelevant
IS Specifications.
80 1.2.5. Aluminium: Aluminium sheets used for sign boards shall
be of smooth, hard and corrosion resistant aluminium alloy conforming
to IS 736-Material designation 24345 or 1900.
<<
273
Section 800
<<
Observation
angle
(in degrees)
Entrance
Angle
(In degrees)
0.2
0.2
0.5
0.5
-4
30
-4
+30
White
Yellow
Orange
Green/
Red
250
150
95
65
274
170
100
62
45
100
60
30
25
45
25
15
10
Blue
20
11
7.5
5,0
Section 800
When totally wet, the sheeting shall not show less than 90 per cent
of the values of retro-reflectance indicated in Table 800.-I. At the end
of 7 years, the sheeting shall retain at least 75 per cent of its original
retro-reftectance.
801.3.3. Engineering grade sheeting: This sheeting shall be of
enclosed lens type consisting of microscOpic lens elements embedded
beneath the surface of a smooth, flexible, transparent, water-proof plastic,
resulting in a non-exposed lens optical reflecting system. The retroreflective surface after cleaning with soap and water and in dry condition
shall have the minimum coefficient of retro-reflection (determined in
accordance with ASTM Standard: E-810) as indicated in Table 800-2.
TABLE 800-2. ACCEPTABLE MINIMUM COEFFICIENT OF RETROREFLECTION FOR ENGINEERING GRADE SHEETING
(CANDELAS PER LUX PER SQUARE METRE)
Observation
angle In
degree
0.2
O~2
0.5
0.5
Entrance
angle In
degree
-4
+30
.4
30
White
Yellow
Orange
Green
Red
Blue
70
31)
30
15
50
22
25
13
25
7.0
13.5
9.0
14.5
4.0
3.5
4.5
2.2
6.0
7.5
3.0
1.7
2.0
0.8
4.0
When totally wet, the sheeting shall not show less than 90 per cent
of the values, of retro-reflection indicated in Table 800-2. At the end
of 5 years, the sheeting shall retain at least 50 per cent of its original
retro-reflectance.
801.3.4. Messages/borders: The messages (legends, letters, numerals
etc.) and borders shall either be screen-printed or of cut-outs. Screen
printing shall be processed and finished with materials and in a manner
specified by the sheeting manufacturer. Cut-outs shall be of materials as
specified by the sheeting manufacturer and shall be bonded with the
sheeting in the manner specified by the manufacturer.
801.3.S. For screen-printed transparent coloured areas on white sheeting, the co-efficient of retro-reflection shall not be less than 50 per cent
of the values of corresponding colour in Tables 800-I and 800-2, as
applicable.
801.3.6. Cut-out messages and borders, wherever used, shall be made
out of retro-reflective sheeting (as per Clause 801.3.2 or 801.3.3 as applicable), except those in black which shall be of non-reflective sheeting.
<<
275
Section 800
Red
Green
Orange
IS
Colour
IS
IS
Colour
Colour
801,3.10. Fabrication
801.3.10.1. Surface to be reflectorised shall be effectively prepared
to receive the retro-refleetive sheeting. The aluminium sheeting shall
be de-greased either by acid or hot alkaline etching and all scale/dust
removed to obtain a smooth plain surface before the application of retroreflective sheeting. If the surface is rough, approved surface primer may
be used. After cleaning, metal shall not be handled, except by suitable
de~ice or clean canvas gloves, between all cleaning and preparation
<<
~276
Traffic Signs
and Appurtenances
Section 800
<<
277
Section 800
(2)
(3)
(8)
<<
High
speed traffic
278
Section 800
of interchanges
<<
279
Section 800
<<
280
Section
800
<<
281
Section 800
<<
282
Traffic
Section 800
TABLE
Note :
(ii)
Component
White
Yellow
Binder
Glass Beads
Titanium Dioxide
Calcium Carbonate and
Inert Fillers
Yellow Pigments
18.0 mm.
30-40
10.0 miii.
1811 mm.
30-40
42.0 max.
See
Note
Amount of yellow pigment, calcium carbonate and inert fillers shall be at the
option of the manufacturer, provided all other requirements of this Specification
are met.
Propertles The properties of thermoplastic material, when tested in accordance
with ASTM D36iBS.3262.(Part I), shall be as below:
(a)
Luminance
White : Daylight luminance at 45 degrees-65 per cent miii, as per AASHTO
M 249
<<
283
Section 800
(b)
(c)
(d)
(e)
(f)
Flow resistance: Not more than 25 per cent as per AASIITO M 249.
(g)
Yellowness Index (for white thermoplastic paint): not more than 0.12 as
per AASHTO M 249
C as pet ASTM
D 36.
(iii) Storage life : The material shall meet the requirements of these Specifications for
a period of one year. The themsoplastic material must also melt uniformly with
no evidence of skins or unmelted particles for the one year storage period. Any
material not meeting the above requirements shall be replaced by the manufac~
turer/ supplier/Contraiior,
(Iv) Reflectorlsation : Shall be achieved by incorporation of beads, the grading and
other properties of the beads shall be as specified ~un
Clause 803.4.3.
(v)
The
2.
Batch number
be clearly and
3.
Date of manufacture
4.
<<
284
Appurtenances
Section 800
Oto3
5 to 20
-
65 to 95
-
0 to 10
-
Type 2
-
Oto5
5to20
-
30 to 75
10 to 30
0 to 15
Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter glass
dish. Place the dish in a 250mm inside diameter desiccator which is filled within
25 mm of the top of a desiccator plate with sulphuric acid water solution
specific gravity L10). Cover the desiccator and let it stand for 4 hours at 2Oto 29
degree C. Remove sample from desiccator, transfer beads to a pan and inspect
for lumps or clusters, Then pour beads into a clean, dry glass funnel having a 100
mm stem and 6 mm orifice. If necessary, initiate flow by lightly tapping the
funnel. The glass spheres shall be essentially free of lumps and clusters and shall
flow freely through the funnel.
(ii)
The requirements of gradation, roundness and refractive index of glass beads and
the amount of glass beads in the compound shall be tested as per BS 6088 and BS
3262 (Part I).
(iii) The Contractor shall furnish to the Employer a copy of certified test reports from
the manufacturer of glass beads obtained from a reputed laboratory showing
<<
285
Section 800
results of all tests specified herein and shall certify that the material meets
all requirements of this Specification. Flowever, if so required, these tests may
be carried out as directed by the Engineer.
(ii)
After transfer to the laying equipment, the material shall be maintained within
the temperature range specified by the manufacturer for achieving the desired
consistency for laying.
(b)
The marking shall not lift from the pavement in freezing weather.
(c)
After application and proper drying, the stripe shall show no appreciable
deformation or discolouration under traffic and under road temperatures upto
60~C.
(d)
The marking shall not deteriorate by contact with sodium chloride, calcium chloride
or oil drippings from traffic.
(e)
lhe stripe or marking shalt maintain its original dimensions and position, Cold
ductility of the material shall be such as to permit normal movement with the road
surface without chopping or cracking.
(I)
Ihe colour of yellow marking shall conform to IS Colour No. 356 as given in lS:
164.
<<
Section 800
803.6. Application
803.6.1. Marking shall be done by machine. For locations where
painting cannot be done by machine, approved manual methods shall be
used with prior approval of the Engineer. The Contractor shall maintain
control over traffic while painting operations are in progress so as to
cause minimum inconvenience to traffic compatible with protecting the
workmen.
803.6.2. The thermoplastic material shall be applied hot either
by screeding or extrusion process. After transfer to the laying apparatus,
the material shall be laid at a temperature within the range specified by
the manufacturer for the particular method of laying being used. The
paint shall he applied using a screed or extrusion machine.
803.6.3. The pavement temperature shall not be less than 10C
during application. All surfaces to be marked shall be thoroughly cleaned
of all dust, dirt, grease, oil and all other foreign matter before
application of the paint.
The material, when formed into traffic stripes, must be readily renewable by placing an overlay of new material directly over an old line of
compatible material. Such new material shall so bond itself to the old line
that no splitting or separation takes place.
Thermoplastic paint shall be applied in intermittent or continuous
lines of uniform thickness of at least 2.5 mm unless specified otherwise.
Where arrows or letters are to be provided, thermoplastic compound may
be hand~sprayed. In addition to the beads included in the material, a
further quatnity of glass beads of Type 2, conforming to the above
noted Specification shall be sprayed uniformly into a mono-layer on to
the hot paint line in quick succession of the paint spraying operation. The
glass beads shall be applied at the rate of 250 grams per square metre area.
803.6.4. The minimum thickness specified is exclusive of surface
applied glass beads, The method of thickness measurement shall be in
accordance with Appendices B and C of BS 3262 (Part 3).
803.6.5. The finished lines shall be free from ruggedness on sides and
ends and be parallel to the general alignment of the carriageway. The
upper surface of the lines shall be level, uniform and free from streaks.
-
<<
287
803.8. Rate
The Contract unit rate for road markings shall be payment in full
compensation for furnishing all labour, materials, tools, equipment,
including all incidental costs necessary for carrying out the work at the
site conforming to these Specifications complete as per the approved
drawing(s) or as directed by the Engineer and all other incidental costs
necessary to complete the work to these Specifications.
804. HECTOMETRE/KILOMETRE STONES
804.1. General
The work covers the supply, painting, lettering and fixing of distance
measurement stones and shall include:
(i)
Flectometre stones
(ii)
Kilometre stones
804.2. The dimengions of the stones and the size, colour, arrange~
ment of letters and script shall be as per IRC : 26 Type Designs for
200 Metre Stones and 1RC: 8 Type Designs for Highway Kilometre
Stones.
804.3. The hectometre/kilometre stones may be made of local
stones, concrete or any other material available locally and approved
by the Engineer. The stones shall be bedded into the ground with
adequate foundations as indicated in the drawings or in the relevant
I.R.C. Specifications or as directed by the Engineer. The orientation and
location of the stones shall be as indicated in the drawings or in the
relevant I .R.C. Specifications or as directed by the Engineer.
804.4. Measurements for Payment
The measurement will be in numbers of 200 metre, kilometre and
5th kilometre stones fixed at site.
804.5. Rate
The Contract unit rate for hectometre/kilometre/5th kilometre stones
shall be payment in full compensation for furnishing all labour, materials,
tools, equipment and making the stones, painting and lettering and fixing
at site and all other incidental costs necessary to complete the work to
these Specifications.
<<
288
Section 800
<<
289
Section 800
Traffic
807.2. The M.S. posts shall conform to IS :226 and shall be of angle
iron of size indicated in the drawings. The angle iron shall be embedded
in concrete to a sufficient depth below ground as indicated in the
drawings. The steel shall be fabricated and painted to conform to Section
1900 of these Specifications.
807.3.
to IS:278.
807.4,
the design
807.5.
<<
290
Section 800
<<
291
Section 800
<<
292
Section 800
the class, type, section and thickness indicated on the plans. Railing posts
shall be made of steel of the section, weight and length as shown on the
plans. All complete steel rail elements, terminal sections, posts, bolts,
nuts, hardware and other steel fittings shall be galvanised. All elements
of the railing shall be free from abrasions, rough or sharp edges and shall
not be kinked, twisted or bent.
810.2.2. Steel beam elements and terminal sections shall be
galvanised (zinc coated, O.55 kg per square metre, minimum single
spot) unless otherwise specified. The galvanising on all other steel parts
shall conform to the relevant IS Specifications. All fittings (bolts, nuts,
washers) shall conform to the IS 1367 and IS 1364. All galvanizing
shall be done after fabrication.
810.2.3. Concrete for bedding and anchor assembly shall conform to
Section 1700 of these Specifications.
810.3. Construction Operations
810.3.!. The line and grade of railing shall be true to that shown on
the plans. The railing shall be carefully adjusted prior to fixing in place,
to ensure proper matching at abutting joints and correct alignment and
camber throughout their length. Holes for field connections shall be drilled
with the railing in place in the structure at proper grade and alignment.
810.3,2. Unless otherwise specified on the drawing, railing steel
posts shall be given one shop coat of paint (primer) and three coats of
paint on structural steel after erection, if the sections are not galvanised.
Any part of assembly below ground shall be painted with three coats of
red lead paint.
810.3,3. Splices and end connections shall be of the type and
designs specified or shown on the plans and shall be of such strength as
to develop full design strength of the rail elements.
810,4. Installation of Posts
810.4.1. Holes shall be dug or drilled to the depth indicated on the
plans or posts may be driven by approved methods and equipment,
provided these are erected in proper position and are free trom distortion
and burring or any other damage.
810.4.2. All post holes that are dug or drilled shall be of such size
as will permit proper setting of the posts and allow sufficient room
for backfilling and tapping.
810.4.3. Holes shall be backfilled with selected earth or stable
293
<<
Section 800
materials in layers not exceeding 100 mm thickness and each layer shall
be thoroughly tamped and rammed. When backfihling and tamping are
completed, the posts or anchors~shall be held securely in place.
810.4,4. Post holes that are drilled in rock and holes for anchor
posts shall be backfilled with concrete.
810.4.5. Posts for metal beam guardrails on bridges shall be bolted to
the structure as detailed on the plans. The anchor bolts shall be set to
proper location and elevation with templates and carefully checked.
810.5. Erection
810.5.1. All guardrail anchors shall be set and attachments made
and placed as indicated on the plans or as directed by the Engineer.
810.5.2. All bolts or clips used for fastening the guardrail or fittings
to the posts shall be drawn up tightly. Each bolt shall have sufficient
length to extend atleast 6 mm through and beyond the full nut, except
where such extensions might interfere with or endanger traffic in which
case the bolts shall be cul off flush with the nut.
810.5.3. All railings shall be erected, drawn and adjusted so that
the longitudinal tension will be uniform throughout the entire length of
the rail.
810.6. Tolerance
The posts shall be vertical with a tolerance not exceeding 6 mm in
a length of 3 metre. The railing barrier shall be erected true to line and
grade.
810.?. Measurements for Payment
810.7.1. Metal beam railing barriers will be measured by linear
metre of completed length as per plans and accepted in place. Terminalsf
anchors of various types shall be paid for by numbers.
810.7.2. No measurement for payment shall be made for projections
or anchors beyond the end posts except as noted above, Furnishing and
placing anchor bolts and/or devices for guard rail posts on bridges
shall be considered incidental to the construction and the costs thereof
shall be included in the price for other items of construction.
810.7.3. No measurement for payment will be made for excavation
or backlilhing performed in connection with this construction.
810.8. Rate
The Contract unit rate shall include full compensation for furnishing
<<
294
Section 800
<<
295
Section
800
<<
296
900
Quality Control for
Road Works
<<
Section 900
901. GENERAL
901.1. All materials to be used, all methods adopted and all works
performed shall be strictly in accordance with the requirements of these
Specifications. The Contractor shall set up a field laboratory at locations
approvedby the Engineer and equip the same with adequate equipment and
personnel in order to carry out all required tests and Quality Control work
as per Specifications and/or as directed by the Engineer. The internal layout
of the laboratory shall be asper Clause 121 and/or asdirected by the Engineer.
The list of equipment and the facilities to be provided shall be got approved
from the Engineer in advance.
901.2. The Contractors laboratory should be manned by a qualified
Materials Engineer/Civil Engineer assisted by experienced technicians, and
the set-up should be got approved by the Engineer.
901.3. The Contractor shall carry out quality control tests on the
materials and work to the frequency stipulated in subsequent paragraphs.
In the absence of clear indications about method and or frequency of tests
for any item, the instructions of the Engineer shall be followed.
901.4. For satisfyinghimselfaboutthe quality ofthe materials and work,
quality control tests will also be conducted by the Engineer (by himself,by
his Quality Control Units or by any other agencies deemed fit by him),
generally to the frequency set forth herein under. Additional tests may also
be conducted where,in the opinion of the Engineer,need forsuch tests exists.
901.5. The Contractor shall provide necessary co-operation and
assistance in obtaining the samples for tests and carrying out the field tests
as requiredby the Engineer from time to time. This may include provision
of labour, attendants, assistance in packing and despatching and any other
assistance considered necessary in connection with the tests.
901.6. For the work of embankment, subgrade an&pavement, construction ofsubsequent layerofsame or othermaterial over thefinished layer shall
be done after obtaiiiing permission from the Engineer. Similar permission
from the Engineer shall be obtained in respect of all other items of works
prior to proceeding with the next stage of construction.
901.7. The Contractor shall carry out modifications in the procedure of
work, if found necessary, as directed by the Engineer during inspection,
Works falling short of quality shall be rectified/redone by the Contractor at
his own cost, and defective work shall also be removedfrom the site ofworks
by the Contractor at his own cost.
<<
299
Section 900
<<
Section 900
<<
301
Section 900
Subgrade
2.
Sub-base + 10mm
(a) Flexible pavement
(b) Concrete pavement
IDry lean concrete or Rolled concretel
3.
4.
Manually laid
5.
+20mm
-25 mm
Manually laid
20mm
6 mm
10mm
+
-
+6 mm
- 6mm
+ 10mm
.10mm
+ l5rnxn
- 15mm
+6mm
-6mm
+ 10mm
- 10mm
+5 mm
-6mm ~
~
<<
302
Section 900
permitted tolerance.
For checking the compliance with the above requirement for
bituminous wearing courses and concrete pavements, measurements of the
surface levels shall be taken on a grid of point~spaced at 6.25 m along the
length and at 0.5 m from the edges and atthe ceure of the pavement. In any
length of pavement, compliance shall be deemed to be met for the final road
surface, only if the tolerance given above is satisfied for any point on the
surface.
902.4. Surface Regularity of Pavemer Courses
The longitudinal profile shall be checked with a 3 metre long straight
edge/moving straight-edge as desired by the Engineer at the middle of each
traffic lane along a line parallel to the centre line of the road.
The maximum permitted number of surface irregularities shall be as per
Table 900-2.
TABLE 900.2. MAXIMUM PERMIITEI) NUMBER OF SURFACE
IRREGULARITIES
Surfaces of
carriageways
and paved
shoulders
1rre~isrity
4mm
7mm
4mm
7mm
300
75
300
75
300
75
300
75
Expressways
20
40
18
Roads of lower
category
40
18
60
27
Length(m)
National Highways/
<<
3 mm
6 mm
8 mm
10 mm
303
I -
Quality Control
Section 900
902.5. Rectification
Where the surface regularity of subgrade and the various pavement
courses fall outside the specified tolerances, the Contractor shall be liable
to rectify these in the manner described below and to the satisfacion of
the Engineer.
(I)
Subgradet Where the surface is high, it shall be trimmed and suitably compacted.
Wherethe same is low, the deficiency shall be corrected by scarifying the lower layer
and adding fresh material and recompacsing to the required densityThe degree of
compaction and the type of material to be used shall conform to the requirements
of Clause 305.
(ii)
Granular Sub-base: Same as at (i)above, except that the degree of compaction and
the type ofmaterial to be used shall conform to the requirements of Clause 401.
(iii) Lime/Cement Stabilized Soil Subbase: For lime/cement treated materials where
the surface is high, the same shall be suitably trimmed while taking care that the
material below is notdisturbed due to this operation. However, where the surface
is low, the same shall be corrected as described herein below.
For cement treated material when the time elapsed between detection of irregularity
and the time of mixing of the material is less than 2 hours, the surface shall be
scarified to a depth of 50 mm supplemented with freshly mixed materials as
necessary and recompacted to the relevant specification. When this time is more
than 2 hours, the full depth of the layer shall be removed from the pavement and
replaced with fresh material toSpecification This shall alan apply to lime treated
material except that the time criterion shall be 3 hours instead of 2 hours.
(lv) Water Bound Macadam/Wet MIx Macadam Sub.baseiBase: Where the surface
is high or low, the top 75 mm shall be scarified, reshaped with added material as
necessary and recompacted to Clause 404. This shall also apply to wet mix macadam
to Clause 406.
(v)
(vi) Dry Lean Concrete Sub.base/Rolled Cement Concrete: The defective length of
the course shall be removed to full depth and replaced with material conforming to
Clauses 601 or 603, as applicable. the area treated shall be at least 3m long, not less
than I lane wide and extend tothe full depth. Beforerelaying the course, the disturbed
subgrade or layer below shall be corrected by levelling, watering and compacting.
(vll) Cement concrete pavement: The defective areas having surface irregularity
exceeding 3 mm but not greater than 6 mm may be. rectified by bump cutting or
scrabbling or grinding using approved equipment. When required by the Engineer
areas which have been reduced in level by the above operation(s) shall be retextured
<<
304
Section 900
<<
(c)
Density Test [IS:2720 (Part S)l: Each soil type to be tested, 2 tests per 3000 cubic
metres of soil.
(d)
305
required by the
Section 900
Works
(e)
Moisture Content Test (IS :2720 (Pa*2)l: One test for every 250 cubic metres of
soil.
(I)
[11.65
[
1.65
(No. of samples)~j
However, for earthwork in shoulders (earthen) and in the subgrade,
at leastone density measuz~ementshall be taken for every 500 square metres
for the compacted area provided further that the number oftests in each set
ofmeasurements shall be atleast 10. In other respects, the control shall be
similar to that described earlier.
903.2,3. Cut formation : Tests for the density requirements of cut
formation shall be carried out in accordance with Clause 903.2.2.
903.3. Tests on Sub-bases and Bases (excluding bitumen bound
bases)
The tests and their frequencies for the different types ofbases and subbases shall be as given in Table900-3. The evaluation of density results and
acceptance criteria for compaction control shall be on lines similar to those
set out in Clause 903.2.2.
903.3.1. Acceptance criteria: The acceptance criteriafor tests on the
strength of cement/lime stabilised soil and distribution of stabiliser content
shall be subject to the condition that the mean value is not less than the
<<
306
Section 900
TABLE 900.3. CONTROL TESTS AM) THEIR MINIMUM FREQUENCY FOR SUB.
BASES AND BASES (EXCLUDING BITUMEN BOUND BASES)
SI. Type of
No. Construction
I
Granular
Test
(i)
(ii)
(iii)
(iv)
(v)
(vi)
2.
Lime/Cement
Stabilised
Soil Sub-base
As required
As required
One test for each
consignment subject
to a minimum of one test
per 5 sonnes
(ii)
Lime/Cement
content
Regularly, through
procedural checks
(iii)
Degree of
puiverisation
Periodically as
considered necessarj
(iv)
CBR or Unconfined
Compressive Strength
testona setof3
specimens
As required
(v)
Aggregate Impact
Value
Grading
Flakiness Index
and Elongation
Index
Atterberg limits
of binding material
(i)
(ii)
(iii)
(iv)
<<
Quality of Iime/
cement
(vii)
Water Bound
Macadam
3
One test per 200 m
One test per 200 m
One test per 250m2
(i)
(vi)
3.
Gradation
Atterberg limits
Moisture content
prior to compaction
Density of
compacted layer
Deleterious
constituents
C.B.R.
Frequency (mm.)
307
Section 900
SI. Type of
No. Construction
Test
Frequency (miss.)
Auerberglimitsof
portion of aggregate
passing 425 micron
sieve
Onelesiper
100 cubic metre
of aggregate
(1)
Aggregate impact
Value
(ii)
Grading
(iii)
Flakiness and
Elongation Index
Atterberg limits of
portion of aggregate
passing 425 micron
sieve
Dthsity of compacted
layer,
(v)
4.
(iv)
(v)
r1.65
--
1.65
times the standard deviation.
(No. of samples)~j
TABLE 900-4.
S.
Type of Construction
No.
I.
Test
Frequency (minimum)
<<
Seal Coat/Surface
Dressing
308
Section 900
Test
Frequency (Minimum)
(v) Watcrabsorptionof
aggregates
(vi) Grading of aggregates
(vii) Stone polishing value
(viii) Temperatureof
binder as application
(jx) Rate of spread of
materials
3.
Open-graded Premix
Carpet/Mix-Seal
Surfacing
Bituminous Macadam
<<
309
Section 900
S. Type of Construction
No.
Frespsency (Minimum)
5.
Bituminous
Penetration Macadarn/
Built-up Spray-Grout
Dense Bituminous
Macadam/Semi Dense
Bituminous Concrete!
Bituminous Concrete
<<
310
3 of
Section 900
S. Type of Construction
No,
Test
Frequency (Minimum)
aggregates
(vi) Sand equivalent test
(vii) Stone Polishing Value
<<
311
do-
As in Serial No.2
As in Serial No. 2
As required
As required, for Semi Dense
Bituminous Concrete/Bituminous Concrete
One set of tests on individual constituents and mixed
aggregate from the dryer for
each 400 tonnes of mix
subject to a minimum of
two tests per plant per day
For each 400 tonnes ofmix
peoduced,asetof 3 Marshall
specimens to be prepared
andtessed forstability, flow
value, density and void
content subject to a minimum oftwo sets beingtested
per plant per day
As required for Bituminous
Concrete
do.
At regular close intervals
-
Quality Control
Section 900
<<
312
Road Works
Section 900
<<
313
Section 900
Quality
Control
the area from which the cores were cut should be replaced,i.e., atleast over
an area extending between two transverse joints where the defects could be
isolated or over larger areas, if necessary, as assessed by additional cores
and their test results. The equivalent flexural strength at 28 days shall be
estimated in accordance with Clause 602.3.3.2,
In order to ensure that the specified minimum strength at 28 days is
attained in 99 per cent of all test beams, the mix shall be proportioned
to give an average strength at28 days exceeding the specified strength by
2.33 times the standard deviation calculated first from the flexural strengths
of test beams made from the trial mix and subsequently from the accumulating result of flexural strengths of job control test beams.
The standard deviation shall be re-calculated from the test results
obtained after any change in the source or quality of materials and the
mix shall be adjusted as necessary to comply with the requirements.
An individual 28 day test strength below thespecified strength shall not
be evidence for condemnation of the concrete concerned ifthe average 28
day strength of this beam plus the preceding 5 and succeeding 4 beams
exceeds the specified strength by 2.33 times the standard deviation and
provided that there is no other evidence that the concrete mix concerned is
substandard.
Beams shalibemade each dayin pairs at intervals, each pairbeing from
a different batch of concrete. At the start of the work, and until such time
as the Engineer may order a reduction in the number of beams required, at
least six pairs of beams and cubes shall be made each day, one of each pair
for testing at 28 days for determination of ifle minimum permissible
flexural strength and the other for testing at an early age for the Engineer
to assess the quality ofthe mix. When the firstthirty numberof28-day results
are available, and for so long as the Engineer is satisfied with the quality
of the mix, he may reduce the number of beams and cubes required.
During the course ~f construction, when the source of any material
is to be changed, or if there is any variation in the quality of the materials
furnished,additional tests and necessary adjustments in the mix shall be made
as required to obtaIn the specified strength.
The flexural strengths obtained on beams testedbefore28 days shall be
used in conjunction with a correlation between them and th~28 day flexural
strengths to detect any deterioration in the quality of the concrete being
produced. Any such deterioration shall be remedied without awaiting the
28 day strengths but the earlier strengths shailnot constitute sole evidence
<<
314
Section 900
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
<<
8
77.5
41.0
85.0
60.0
87.5
71.0
81.5
90.0
92.0
94.0
101.0
96.0
97.5
98.5
100.0
102.0
107.0
103.5
1043
1093
105.5
110.0
113.0
106.5
110.5
114.0
116.5
119.0
121,0
123.5
125.0
126.0
127.5
129.0
130.5
131.5
1323
1333
135.0
135.5
108.0
112.0
115.0
1173
1193
122.0
123.5
111.0
1143
117,0
1193
121.5
1233
125.0
1263
1253
1125
115.5
118.0
120.0
122.0
124.0
1253
127.0
127.0
128.0
128.5
1283
1293
1303
1313
132$
134.0
135.0
1353
1293
131.0
132.0
133.0
134.0
135.0
136.0
130.0
131.0
132.0
133.0
1343
135.5
136.0
315
116.0
118.5
120.5
122.5
124.5
126.0
1273
129.0
130.0
131.5
132.5
1333
134.5
135,5
136.5
I-a-a----.
Section 900
210
220
230
240
250
260
270
280
290
3(X)
310
320
330
340
350
360
136.5
137.0
138.0
139.0
139.5
140.5
141.0
142.0
142.5
143.0
143.5
144.0
144.5
145.0
146.0
146.0
136.5
1373
138$
139.0
140.0
1403
141.0
142.0
142.5
143.0
1433
144.5
145.0
1453
146.0
146.0
137.0
137.5
138.5
139.0
140.0
140.5
141.5
142.0
142.5
143.0
144.0
144.5
145.0
145.5
146.0
146.5
137.0
1373
138.5
139.5
140.0
140.5
141$
142.0
142.5
!43.0
144.0
144.5
145.0
145.5
146.0
146.5
137.0
138.0
138.5
139.5
140.0
141.0
141.5
142.0
142.5
143.5
144.0
144.5
145.0
145.5
146.0
146.5
<<
Section 900
Clause 902.3
(ii)
Clause 902.2.
(v)
Level tolerance
Widthof pavement and position of
paving edges
(iii) Pavement thickness
(iv) Alignment ofjoints, widths,
depths of dowel grooves
Surface regularity both
transversely and longitudinally
2.
Cement
2.
Coarse and
Fine
aggregates
(i) Gradation
IS: 2386
(Pt 1)
(ii) Deleterious
IS: 2386
(Pt. 2)
constituents
<<
IS: 269
IS: 455
IS : 1489
IS : 8112
IS : 12269
317
Manufactwer.
One zest for every days
work of each fraction of
coarse aggregate and fine
aggregate. initially; may be
relaxed later at the discretion of the engineer.
-do-
Section
900
3.
Coarse
Aggregate
4.
Water
5.
Concrete
IS:2386
(Pt. 3)
IS:2 386
(Pt.4)
lS:2386
(Pt5)
Regularly as required
subjectto a minimum of one
zest a day for coarse aggre.
gale & two tests a day for
frne aggregate. This data
shall be used for correcting
the waterdemand ofthe mix
on daily basis.
Once foreach source of
supply and subsequently
on monthly basis.
Before approving the
aggregates and every month
subsequently
IS:2386
(Pt.7)
lS:456
-do-
(i) Strength of
concrete
lS:516
IS:5l6
IS:1199
form paving
<<
318
Section 900
(ii)
Density
in. or
3 density holes for each 2000 sq.m. or past thereof laid each day.
(iii) Cores : Only when Engineer instructs. They shall not be cut on regular basis.
<<
319
1000
Materials for Structures
<<
Section 1000
100L GENERAL
Materials to be used in the work shall conform to the
specifications mentioned on the drawings, the requirements laid down
in this section and specifications for relevant items of work covered
under these specifications.
If any material, not covered in these specifications, is required to
be used in the work, it shall conform to relevant Indian Standards,
if there are any, or to the requirements specified by the Engineer.
1002. SOURCES OF MATERIAL
The Contractor shall notify the~Engineer of his proposed sources
of materials prior to delivery. If it is found after trial that sources
of supply previously approved do not produce uniform and satisfactory
products, or if the product from any other source proves unacceptable
at any time, the Contractor shall furnish acceptable material from other
sources at his own expense.
1003. BRICKS
Burnt clay bricks shall conform to the requirements of IS:l077,
except that the minimum compressive strength when tested flat shall
not be less than 8.4 MPa for individual bricks and 10.5 MPa for average
of 5 specimens. They shall be free from. cracks and flaws and nodules
of free lime. The brick shall have smooth rectangular faces with
sharp corners and emit a clear ringing sound when struck. The size
may be according to local practice with a tolerance of ~ per cent.
1004. STONES
Stones shall be of the type specified. It shall be hard, sound, free
from cracks, decay and weathering and shall be freshly quarried
from an approved quarry. Stone with round surface shall not be used.
The stones, when immersed in water for 24 hours, shall not absorb
water by more than 5 per cent of their dry weight when tested
in accordance with IS:1 124.
The length of stones shall not exceed 3 times its height nor
shall they be less than twice its height plus one joint. No Stone shall
be less in width than the height and width on the base shall not
be greater. than three-fourth of the thickness of the wall nor less than
150 mm.
323
<<
Section 1000
b)
c)
d)
e)
<<
324
Section 1000
12.5mm
63mm
40mm
20 mm
12.5mm
100
95-100
30.70
10 mm
10-35
0-5
25.55
0-10
4.75mm
<<
20mm
100
95.100
325
100
90-100
40.85
0-10
Section 1000
1008.
SANDIFINE AGGREGATES
Zone II
100
90-100
60-95
30.70
100
90-100
75-100
55-90
15-34
35.59
5-20
0-10
8-30
0-10
Zone Ill
100
90-100
85-100
75-100
60.79
12.40
0-10
1009. STEEL
1009.1. Cast Steel
The use of cast steel shall be limited to bearings and other similar
parts. Steel for castings shall conform to Grade 280-520N of IS: 1030.
In case where subsequent welding is unavoidable in the relevant cast
steel components, the letter N at the end of the grade designation of
the steel casting shall be replaced by letter W. 0.3 per cent to 0.5 per
cent copper may be added to increase the corrosion resistance properties.
<<
326
Section 1000
Plain hard drawn seel wire conforming to IS:1785 (Part I) and 1S~1785(Part II).
(b)
(c)
(d)
Grade
Designation
Elastic
Modulus GPa
Specification
S 240
lS:432 Part 1
Mild Steel Bar
240
200
S 415
415
200
Strength Deformed
Bars (HYSD)
Other grades of bars conforming to IS:432 and IS: 1786 shall not
he permitted.
All steel shall be procured from original producers, no re-rolled steel
shall be incorporated in the worL
Only new steel shall be delivered to the site. Every bar shall be
inspected before assembling on the work and defective, brittle or burnt
bar Shall be discarded. Cracked ends of bars shall be discarded.
Fusion-bonded epoxy coated reinforcing bars shall meet the requirements of IS: 13620. Additional requirements for the use of such reinforcement bars have been given below
(a) Patch up materials shall be procured in sealed containers with certi(icates from
the agency who has supplied the fusion bonded epoxy bars.
<<
327
Section 1000
(e)
(I)
While bending the bars, the pins of work benches shall be provided with PVC
or plastic sleeves.
(g)
The coated steel shall not be directly exposed to sun rays or rains and shall
be protected with opaque polyethelene sheets or such other approved materials
(Ii)
While concreting, the woTkmen or trolleys shall not directly move on coated bars
but can move on wooden planks placed on the bars.
370 MPa
147000 Mls
230 Mls
370 Mls
1370 Mls
<<
IS:2062
IS:8500
328
Section 1000
IS
1148
IS:1 149
(0110
IS: 1161
IS:4923
lS:1 1587 :
IS:808
IS:1239
IS:1730
Dimension for Steel Plate, sheet and strip for structural and general
engineering purposes
IS: 1731
IS: 1732
IS:1852
products
The use of structural steel not covered by the above standards may
be permitted with the specific approval of the authority. Refer to Section
1900 for further details.
1009.7. Stalnless Steel
Stainless steel shall be austenitic chromium-nickel steel, possessing
rust, acid and heat resistant properties conforming to IS:6603 and IS:6911.
Mechanical properties/grade for such stainless steel shall be as specified
by the accepting authority, but in no case be inferior to mild steel.
Generally, stainless steel is available as per AISI grades. AISI 304 which
is equivalent to grade O4Crl8Ni 110 of IS:6911 satisfies the requirements
of mechanical properties of structural steel. Other grades of stainless steel
for specific purposes may be provided as per specific requirements. For
application in adverse/ corrosive environment, stainless steel shall
conform to AISI 316L or 02G17 Ni Mo2 of IS:6911.
1010. WATER
Water used for mixing and curing shall be clean and free from
injurious amounts of oils, acids, alkalis, salts, sugar, organic materials
or other substances that may be deleterious to concrete or steel. Potable
water is generally considered satisfactory for mixing concrete. Mixing
and curing with sea water shall not be permitted. As a guide, the following
concentrations represent the maximum permissible values
<<
(a)
(b)
329
-.--;-
Section 1000
(c)
The permissible limits for solids shall be as follows when tested in accordance
with lS:3025
Permissible Limits (max)
Organic
Inorganic
Sulphatcs (SO
200 mg/lit
3000 mg/lit
4)
Chlorides (Cl)
Suspended matter
500 mg/lit
500 mg/lit *
2000 mg/lit
~ In case of structures of lengths 30m and below, the permissible limit of chlorides
may be increased upto 1000 mg/lit.
All samples of water (including potable water) shall be tested and suitable measures
taken where necessary to ensure conformity of the water so the requirements stated
berein.
(d)
1011. TIMBER
The timber used for structural purposes shall conform to IS:883,
1012. CONCRETE ADMIXTURES
1012.1. General
Admixtures are materials added to the concrete before or during
mixing with a view to modify one or more of the properties of concrete
in the plastic or hardened state.
Concrete admixtures are proprietary items of manufacture and shall
bc obtained only from established manufacturers with proven track record,
qttality assurance and full fledged laboratory facilities for the manufacture
and testing of concrete.
The contractor shall provide the following information concerning
each admixture after obtaining the same from the manufacturer
(a)
Norsnal dosage and detrimental effects, if any, of under dosage and over dosage.
(b)
(c)
(d)
Values of dry material content, ash content and relative density of the admixture
which can be used for Uniformity Tests.
(e)
Whether or not the admixture leads to the entertainment of air when used as per
the manufacturers recommended dosage, and if so to what extent.
(Q
Where two or more admixturea are proposed to be used in any one mix,
confirmation as to their compatibility.
(g)
<<
330
Section 1000
(h)
Except where resistance to freezing and thawing and to disru11ive action of de.
icing salts is necessary, the air content of freshly mixed concrete in accordance
with the pressure method given in lS:1199 shall not be more than 2 per cent
higher than that of the corresponding control mix and in any case not more than
3 per cent of the test mix.
(c)
The chloride content of the admixture shall not exceed 0.2 per cent when tested
in accordance with IS:6925. In addition, the maximum permissible limit of chloride
content of all the constituents as indicated in Section 1700 shall also be observed
(d)
Uniformity tests on the admixtures are essential to compare qualitatively the composition of different samples taken from batch to batch or from the same batch
at different times.
The tests that shall be performed along with permissible variations in the same
are indicated below
-
Dry Material Content to be within 3 per cent and 5 per cent of liquid and
solid admixtures respectively of the value stated by the manufacturer
Ash content
turer.
<<
Section 1000
Section 1000
Tendon: Wire, strand and bar from which tendons are to be fabricated shall be
stored about 300mm above the ground in a suitably covered and closed space
so as to avoid direct climatic influences and to protect them from splashes from
any other materials and from the cutting operation of an oxy-acetylene torch or
arc welding process in the vicinity. Under no circumstances, tendon material shall
be subjected td any welding operation or on site heat treatment or metallic coating
such as galvanising. Storage facilities and the procedures for transporting material
into or out of store, shall be such that the material does not become kinked or
notched. Wire or strand shall be stored in large diameter coils which enable the
tendons to be laid out straight. As a guide, foe wires above 5mm dia, coils of
about 2sn dia without breaks or joints shall be obtained from manufacturer and
stored. Protective wrapping for tendons shall be chemically neutral, All prestressing
steel must be provided with temporary protection during storage.
(5)
<<
333
Section 1000
<<
334
Section 1000
<<
335
Pile Foundations
1100
Pile Foundations
<<
Pile Foundations
Section 1100
1101. DESCRIPTION
1.5 times estimated length of pile in soil but not less than 15 m beyond the probable
length of pile
ii)
iii)
4 times diameter of pile in sound, hard rock but min[mum 3 m in such rock
1102.2. The sub-surface investigation shall define adequately stratification of sub-strata including the nature and type of strata, its variation
and extent and specific properties of the same. The investigation shall
be adequate for the purpose of selection of appropriate piling system
and for estimating design capacities for different diameters and length
of piles.
339
<<
Pile Foundations
Section 1100
1102.3. Pressure meter tests may be used in the case of rock, gravel
or soil for direct evaluation of strength and compressibility characteristics. Though these tests are of specialised nature they are most
appropriate for difficult/uncertain sub-strata especially for important
projects,
1102.4. For piles socketed into rocks, it is necessary to determine
the uniaxial compressive strength of the rock and its quality.
The investigation shall also include location of ground water table
and other parameters including results of chemical tests showing sulphate
and chloride content and any other deleterious chemical content in soil
and/or ground water, likely to affect durability.
1103. TYPE OF PILES
The piles may be of reinforced concrete, prestressed concrete,
steel or timber. The piles may be of solid or hollow sections or steel
cased piles filled with concrete. Concrete piles may be driven castin-situ or precast or bored cast-in-situ or precast piles. driven into
preformed bores. The shape of piles may be circular, square, hexagonal,
octagonal, H or I Section.
1104. MATERIALS
1104.1. The basic materials shall conform to the specifications for
materials given in Section 1000. The specifications for steel reinforcement, structural concrete, prestressed concrete and structural steel
to be used in pile foundations shall be as given in the relevant sections.
1104.2. Concrete in Piles
Grade of concrete to be used in cast-in-situ piles shall not be less
than M 20 and the cement content shall not be less than 400 kg per
cubic meter of concrete. Grades of concrete for precast reinforced and
prestressed concrete piles shall not be less than M 25 and M 35
respectively. Maximum water cement ratio shall be 0.5 for cast-in-situ
piles and 0.45 for precast piles.
The minimum slump of concrete for driven cast-in-situ piles shall
be 1,00 mm to 150 mm and that of bored cast-in-situ piles 150 mm
to 200 mm. The slump should not exceed 200 mm in any case.
Concrete mix should have homogeneous mixture with required
workability for the system of piling adopted. Suitable and approved
admixtures may be used in concrete mix where necessary.
<<
340
Pile Foundations
Section 1100
<<
Pile Foundations
Section 1100
Strike side.
shutters
(hours)
End of
wet curing
(days)
Lift from
castIng
bed (days)
Ordinary Portland
24
10
12
Drive
(days)
.
28
10
<<
342
Pile Foundations
Section 1100
150 mm. Not more than one extension shall be permitted. In case
more than one extension is permitted by the Engineer, only approved
mechanical couplers shall be used.
Driving shall not be resumed until
(i)
The strength of the concrete in the extension is at least equal to the specified
characteristic strength of concrete in pile, and
(ii)
<<
343
Section
Pile
1100
Foundations
<<
344
Pile Foundations
Section
1100
<<
345
Section 1100
Pile Foundations
<<
(c)
The tremie pipe wilt have to be large enough with due regard to the size of
aggregate. For 20 mm aggregate the tremie pipe should be of diameter not less
than 150 mm and for larger aggregate, larger diameter tremie pipes may be
necessary.
(11)
The first charge of concrete should be placed with a sliding plug pushed down
the tube ahead of it to prevent mixing of water and concrete.
(e)
The tremie pipe should always penetrate well into the concrete with an adequate
margin of safety against accidental withdrawal if the pipe is surged to discharge
the concrete.
(f)
The pile should be concreted wholly by tremie and the method of depoaitinn should
not be changed part way up the pile to prevent the taitance from being entrapped
within the pile.
(g)
All
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347
Pile Foundations
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348
Section 1100
Pile Foundations
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349
Pile Foundations
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350
Pile Foundations
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351
Section 1100
Pile Foundations
specified set (or less) is obtained when the toe of the pile is at
founding level. Preboring shall be as approved by the Engineer and
shall not extend below one metre above the founding level and the
pile shall be driven to at least one metre below the prebored hole. To
ensure that the pile is properly supported laterally in the hole, any
space remaining around the pile at the ground level after driving is
finished shall be backfilled with approved granular material.
When water jetting is used, at least two jets shall be attached to
the pile symmetrically when this type of technique is used. The volume
and pressure of water at the outlet nozzles shall be sufficient to freely
erode material adjacent to the toe of the pile. The maximum depth
of jetting shall be such that the specified set (or less) is obtained
when the toe of the pile is at founding level. Jetting shall cease as
directed by the Engineer and shall not proceed below one metre above
the founding level and the pile shall be driven at least one metre below
the pre..bored hole.
To avoid very hard driving and vibration in materials such as
sand, jetting of piles by means of water may be carried out only by
express permission of the Engineer and in such a manneras hot to impair
the bearing capacity of piles already in place, the stability of the
soil or the safety of any adjoining buildings. Details of the arrangement
for jetting shall be got approved from the Engineer in advance.
If, for jetting, large quantities of water are used, it may be necessary
to make provision for collection of water when it comes to the ground
surface, so that the stability of the piling plant is not endangered by
the softening of the ground.
Jetting shall be stopped before completing the driving which
shall always be finished by ordinary methods. Jetting shall be stopped
if there is any tendency for the pile tips to be drawn towards the
pile already driven owing to the disturbance to the ground.
1112. RAKER (INCLINED) PILES
The maximum rake to be permitted in piles shall not exceed the
following
<<
I)
I m S for large diameter cast-in-situ piles viz 0.75 m diameter and above
ii)
iii)
352
Pile Foundations
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1100
<<
353
Section 1100
Pile
Foundations
stripped of concrete and the reinforcement anchored into the cap. Manual
chipping may be permitted after three days of pile casting, while
pneumatic tools for chipping shall not be used before seven days
after pile casting. The top of pile alter stripping shall project at least
150 mm into the pile cap. A layer of surface reinforcement may be
provided with a cover of 25 mm to retain the integrity of concrete below
the main cap reinforcement which is to be laid 25 mm above the pile
top.
Concreting of the pile cap shall be carried out in dry conditions.
The bottom of the pile cap shall be laid preferably as low as possible
taking account of the water level prevalent at the time of casting.
The top of concrete in a pile shall be brought above cut-off
level to permit removal of all laitance and weak concrete before pile
cap is laid. This will ensure good concrete at the cut-off level.
1115. IMPORTANT CONSIDERATIONS, INSPECTION/
PRECAUTIONS FOR DIFFERENT TYPES OF PILES
1115.1. Driven Cast-in-Situ Piles
1115.1.1, Specialist literature and the guidelines from the pile
construction industry shall be consulted regarding the method of installation, equipment and accessories for pile driving and recording
of data.
1115.1.2. During installation of piles the final set of penetration
of pile per blow of hammer shall be checked taking an average of
last 10 blows.
1115.1.3. The pile shoes which may be of either cast iron conical
type or mild steel flat type shall have double reams for proper seating
of the removable casing tube inside the space between the reams.
1115.1.4. Before commencement of pouring of concrete, it shall be
ensured that there is no ingress of water in the casing tube from
the bottom. Further adequate control during withdrawal of the casing
tube is essential so as to maintain sufficient head of concrete inside
the casing tube at all stages of withdrawal.
1115.1.5. Concrete in piles shall be cast upto a minimum height
of 600 mm above the designed ~toplevel of pile, which shall be stripped
off at the time of construction of pile cap.
<<
354
Section 1100
Pile Foundations
v)
The liquid limit of bentonite not less than 400 per cent
These aspects shall act as controlling factors for preventing contamination of bentonite slurry for clay and silt.
1115.2.4. The bores shall be washed by bentonite flushing to ensure
clean bottom at two stages viz, after completion of boring and prior Io
concreting alter placing of reinforcement cage. Flushing of bentonite
shall be done continuously with fresh bentonite slurry till the consistency
of inflowing and out-flowing slurry is similar.
1115.2.5. Tremie of 150 mm to 200 mm diameter shall be used for
concreting. The tremie should have uniform and smooth cross-section
inside, and shall be withdrawn slowly ensuring adequate height
of concrete outside the tremie pipe at all stages of withdrawal.
Other recommendations for tremie concreting are
(i)
(ii)
The tremie shall be water-tight throughout its length and have a hopper attached
at its head by a water-tight connection
<<
355
Pile Foundations
Section 1100
(iii) The tremie pipe shalt be large enough in relation to the size of aggregates. For
20 mm aggregate the tremie pipe shall be of diameter not less than 150 mm and
for larger size aggregate tremie pipe of larger diameter is required.
(iv) The tremie pipe shall be lowered to the bottom of the bore-hole, allowing water
or dotting mud to rise inside it before pouring concrete.
(v)
The tremie pipe shall always be kept full of concrete and shall penetrate well
into the concrete in the bore-hole with adequate margin of safety against accidental
withdrawal if the pipe is surged to discharge the concrete.
ii)
5 mm
h)
Variation in length
25
c)
5 mm
d)
<<
Pile Length
in mm
1000
Driven Piles
a)
50 mm,
b)
c)
75 mm
d)
iii)
mm
-10 mm
in 50
: 25 men
Bored Piles
50
a)
b)
I in 50
c)
d)
356
mm,
: 50 men
25 mm
-10
mm
Pile Foundations
Section 1100
Variation in dimensions
(b)
: 50mm
15 mm
(c)
(d)
10 mm
mm
: 25 mm
<<
357
Section 1100
Pile Foundations
358
<<
Well Foundations
1200
Well Foundations
<<
Well Foundations
Section 1200.
1201. DESCRIPTION
This work consists of construction of well foundation, taking it down
to the founding level through all kinds of ~ub-sLrata,plugging the
bottom, filling the inside of the well, plugging the top and providing
a well cap in accordance with the details shown on the drawing -and
as per these specifications, or as directed by the Engineer.
In case of well foundations of size larger than 12 m diameter,
supplemental construction specifications will be necessary.
-
<<
1202. GENERAL
1202.1, Wells may have a circular, rectangular, or D-shape in plan
and may consist of one, two or more comprirtments in plan. The outer
wall of the well is known as -well stein~g which may be cellular.
The process of taking down the web the founding level is
known as well sinking. Aftu reaching the fot~ndinglevel, the hollow
inside the well, (dredge hole) is plugged at the bottom by concrete
(bottom plug). The dredge hole is then filled with approved filling
upto the level indicated on the drawings and provided with a concrete
plug (top plug).
To facilitate sinking of well, steel cutting edge is fabricated and
connected to a concrete well curb of required shape. On top of the
well curb, adequate height of well steining is cast and the process
of sinking is carried out. After a portion of the well has been sunk,
another height of well staining is cast on top of the previous section
and further sinking carried out. This process is continued till the bottom
level of the well reaches the founding level.
At the top of the well steining, an adequately designed well cap
is laid which transmits the loads and forces from the sub-structure (piers
or abutments) to the foundations.
1202.2. At least one bore-hole must be available/carried out in accordance with these specifications at each well foundation location,
prior to commencement of work, The depth of bore-holes should extend
upto a depth equal to one and a half times the outer diameter/least
dimension of the well below the anticipated founding level. The results
of soil exploration should be presented in accordance with clause
7.4 of IRC:78. In case the well foundation is to rest on a rocky strata,
it may be necessary to undertake additional borings /probings prior to
commencement of work to ascertain the actual profile and the quality
361
Well Foundations
Section 1200
of the rocky strata, at the level at which the well has to be seated,
etc.
12023, Blasting may have to be resorted to in order to facilitate
sinking through difficult strata, such as boulders and rocks etc. In case
blasting is anticipated, protective/strengthening measures specified in
clause 710.6 (IV) of IRC:78 shall be taken. The grade of concrete in
bottom 3 metres of steining shall not be leaner than M 20 or as shown
on the drawings.
1202.4, In case the bore hole data shows the presence of steeply
dipping rock, chiselling may have to be resorted to so as to obtain
proper seating of the fouodation. For this purpose, the well may require
to be, dewatered completely under high air pressure inside the well. This
process is known as pneumatic sinking. Pneumatic sinking may also have
to be resorted to in cases where obstacles such as tree trunks, large
sized boulders or hard strata etc. cannot be removed by open dredging.
The necessity of adop4ng pneumatic sinking shall be decided by the
EngineeP.
The curb and steining have to be specifically designed for speciai
loading* ~Thenpneumatic sinking is adopted.
1203, SETTING OUT AND PREPARATIONS FOR SINKING
120~1.Necessary reference points shall be fixed, away from the
zone of blow-ups or possible settlements resulting from well sinking
operations. Such reference points shall be connected to the permanent theodolite stations with the base line on the banks. The centre
of the individual wells shall be marked with reference to these stations.
The distance, wherever practicable, shall be checked with the help of
accurate tapes and precision distomat.
Reference points shall also be fixed to mark X-X axis (usually
traffic direction) and Y-Y axis (normal to X-~Caxis) accurately.
A temporary bench mark shall also be established near the well
foundation, away from the zones of blow-ups or possible settlement.
The bench mark shall be checked regularly with respect to the
permanent bench mark established at the bridge site.
1203.2. For wells which are to be pitched in water, an earthen or
sand island shall be constructed. Sand islands are practicable for water
depths of about 5 metres under stable bed soil conditions. For greater
depths or in fast flowing rivers or for locations where soil is too weak
to sustain sand island, floating caissons may have to be adopted.
362
<<
Section 1200
Well Foundations
(b)
(c)
Submersible pimps
Air compressors, air locks and other accessories where pneumatic sinking of well
is anticipated.
363
<<
Well Foundations
Section 1200
(e)
(I)
(g)
<<
364
Well Foundations
Section 1200
<<
365
Well Foundations
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Section 1200
Well Foundations
shall only be done in the presence of the Engineer and not before the
concrete in the steining has hardened sufficiently and is more than 7
days old. When likelihood of blasting is predicted in advance, protection
of the bottom portion of the well shall be done as per these specifications.
After blasting operations are completed, the well curb and steining should
be examined for any cracks and remedial measures taken.
If blasting has been used after the well has reached the design
foundation level, normally 24 hours shall be allowed to Lapse before
the bottom plug is laid.
The charges shall be exploded well below the cutting edge by
making a sump so as to avoid chances of any damage to the curb or
to the steining of the well. A minimum-sump of I metre depth should
be made before resorting to blasting. Use of large charges, 0.7 kg
or above, may not be allowed except under expert direction and with
the permission from the Engineer. Suitable pattern of charges may
be arranged with delay detonators to reduce the number of charges
fired at a time. The burden of the charge may be limited to 1 metre
and the spacing of holes may normally be kept as 0.5 to 0.6 metres.
All prevalent laws concerning handling, storing and using of explosives shall be ~strictlyfollowed.
All safety precautions shall be taken as per IS:4081 Safety Code
for B lasting and related Drilling Operations, to the extent applicable,
whenever blasting is resorted to.
There shoull be no equipment inside the well nor shall there be
any labour in the close vicinity of the well at the time of exploding
the charges.
If rock blasting is to be done for seating of the well, the
damage caused by flying debris should be minimised by covering
blasting holes by nibber mats before blasting.
1207.5, Use of Divers
Use of divers may be made both for sinking purpose like removal
of obstructions, rock blasting and for inspection. All safety precautions
shall be taken as per any acceptable safety code for sii~kingwith divers
or any statutory regulations in force.
Only persons trained for the diving operation shall be employed
and shall be certified to be fit for diving by an approved doctor.
They shall work under expert supervision. The diving and other
<<
367
Section 1200
Well Foundations
<<
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Well Foundations
Section 1200
shall be kept clear and in good condition at all times and shall be
constructed, inspected and maintained to the entire satisfaction of the
Engineer.
A 1.0 m wide platform with 1.0 m high railing shall be provided
all round the caisson air locks.
Where 15 or more men are employed, caissons shall have two locks,
one of which shall be used as a man lock.
Locks shall be located so that the lowest part of the bottom door
shall not be less than 1 metre above high water level.
The supply of fresh air to the working chamber shall at all times
be sufficient to permit work to be done without any danger or excessive
discomfort. All air supply lines shall be supplied with check valves and
carried as near to the face as practicable.
A man-lock shall be used solely for the compression or decompression of persons, and not for the passage of plant and
material and shall be maintained in a reasonably clein and sufficiently
warm state. However, any hand tool or hand instruments used for
the purpose of the work may be carried into the man-lock.
Where it is not reasonably practicable to provide a separate manlock for use by persons only, the lock when it is in actual use for
compression or decompression of a person or persons shall not be put,
simultaneously, to any other use and shall be in a reasonably clean and
sufficiently warm stale.
1207.6.3. Valves
Exhaust valves shall be provided, having risers extending to the
upper part of the chamber. These shall be operated, whenever
necessary specially after a blast. Precautions shall be taken that men
are not allowed to resume work after a blast until the gas and smoke
are cleared.
1207.6.4. Medical supervision and certification
Every employee absent from work for 10 or more consecutive days
due to illness or any other disability shall be required to pass the regular
physical examination by the doctor before being permitted to return
to work.
After a person has been employed continuously in compressed air
for a period of 2 months, he shall be re-examined by the doctor and
<<
369
Section 1200
Well Foundations
shall not be permitted to work until such re-examination has been made
and the report is satisfactory.
No person known to be addicted to the excessive use of
intoxicants shall be permitted to work in compressed air.
The doctor shall, at all times, keep a complete and full record of
examinations made by him, which shall contain dates of examinations, a
clear and full description of the person examined, his age and
physical condition at the time of examination and a statement as
to the period such a person has been engaged in such employment.
Records shall be kept at the place where the work is in progress
and shall be subject to inspection by authorised officers.
Every man lock shall always have a doctor or a responsible person
in attendance. In case the person in charge is not a doctor he must
have positive means of promptly communicating with and securing the
services of a competent doctor in case of emergency, Such arrangements
shall invariably be subject to the approval of the Engineer.
if the air pressure exceeds 0.2 MPa gauge or if 50 or more men
are employed, it is obligatory for the person in charge of medical
lock to be a doctor experienced in this type of work.
All cases of compressed-air illness shall be reported and copies of
all such reports shall be kept on file at the place of work.
1207.6.5. Lighting
All lighting in compressed air chambers shall be operated only by
electricity. Two independent electric lighting systems with independent sources of supply shall be used. These shall be so arranged that
the emergency source shall become automatically operative in case of
failure of the regularly used source.
The minimum intensity of light on any walkway ladder, stairway,
or lower working level shall be one-quarter (1/4) candlepower. In all
work places, the lighting shall always be such as to enable workmen
to see their way about clearly. All external parts of lighting fixtures and
electrical equipment lying within 2.5 metres above the floor shall be
constructed of non-combustible, non-absorbing insulating materials. If
metal is used it must be effectively earthed. Portable lamp shall have
non-combustible, non-absorbing insulating sockets, approved handles,
basket guards and approved cables. The use of worn or defective
portable and pendant conductors, shall be prohibited.
<<
21(1
Section 1200
Well Foundations
The weight of the pneumatic platform and that of steining and kentledge, if
any, shall be sufficient to resist the uplift from air inside, skin friction being
rtglected in this case. If, at any section the total weight acting downwanls is
<<
371
Well Foundations
Section 1200
leas than the uplift pressure of air inside, additional kentledge shall be placed
on the well.
If it is not possible to make the well heavy enough during excavation, blowing
down may be used. The men should be withdrawn and air pressure reduced,
The well should then begin to move with small reduction in air psessure. Blowing
down should only be used when the ground is such that it will not heave
up inside the chamber when the pressure is reduced. When the well does not
move with the seduction in air pressure, kentledge should be added~,Blowing
down should be in short stages and the drop should not exceed, 03 metre at
any stage. To control sinking during blowing down, use of packings are
recomsnended.
b)
The pneumatic sinking plant and other allied machinery shall not only be of proper
design and make, but also shall be worked by competent and well trained
personnel. Every part of the machinery and its fixtures shall be minutely
examined before installation and use. Availability ofappropriate spares, standbys,
safety of personnel as recommended in 15:4138 for working in compressed air
must be ensured at site. Codes far safety and for working in compressed air
and other labour laws and practices prevalent in the country, as specified to
provide safe, efficient and expeditious sinking shall be followed,
c)
inflammable materials shall not be taken into air locks and smoking shall be
prohibited. Wherever gases are suspected to be issuing out of dredge hole, the
sante shall be analysed by trained personnel and necessary precautions adopted
to avoid hazard to life and equipment,
d)
Where blasting is resorted to, it shall be carefully controlled and all precautions
regarding blasting shall be observed. Workers shall be allowed inside after
blasting only when a competent and qualified person has examined the chamber
and steining thoroughly and found the same to be safe,
<<
a)
When the wells have to be sunk close to each other and clear distance between
them is not greater than the diameter of wells, sinking shall be taken up on all
wells and they shall be sunk altemately so that sinking of wells proceeds
uniformly. Simultaneous and even dredging shall be carried out in the wells in
such a manner that the difference in the levels of the sump and cutting edge
in the adjacent wells does not exceed half the clear gap between them. Plugging
of all the wells shall be done together.
b)
c)
Bore chart shall be referred to constantly during sinking for taking adequate
care while piercing different types of strata. The type of soil as obtained
during the well sinking should be compared with bore chart s& as to
take prompt decisions.
d)
e)
All necessary precautions shall be taken against any possible damage to the
372
Well
Foundations
Seclion 1200
foundations of existing structures in the vicinity of the wells, prior to commencemnt of dredging from inside the welL
f)
The dredged material shall not be allowed to accumulate over the well. It shall
be dumped and spread, as far away as possible, and then continuously and
simultaneously removed, as directed by the Engineer. In case the river stream
flows along one edge of the well being sunk, the dredged material shall not
be dumped on the dry side of the bank but on the side on which the over
current flows.
g)
Very deep rump shall not be made below the well curb, as it entails risk of
jumping (sudden sinking) of the well. The depth of rump shall be generally limited
to one-sixth of the outes diameter/least lateral dimension of the well in plan.
Normally, the depth of sump shall not exceed 3.0 metres below the level of the
cutting edge unless otherwise specifically permitted by the Engineer.
h)
hi case a well sinks suddenly with a jerk, the steinjpg of the well shall be
examined to the satisfaction of the Engineer to see that no damage has occurred
to it,
i)
In pneumatic sinking, the well shall not, at any time, be dropped to a depth
greater than 500 mm by the method of blowing down,
j)
Dewatering shall be avoided if sand blows are expected. Any equipment and
men workmg inside the well shall be brought out of the well as soon as there
are any indications of a sand-blow.
k)
Sand blowing in wells can often be minimised by keeping the level of water
inside the well higher than the water table and also by adding heavy kentledge.
I)
<<
Section
1200
Well Foundations
1215(g).
In case the Engineer, in his discretion, rejects the well, the Contractor
shall dismantle the rejected well to the extent directed by the Engineer
and remove the debris. Further, the Contractor shall, at his own risk
and expense complete the bridge with modified span arrangement
acceptable to the Engineer.
1207,9. Seating of Wells
The well shall be uniformly seated at the founding strata. it
shall be ensured by test borings that the properties of the soil encountered
at the founding strata and upto a depth of one and a half times the
well diameter is identical to that adopted in the design. The procedure
for test borings shall satisfy the provisions of these specifications.
In case the soil encountered is inferior to that adopted in design,
<<
374
Well
Foundations
Se~tion1200
for
emergency situation.
<<
375
Section 1200
Well Foundations
<<
376
Well Foundations
Section 1200
1212. TOLERANCES
The permissible tilt and shift shall not exceed I (horizontal) in 80
(vertical) and the shift at the well base shall not be more than 150
mm in any resultant direction.
For the well steining and well cap the permissible tolerances
shall be as follows
a)
Variation in dimension
: 50mm
b)
: 15 mm
c)
d)
10
mm
: 25mm
The cutting edge shall be measured in tonnes based on the net weight of metal
used in it, as per Section 1900.
b)
The concrete in curb, well steining and well cap shall be measured in cubic
metres in each of the items as per Section 1700. The reinforcements shall be
measured in tonnea separately in each of the items, as per Section 1600.
c)
The measurement for well sinking shall be made in twining metres for
different depths and in different types of strata (for example, predominantly sand/
clay soil, soft rock, hard rock, etc) as specified in the Contract. The depth
of sinking shall be measured from the level specified in the Contract. If no
level has been specified in the Contract, sinking shall be measured from she
low waler level or from the level at which the cutting edge was laid, whichever
is higher.
d)
The qusntity of concrete in bottom and top plug shall be measured in cubic
metres as per Section 1700.
e)
The
fl
a)
The Contract unit rates ofcutting edge shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, samplinj and testing,
quantity
in cubic metres.
1215. RATE
<<
377
I-.
Well Foundations
Section 1200
Steel Work
h)
The Contract unit rates for concrete in curb, steining, bottom plug, top plug
and well cap, shall cover all costs of labour, material, tools, plant and
equipment, forthwork and staging including placing in position, sampling and
testing, and, supervision, all as per respective Section of Stnsctural Concrete
and as described in this section.
c)
The Contract unit rates for reinforcement in curb, steining, and well cap, shall
cover all costs of labour, material, tools, plant and equipment, including bending
to shape, placing in position, sampling, testing and supervision, all as per
respective Section of Steel Reinforcement and as described in this section.
d)
The Contract unit rates for sand filling shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, sampling, testing and
supervision, all as described in this section.
e)
The Concrete unit rates for sinking shall cover the costs of labour, tools, and
equipment and plant and for all operations and other incidentals for sinking of
well including seating exceptingrprovisions of pneumatic sinking as described in
this Section. The unit rates shall specify the strata such as types of soil, rock,
etc. The rate shall cover all testing and supervision required for the work.
I)
g)
If any well with tilt and/or shift exceeding beyond permissible values
is accepted by the Engineer, the Contractor shall give a ~reductionin
the rates as follows
S,Nu,
1.
5 per cent
2.
Tilt exceeding 1 in 60
but equal to or within I in 50
10 per cent
3.
lilt exceeding I in 50
20 per cent
4.
2 per cent
5.
6.
10 per cent
per cent
<<
378
Brick Masonry
1300
Brick Masonry
<<
Brick Masonry
Secuon 1300
1301. DESCRIPTION
This work shall consist of construction of structures with bricks
jointed together by cement mortar in accordance with the details shown
on the drawings or as approved by the Engineer.
1302. MATERIALS
All materials to be used in the work shall conform to the
requirements laid down in Section 1000.
1303. PERSONNEL
Only trained personnel shall be employed for construction and
supervision.
1304. CEMENT MORTAR
Cement and sand shall be mixed in specified proportions given in
the drawings. Cement shall be proportioned by weight, taking the unit
weight of cement as 1.44 tonne per cubic metre. Sand shall be proportioned by volume taking into account due allowance for bulking.
All mortar shall be mixed with a ~ninimum quantity of water to
produce desired workability consistent with maximum density of mortar.
The mix shall be clean and free from injurious type of soil/acid/alkali!
organic matter or deleterious substances.
The mixing shall preferably be done in a mechanical mixer
operated manually or by power. Hand mixing can be resorted to as
long as uniform density of the mix and its strength are assured subject
to prior approval of the Engineer. Where permitted, specific
permission is to be given by the Engineer. Hand mixing operation shall
be carried out on a clean water-tight platform, where cement and
sand shall be first mixed dry in the required proportion by being turned
over and over, backwards and forwards several times till the mixture
is of uniform colour. Thereafter, minimum quantity of water shall be
added to bring the mortar to the consistency of a stiff paste. The mortar
shall be mixed for at least two minutes after addition of water.
Mortar shall be mixed only in such quantity as required for
immediate use. The mix which has developed initial set shall not be
used. Initial set of mortar with ordinary Portland Cement shall
normally be considered to have taken place in 30 minutes after mixing.
In case the mortar has stiffened during initial setting time because
of evaporation of water, the same can be re-tempered by adding water
381
<<
Section 1300
Brick Masonry
<<
382
Brick Masonry
Section 1300
<<
383
Brick Masonry
Section 1300
<<
384
Brick Masonry
Section 1300
1312.3. Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by
volume of cement and sand or as shown on the drawing. The mortar
shall be filled and pressed into the raked joints before giving the
required finish. The pointing shall be ruled type for which it shall,
while still green, be ruled along the centre with half round tools of
such width as may be specified by the Engineer. The super flush mortar
shall then be taken off from the edges of the lines and the surface of
the masonry shall be cleaned of all mortar, The work shall conform
to IS:2212.
1312.4. Plastering
Plastering shall be done where shown on the drawing. Superficial
plastering may be done, if necessary, only in structures situated in fast
flowing rivers or in severely aggressive environment.
Plastering shall be started from tOp and worked down. All putlog
holes shall be properly filled in advance of the plastering while the
scaffolding is being taken down. Wooden screeds 75 mm wide and of
the thickness of the plaster shall be fixed vertically 2.5 to 4 metres
apart, to act as gauges and guides in applying the plaster. The mortar
shall be laid on the wall between the screeds using the plasters float
and pressing the mortar so that the raked joints are properly filled.
The plaster shall then be finished off with a wooden straight edge
reaching across the screeds. The straight edge shall be worked on the
screeds with a small upward and sideways motion 50 mm to 75 mm
at a time. Finally, the surface shall be finished off with a plasterers
wooden float. Metal floats shall not be used.
When recommencing the plastering beyond the work suspended
earlier, the edges of the old plaster shall be scrapped, cleaned and
wetted before plaster is applied to the adjacent areas.
No portion of the surface shall be left unfinished for patching up
at a later period.
The plaster shall be finished true to plumb surface and to the proper
degree of smoothness as directed by the Engineer.
The average thickness of plaster shall not be less than the
specified thickness. The minimum thickne~over~any portion of the
surface shall not be less than the specified thickness by more than
3mm.
<<
385
Brick Masonry
Section 1300
Any cracks which appear in the surface and all portions which
sound hollow when tapped, or are found to be soft or otherwise
defective, shall be cut in rectangular shape and re~doneas directed
by the Engineer.
1312.5. Curing of Finishes
Curing shall be commenced as soon as the mortar used
for finishing has hardened sufficiently not to be damaged during
curing. It shall be kept wet for a period of at least 7 days. During
this period, it shall be suitably protected from all damages.
1312.6. Scaffolding for Finishes
Stage scaffolding shall be provided for the work. This shall
independent of the structure.
be
<<
386
Brick Masonry
Section 1300
<<
387
Stone Masonry
1400
Stone Masonry
<<
Stone Masonry
Section 1400
1401. DESCRIPTION
This work shall consist of the construction of structures with stones
jointed together by cement mortar in accordance with the details shown
on the drawings and these specifications or as approved by the Engineer.
1402. MATERIALS
All materials used in stone masonry shall conform to Section 1000
except cement mortar for stone masonry which shall conform to
Clause 1304.
1403. PERSONNEL
Only trained personnel shall be employed for construction and
supervision.
1404. TYPE OF MASONRY
The type of masonry used for structures shall be random masonry
(coursed or uncoursed) or coursed rubble masonry (First sort). However,
for bridge work generally, course rubble stone masonry shall be used.
The actual type of masonry used for different parts of structures shall
be specified on the drawings.
For facing work, ashlar masonry shall be used where indicated on
the llrawings.
1405. CONSTRUCTION OPERATIONS
1405.1. General Requirements
The dressing of stone shall be as specified for individual type
masonry work and it shall also conform to the general requirements
of 15:1597 and requirement for dressing of stone covered in 15:1129.
Other specific requirements are covered separately with respect to
particular types of rubble stone work.
1405.2. Laying
1405.2.1. The masonry work shall be laid to lines, levels, curves
and shapes as shown in the plan. The height in cach course shall be
kept same and every stone shall be fine tooled on all beds joints and
face full and true. The exposed faces shall be gauged out, grooved,
regulated and sunk or plain moulded as the case may be. The faces
of each stone between the draft be left rough as the stone comes from
quarry except where sacrificial layer is to be provided or plastering is
resorted to due to aggressive environment.
<<
391
Section 1400
Stone Masonry
<<
392
Stone Masonry
SecLion 1400
<<
393
section 1400
Stone Masonry
<<
394
Section
Stone Masonry
1400
and close joint. Face stone shall extend and bond well in the back.
These shall be arranged to break joints, as much as possible,
and to avoid long vertical lines of joints.
1405.3.8. Joints : The face joints shall not be more than 20 mm
thick, but shall be sufficiently thick to prevent stone-to-stone contact
and shall be completely filled with mortar.
1405.4. Square Rubble Coursed Rubble (First Sort)
1405.4.1. Dressing : Face stones shall be hammer dressed on all
beds and joints so as to give them rectangular shape. These shall
be square on all joints and beds. The bed joints shall be chisel drafted
for at least 80 mm back from the face and for at least 40 mm for
the side joints. No portion of the dressed surface shall show a depth
of gap more than 6 mm from the straight edge placed on it. The
remaining unexposed portion of the stone shall not project beyond the
surface of bed and side joints. The requirements regarding bushing
shall be the same as for random rubble masonry.
1405.4.2. Hearting stones : The hearting or interior filling of the
wall face shall consist of flat bedded stone carefully laid, on prepared
beds in mortar. The use of chips shall be restricted to the filling
of interstices between the adjacent stones in hearting and these shall
not exceed 1Q per cent of the quantity of masonry. While using chips
it shall be ensured that no hollow spaces are left anywhere in the
masonry.
1405.4.3. Bond stones : The requirements regarding through or
bond stone shall be the same as for random rubble masonry, but these,
shall be provided at 1.5 metre to 1.8 metre apart clear in every course.
1405.4.4. Quoin stone : The quoins shall be of the same height
of the course in which these occur and shall be formed of header stones
not less than 450mm in length. They shall be laid lengthwise alternately
along each face, square in their beds which shall be fairly dressed
to a depth of at least 100 mm.
-
1405.4.5. Face stone : Face stones shall tail into the work for
not less than their heights and at least one-third of the stones shall
tail into the work for a length not less than twice their height. These
shall be laid as headers and stretchers alternately.
1405.4.6, Laying: The stones shall be laid on horizontal courses
and all vertical joints should be truly vertical. The quoin stones should
be laid header and stretcher alternately and shall be laid square
<<
395
Stone Masonry
Section 14(X)
<<
396
Stone Masonry
Section 1400
1405.6L Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by
volume of cement and sand or as shown on the drawing. The mortar
shall be filled and pressed into the raked out joints before giving
the required finish. The pointing shall conform to Clause 1312.3 of
the specification. The work shall conform to 15:2212. The thickness
of joints shall not be less than 3 mm for Ashlar masonry. However,
the maximum thickness of joints in different works shall be as follows:
Random Rubble
20 mm
Coursed Rubble
L5 mm
Ashlar Maonry
5 mm
l405.7. Curing
Curing shall conform to Clauses 1309 and 1312.5
1405.8. Scaffolding
For scaffolding Clause 1310 shall apply.
1405.9. Weep Holes
Weep holes shall conform to Clause 2706.
1405.10. Jointing with Existing Structures
For Jointing with existing structures, the specifications given under
Clause 1308 shall apply.
1406. ARCHITECTURAL COPING FOR WING/RETURNI
PARAPET WALLS
Architectural coping for wing/return/parapet walls shall conform to
:lause 1311
1407, TESTS AND STANDARD OF ACCEPTANCE
All work shall be done to the lines and levels as indicated on
he drawing or as directed by the Engineer subject to tolerances as
pecified in these specifications.
Mortar cubes shall be taken in accordance with 15:2250 for
compressive strength, consistency of mortar and its water retentivity.
The frequency of testing shall be one sample for every two cubic
metres of mortar sul~jectto a minimum 3 samples for a thys work.
1408, MEASUREMItNTS FOR PAYMENT
Stone masonry shall be measured in cubic metres.
<<
397
Stone Masonry
Section 1400
<<
398
Formwork
1500
Formwork
<<
Formwork
Section 1500
1501. DESCRIPTION
<<
401
Section 1500
Formwork
<<
402
Section 1500
Formwork
<<
403
Section 1500
Formwork
for the construction of any one structure. The contractor shall make
good any ithperfections in the resulting finish as required by the
Engineer. Internal ties and embedded metal parts shall be carefully
detailed and their use shall be subject to the approval of tfie Engineer.
1506. PRECAUTIONS
-.
(i)
(ii)
Where necessary, forsnwork shall be so arranged that the soffit form, properly
supported on props only can be retained irs position for such period as may
be required by
matu:ring conditions.
(iii)
(iv)
Provision shall be made for safe access en, to and about the forrnwork at the
levels as required.
(v)
(vi) Water used for curing should not be allowed to stagnate near the
supporting the staging and should be properly drained.
base plates
<<
(i)
The contact surfaces of the forms shall be cleaned carefully and dried before
applying a release agent
(ii)
Section 1500
Formwork
(iii) The form surfaces shall be evenly and thinly coated with eleare ageuL The
vertical surface shall be treated before horizontal surface and any excess wiped
Out.
(iv) The release agent shall not come in contact with reinforcement or the
hardened concrete
b)
Soffits
of Slabs
(with props
left under)
3 days
c)
14 days
d)
Softit of Girders
(with props left under)
7 days
e)
21 days
<<
405
Section 1500
Formwork
<<
Formwork
Section 1500
<<
407
16D0
Steel Reinforcement
(Untensioned)
<<
Section 1600
1601, DESCRIPTION
This work shall consist of furnishing and placing coated or
uncoated mild steel or high strength deformed reinforcement bars
(untensioned) of the shape and dimensions shown on the drawings and
conforming to these Specifications or as approved by the Engineer.
1602. GENERAL
Steel for reinforcement shall meet with the requirements of Section
1000.
411
<<
I~~s..
-.~
Section 1600
.... .-
The reinforcement cage should generally be fabricated in the yard at ground level
and then shifted and placed in position. The reinforcement shall he placed strictly
in accordance with the dr%wings and shall be assembled in position only
when the structure is otherwise ready for plac:ing of concrete. Prolonged time
gap between assembling of reinforcements and casting of concrete, which
may result in rust formation on the surface, shall not be permitted.
b)
c)
(ii)
<<
Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks
etc., as devices for positioning reinforcement shall noI~be permitted.
liars coated with epoxy or any other approved protective coating shall be
412
Section 1600
placed on supports that do not damage the coating. Supports shall be installed
in a manner suchthat planes of weakness are not created in hardened concrete.
The coated reinforcing steel shall be held in place by use of plastic or plastic
coated binding wires especially manufactured for the purpose. Reference shall
be made to Section 1000 for other requirements.
e)
<<
Section 1600
Welding may be carried out by metal arc welding process. Oxyacetelene welding shall not be permissible. Any othtr process may be
tised subject to the approval of the Engineer and necessary additional
requirements to ensure satisfactory joint performance. Precautions on
over heating, choice of electrode, selection of correct turrent in arc
welding etc., should be strictly observed.
All bars shall be butt welded except for smaller diameter bars
(diameter of less than 20 mm) which may be lap welded. Single-V or
Double-V butt joints may generally be used. For vertical bars single
bevel or double bevel joints may be used.
Welded joints shall be located well away from bends and not less
than twice the bar diameter away from a bend.
Generally, shop welding in controlled conditions is to be
preferred, where feasible. Site welding where necessary shall, however,
be permitted when the facilities, equipment, process, consumables,
operators, welding procedure are adequate to produce and maintain
uniform quality at par with that attainable in shop Nelding to the
satisfaction of the Engineer.
Joint welding procedures which are to be ~employed shall
invariably be established by a procedure specification. All welders
and welding operators to be employed shall have to be qualified by
tests prescribed in IS:2751. inspection of welds shall conform to
IS:822 and destructive or non-destructive testing may be undertaken
when deemed necessary. Joints with weld defects detected by visual
inspection or dimensional check inspection shall not be accepted.
Suitable means shall be provided for holding the bars securely in
position during welding. It must be ensured that no voids are left
in welding. When welding is done in 2 or 3 stages, previous surface
shall be cleaned properly. Bars shall be cleaned of all loose scale, rust,
grease, paint and other foreign matter before carl%ring out welding.
Only competent and experienced welders shall be employed on the
work with the approval of the Engineer. No welding shall be done on
coated bars.
M.S. electrodes used for welding shall conform to IS:8l4.
1606.2.4. Welded joints shall prefeiably be located at points where
steel will not be subject to more than 75 per cent of the maximum
permissible stresses and welds so staggered that at any one section,
not more than 20 per cent of the bars are welded.
<<
414
Section
1600
<<
415
Structural Concrete
1700
Structural Concrete
<<
Structural Concrete
Section 1700
1701. DESCRW~ION
The work shall consist of furnishing and placing structural concrete
and incidental construction in accordance with these specifications and
in conformity with the lines, grades and dimensions, as shown on the
drawings Or as directed by the Engineer.
1702. MATERIALS
All materials shall conform to Section 1000 of these Specifications.
1703. GRADES OF CONCRETE
1703.1. The grades of concrete shall be designated by the characteristic strength as given in Table 1700-I, where the characteristic strength
is defined as the strength of concrete below which not more than 5 per
cent of the test results are expected to fall.
TABLE 1700-1.
,Grade Designation
M 15
M 20
M 25
M 30
M 35
M 40
M 45
M 50
M 55
a)
b)
c)
FCC members
360
RCC members
PSC members
400
400
419
<<
0.45
0.45
0.40
0.45
0.40
0.40
.. ..d.--
Stiucuiral Concrete
Section 1700
(B) MINIMUM STRENGTH OF CONCRETE
Member
a)
b)
c)
Conditions of Exposure
PCCniranbers
RcCmernbers
PSCmembers
Moderate
Severe
M25~
M30
M35
M35
M40
M40
STRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO
Structural Member
~
~
a)
b)
FCC members
RCC members
Exposure conditions
Normal
Severe
Exposure conditions
Normal
Severe
250
310
310
400
ratio
0.50
0.45
0.45
0.40
a)
b)
PCCmembers
RCCmembers
Conditions of Exposure
Moderate
Severe
MiS
M20
M25
M20
(ii)
For underwater concretinj, the cement content shall be increased by 10 per cent.
Cmii) Severe conditions of exposure shall mean alternate wetting and drying due to sea
spray, alternate wetting and drying combined with freezing and buried in soil
having corrosive effect
(iv) Moderate conditions of exposure shall mean other that those mentioned in (iii)
abovt
The cement content shall be as low as possible but not less than
the quantities specified above. In no case shall it exceed 540 kg/cu.m.
of concrete.
1703.3. Concrete used in any component or structure shall be
specified by designation along with prescribed method of design of mix
i.e. Design Mix or Nominal Mix. For all items of concrete, only
Design Mix shall be used, except where Nominal Mix concrete is
permitted as per drawing or by the Engineey.Nominal Mix may be
420
<<
Section
Structural Concrete
1700
(a)
(b)
<<
TYPE
SLUMP (mm)
25
25
2.
40
50
3.
50
75
4.
75
5.
100
421.
125
200
Section 1700
Structural Concrete
The current margin for a concrete mix shall be determined by the Contractor and
shall be taken as 1.64 times the standard deviation of sample test results taken
from at least 40 separate batches of concrete of nominally similar proportions
produced at site by the same plant under similar supervision, over a period
exceeding 5 days, but not exceeding 6 months.
(ii)
Where there is insufficient data to satisfy the above, the current margin for the
initial design mix shall be taken as given in Table 1700-5
Concrete Grade
M 15
M 20
N4 25
M 30
M 35
M 40
M 45
M 50
M 55
TABLE 1700.5.
Current Margin
CMPa)
10
JO
11
12
12
12
13
13
14
(MPa)
25
30
36
42
47
52
58
63
69
The initial current margin given in the Table 1700-5 shall be used
tifl sufficient data is available to determine the current margin as per
sub-clause (i) above,
1704.2.2. Trial mixes
The Contractor shall give notice to enable the Engineer to be present
at the making of trial mixes and preliminary testing of the cubes. The
Contractor shall prepare trial mixes, using samples of approved materials
typical of those he proposes to use in the works, for all grades to the
Engineers satisfaction prior to commencement of concreting. The initial
trial mixes shall generally be carried out in an established laboratory
approved by the Engineer. In exceptional cases, the Engineer may permit
the initial trial mixes to be prepared at the site laboratory of the
Contractor, if a full fledged concrete laboratory has been established well
before the start of construction, to his entire satisfaction. In all cases
complete testing of materials forming the constituents of proposed Design
Mix shall have been carried out prior to making trial mixes.
Sampling and testing procedures shall be in accordance with these
specifications.
<<
422
Structural Concrete
Section 1700
When the site laboratory is utilised for preparing initial mix design,
the concreting plant and means of transport employed to make the trial
mixes shall be similar to that proposed to be used in the works.
Test cubes shall be taken from trial mixes as follows. For each mix,
set of six cubes shall be made from each of three consecutive batches.
Three cubes from each set of six shall be tested at an age of 28 days
and three at an earlier age approved by the Engineer. The cubes shall
be made, cured, stored, transported and tested in accordance with these
specifications. The average strength of the nine cubes at 28 days shall
exceed the specified characteristic strength by the current margin minus
3.5 MPa.
1704.23. Control of strength .of design mixes
a)
b)
c)
1704.3.
Grade
MIS
350
M20
250
do--
<<
423
Section 1700
Structural Concrete
b)
Prestiessed Concrete
The total sulphuric anhydride (SO,) content of all the constituents of concrete as
a peitentage of mass of cement in the mix shall be limited so 4 per cent
6)
Quantities of each material per cubic metre cYf fully compacted concrete
c)
d) Statement giving the proposed mix proportions for nominal mix concrete.
Any change in the source of material or in the mix proportions shall
be subject to the Engineers prior approval.
t705. ADMIXTURES
Use of admixtures such as superplasticisers for concrete may be made
with the approval of the Engineer.
As the selection of an appropriate concrete admixture is an integral
part of the mix design, the manufacturers shall recommend the use of
any one of his products only after obtaining complete knowledge of all
the actual constituents of concrete as well as methodologies of manufacture, transportation and compaction of concrete proposed to be used
in the project.
1706. SiZE OF COARSE AGGREGATE
The size (maximum nominal) of coarse aggregates for concrete to
<<
424
Structural Concrete
Section
1700
TABLE 1700-7.
Maximum Nominal Size of Coarse Aggregate
(mm)
I)
RCC
ii)
40
iii)
40
iv)
well curb
20
RCC
work in girders,slabs,
wearing coat, kerb, approach
slab, hollow piers and
abutments, pier/abutment
caps, piles
v)
PSC work
vi)
20
20
As specified by Engineer
10 mm less than the minimum lateral clear distance between main reinforcements
b)
For overall bridge length of test than 200 metres - batch type concrete mixer
diesel or electric operated, with a minimum size of 200 litres, automatic water
measuring system and integral weigher (hydraulic/pneumatic type)
ii)
For overall bridge length of 200 metres or more - concrete batching and
mixing plant fully automatic with minimum capacity of 15 cu.m.per hour.
<<
425
Structural Concrete
Section 1700
Measurement of Cement
Measurement of Water
Measurement of Aggregate
Measurement of Admixture
b)
c)
ii)
iii)
size 25 mm to 70 mm
minimum 500 watts
full width of carriageway
(upto two lanes)
Internal vibrators
Form vibrators
Screed vibrasors
<<
426
Structural Concrete
Section 1700
<<
427
Structural Concrete
Section 1700
that the periods indicated above are unacceptable. In all such matters,
the Engineers decision shall be final.
Concrete shall be thoroughly compacted by vibration or other means
during placing and worked around the reinforcement, tendons or duct
formers, embedded fixtures and into corners of the formwork to produce
a dense homogeneous void-free mass having the required surface finish.
When vibrators are used, vibration shall be done continuously during the
placing of each batch of concrete until the expulsion of air has practically
ceased and in a manner that does not promote segregation. Over vibration
shall be avoided to minimise the risk of forming a weak surface layer.
When external vibrators are used, the design of formwork and disposition
of vibrator shall be such as to ensure efficient compaction and to avoid
surface blemishes. Vibrations shalt not be applied through reinforcement
and where vibrators of immersion type are used, contact with reinforcement and all inserts like ducts etc., shall be avoided. The internal vibrators
shall be inserted in an orderly manner and the distance between insertions
should be about one and a half times the radius of the area visibly affected
by vibration. Additional vibrators in serviceable condition shall be kept
at site so that they can be used in the event of breakdowns.
Mechanical vibrators used shall comply with IS:2502, IS:2506,
JS:2514 and IS:4656.
1710. CONSTRUCTION JOINTS
approved from the Engineer before any work is started. Concrete shall
contain 10 per cent more cement than that required for the same mix
placed in the dry.
Concrete shall not be placed in water having a temperature below
<<
428
Structural Concrete
Section 1700
<<
429
Structural Concrete
Section 1700
quantity has been placed, the lower end of the tremie pipe shall be kept
below the surface of the plastic concrete. This will cause the concrete
to build up from below instead of flowing out over the surface and thus
avoid formation of layers of laitance. If the charge in the tremie is lost
while depositing, the tremie shall be raised above the concrete surface
and unless sealed by a check valve, it shall be replugged at the top end,
as at the beginning, before refilling for depositing further concrete.
1712. ADVERSE WEATHER CONDITIONS
1712.1. Cold Weather Concreting
Where concrete is to be deposited at or near freezing temperature,
precautions shall be takel) to ensure that at the time of placing, it has
a temperature of not less than 5 degrees Celsius and that the temperature
of the concrete shall be maintained above 4 degrees Celsius until it has
thoroughly hardened. When necessary, concrete ingredients shall be
heated before mixing but cement shall not be heated artificially other
than by the heat transmitted to it from other ingredients of the concrete.
Stock-piled aggregate may be heated by the use of thy heat or steam.
Aggregates shall not be heated directly by gas or on sheet metal over
fire. In general, the temperature of aggregates or water shall not exceed
65 degrees Celsius. Salt or other chemicals shall not be used for the
prevention of freezing. No frozen material or materials containing ice
shall be used. All concrete damaged by frost shall be removed, It is
recommended that concrete exposed to freezing weather shall have
entrained air and the water content of the mix shall not exceed 30 litres
per 50 kg of cement.
1712.2. Hot Weather Conditions
When depositing concrete in very hot weather, precautions shall be
taken so that the temperature of wet concrete does not exceed 40 degrees
Celsius while placing. This shall be achieved by stacking aggregate under
the shade and keeping them moist, using cold water, reducing the time
between mixing and placing to the minimum, cooling formwork by
sprinkling water, starting curing before concrete dries out and restricting
concreting as far as possible to early mornings and late evenings. When
ice is used to cool mixing water, it will be considered a part of the
water in design mix. Under no circumstances shall the mixing operation
be considered complete until all ice in the mixing drum has melted.
The Contractor will be required to state his methodology for the Engineers approval when temperatures of concrete are likely to exceed 40
degrees Celsius during the work.
<<
430
Structural Concrete
Section 1700
b)
and wind
c)
d)
e)
Vibration and impact which may disrupt the concrete and interfere with its bond
to the reinforcement
Where members are of considerable size and length, with high cement
content, accelerated curing methods may be applied, as approved by the
Engineer.
1713.1. Water Curing
Water for turing shall be as specified in Section 1000.
Sea water shall not be used for curing. Sea water shall not come
into contact with concrete members unless it has attained adequate
strength.
Exposed surfaces of concrete shall be kept continuously in a damp
or wet condition by ponding or by covering with a layer of sacks, canvas,
Hessian or similar materials and shall be kept constantly wet for a period
of not less than 14 days from the date of placing of concrete.
1713.2. Steam Curing
Where steam curing is adopted, it shall be ensured that it is done
in a suitable enclosure to contain the live steam in order to minimise
moisture and heat losses. The initial application of the steam shall be
after about four hours of placement of concrete to allow the initial set
of the concrete to take place.
Where retarders are used, the waiting period before application of
the steam shall be increased to about six hours.
The steam shall be at 100 per cent relative humidity to prevent loss
of moisture and to provide excess moisture for proper hydration of the
cement. The application of steam shall notbe directly on the concrete
and the ambient air temperature shall increase at a rate not exceeding
<<
431
Structural Concrete
Section 1700
<<
432
Section 1700
Structural Concrete
b)
1715. TOLERANCES
Tolerances for dimensions/shape of various components shall be as
indicated in these specifications or shown on the drawings or as directed
by the Engineer.
1716. TESTS AND STANDARDS OF ACCEPTANCE
1716.1. Concrete shall conform to the surface finish and tolerance
as prescribed in these specifications for respective components.
1716.2, Random sampling and lot by lot of acceptance inspection
shall be made for the 28 days cube strength of concrete.
1716.2.1. Concrete under acceptance shall be notionally divided into
loLs for the purpose of sampling, before commencement of work. The
delimitation of lots shall be determined by the following
(i)
(ii)
At least one cube formthg an item of the sample representing the lot shall be
taken from concrete of the same grade and mix proportions cast on any day.
(iii) Different grades of mixes of concrete shall be divided into separate lots
(iv) Concrete of a lot shall be used in the same identifiable component of the bridge
2,
A randorrt sampling procedure to ensure that each of the concrete batches forming
the lot under acceptance inspection has equal chance of being chosen for taking
cubes shall be adopted.
3.
150 mm cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with 15:516. The 28~daytest strength result
for each cube shall form an item of the sample.
<<
433
Structural Concrete
Section 1700
No. of samples
1
2
3
4
4 plus one additional
for each
5 or sample
part thereof
actditional 50 m
1-5
6~15
16-30
31-50
51 and above
The mean strength determined from any group of fourconsecutive samples should
exceed the specified characteristic compressive strength.
b)
Strength of any sample is not less than the specified characteristic compressive
strength minus 3 MPa.
<<
414
Structural Concreic
Section 1700
(ii)
After 28 days of curing, the test specimcn is fitted in a machine such that thc
specimen can be placed in water under pressure upto 7 bars. A typical machine
is shown in Appen4Lz 1700/fl.
150
(iii) At first a pressure of one bar ir applied for 48 hours, followed by 3 bars for
24 hours and 7 bars for next 24 hours.
(iv) After the passage of the above period, the specimen is taken out and split in the
middle by compression applied on two round bars on opposite sides above and
below,
(v)
The water penetration in the broken core is to be measured with a scale and the
depth of penetration assessed in mm (max. permissible limit 25 mm).
<<
435
Structural Concrete
Section 1700
incidental expenses, sampling and testing, quality assurance and supervision. Unless mentioned separately as an item in the Contract, the
contract unit rate for concrete shall also include the cost of providing,
fixing and removing formwork required for concrete work as per Section
1500.
Where concrete is found to be acceptable as sub-standard work, the
Contractor shall pay a discount over the contract unit rate, as decided
by the Engineer. For deficiency in compressive strength of concrete when
accepted by the Engineer, the reduction in rate may be applied as under
Per cent reductton
<<
Design Strength
Observed Strength
x 100
Design Strength
436
Prestressing
1800
Prestressing
<<
Prestressing
Section 1800
1801. DESCRIFFION
Structural concrete containing prestressed steel reinforcement to introduce precompression is termed as prestressed concrete.
The work shall be carried out in accordance with the drawing and
these specifications or as approved by the Engineer.
Concrete and untensioned steel for the construction of prestressed
concrete members shall conform to the requirements of sections 1700
and 1600 for Structural Concrete and Steel Reinforcement respectively
in so far as the requirements of these Sections apply and are not
specifically modified by requirements set forth herein.
1802. MATERIALS
~J8O2.1.All materials shall conform to Section 1000.
1802.2. Sheathing
~4802.2,1.The sheathing ducts shall be of the spiral corrugated
type, Unless otherwise specified, the material shall be Cold Rolled
Cold Annealed (CRCA) Mild Steel conforming to !S:5 13 intended for
mechanical treatment and surface refining but not for quench hardening
or tempering.
The material shall normally be bright finished. However, where
specified, as in case of use in aggressive environment, galva..
aired or lead-cOated mild steel strips shall be used.
The thickness of sheathing shall be as shown on the drawing, but
shall not be less than 0.3 mm, 0.4 mm and 0.5 mm for sheathing ducts
having internal diameter of 50 mm, 75 mm and 90 mm respectively.
For bigger diameter of ducts, thickness of sheathing shall be based
on recommendations of prestressing system supplier or as directed by
the Engineer.
The sheathing shall conform to the requirement as per tests
specified in Appendix 1800/!.
L~
439
<<
Section 1800
Prestressirg
<<
440
Section
Prestressing
1800
<<
441
Section 1800
Prestressing
<<
Prestressing
Section 1800
<<
443
Section 1800
Prestressing
1804.8
pressure
or grout.
Anchorages
All bearing surflices of the anchorages shall be cleaned prior to concretmg and tensioning.
Anchor cones, blocks and plates shall he securely positioned and
maintained during concreting such that the centre line of the duct
passes axially through the anchorage assembly.
The~ anchorages shall he recessed from the concrete surface by a
minimum cover of 11)1) mm.
After the prestressing operations are completed and prestressing
wires/strands are cuL, the surface shall he painted with two coats
of epoxy of suitable formulation having a dry film thickness of 80
<<
444
Section 1800
Prcstressing
microns per coat and entire recess shall be filled with concrete or
non-shrink/pre-packaged mortar or epoxy concrete.
1804.9. Structural Concrete
Structural concrete shall conform to Section 1700. The formwomk
shall conform to Section 1500.
\/t8O5. SUPERVISION
Al! prestressing and grouting operations shall be undertaken by
trained personnel only. A representative of supplier of the prestressing
system shall be present during all tensioning and grouting operations
and shall ensure, monitor and certify their correctness.
(ii)
(iii)
strands of the tendon. Suitable facilities for handling and attaching the multi~
putt jack to the tendons shalt be provided.
The tensioning equipment shalt be such that it can apply controtted total force
gradually on the concrete without inducing dangerous tecondary stresses in steel,
anchorage or concrete; and
(iv) Means shalt be provided for direct measurement of the force by use of dynamo~
meters or pressure gauges fined in the hydraulic system itself to determine the
pressure in the jacks. Facilities shalt also be provided for the tinear measurement
of the extension of prestressing steel to the nearest mm and of any slip of the
gripping devices at trai~sfer.
<<
445
Section t800
Prestressing
<<
a)
b)
tf the catcutated elongation has not been reached at the specified gauge pressure,
continue tensioning by intervats f 5 kg/sq. c.m. until the calculated elongation
is reached provided the gauge pressure does not exceed 1.05 times the
specified gauge pressure.
c)
tf the otongation at 1.05 times the specified gauge pressure is less than 0.95
times
the calculated elongation, the following measures must be taken, in
succession, to determine the cause of this lack of discrepancy
i)
ii)
Desension the cable. Slide it in its duct to check that it is not blocked by
446
Section 1800
Prestressing
mortar which has entered through holes in
if free.
iii)
Re establish the modulus of elasticity of steel for the particular lot from an
approved laboratory.
If the required elongation is still not obtained, further finishing operations such
as cutting or sealing, should not be undertaken without the approsal of
the Engineer.
d)
When stressing from one end only, the slip at the end remote from the jack
shall be accurately measured and an appropriate allowance made in the measured
extension at the jacking end.
<<
447
Section 1800
Prestressing
<<
448
Section 1800
Prestressing
In order to remove slack and to lift tendons off the bed floor, an
initial force approved by the Engineer shall be applied to the tendons.
Allowance shall be made for this force in calculating the required
elongation.
Tendons shall be marked for measurement of elongation after the
initial force has been applied. When required by the Engineer, tendons
shall be marked at both the jacking end and dead end of the stressing
bed and at couplers if used so that slip and draw-in may be measured.
Where deflected strands have been specified, the Engineer may
direct the elongation or strain gauge measurements be taken at various
positions along the tendon to determine the force in the tendon at those
positions.
1809,4. Transfer of Prestress
While the process of tensioning can be accomplished by means of
hydraulic jacks, some positive mechanical means shall be provided to
maintain the tension during the entire period between the tensioning
of the wires/strands and transfer of the prestressing force to the concrete
element.
Transfer of prestress shall not proceed until the Engineer has
approved the proposed method. Tendons and deflection devices shall
be released in such a pre-determined order that unacceptable tensile
stresses are not induced in the concrete.
Prior to transfer of the force to the units, all tendons shall be tested
for tightness and any loose tendon shall be reported to the Engineer
who will decide whether the ti1~itsaffected shall be rejected.
The Engineer may require that tendons be marked at each end
of any unit to allow measurement of the pull-in of the concrete.
Tendons shall be released gradually and preferably simultaneously.
Under no circumstances shall tendons be cut while under ten~on.
On completion of the transfer of prestress, the projecting lengths of
tendon shall be cut off flush with the end surface of the unit, unless
otherwise shown, by a method approved by the Engineer.
In no case shall the transfer of prestressing force to the concrete
elements take place before concrete attains the strength specified in the
drawings. To determine the specified strength, additional cube testing
shall be undertaken at the Contractors cost. In case steam curing is
employed, the cubes shall be pLaced in the same environment as the
<<
t49
Section 1800
Prestressing
<<
450
Prestressing
Section 1800
ipt: TRANSPORTATION
N A~12. TOLERANCES
Permissible tolerances for positional deviation of Prestressing tendons
shalt be limited to the following
a)
5 mm
h)
5 mm
c)
5 mm
<<
451
Section 1800
Prestressing
<<
452
Structural Steel
1900
Structural Steel
<<
Structural Steel
Section 1900
1901. DESCRIFFION
<<
455
Section 1900
Structural
Steel
lS:4367 Alloy & tool steel forgings for general industrial use
1903,2.2. Fasteners : Bolts, nuts, washers and rivets shall comply
with the following or relevant IS Standards as appropriate
IS: 1929 Hot forged steel rivets for hot closing (12-36mm dia)
IS:2l55
IS:1363
IS:1364 Hexagon head bolts, screw & nuts product grade A & B
IS: 1367 Technical supply conditions for threaded steel fastener
(Parts 1 to 18)
IS:3640
IS:3757
IS:6623
IS:6639
IS:5624
<<
Structural Steel
Section 1900
IS:7002
IS:5369
IS:5370
IS:5372
IS:5374
ES:6610
IS:6649
1903.4. Paints
All materials for paints and enamels shall conform to the requiremetns specified on the drawings or other special provisions laid down
by the Engineer.
<<
457
Section
1900
Structural Steel
Ordinary i.e. pants based on drying oils, alkyd resin, modified alkyd resin,
Chanical Resistant
before use).
c)
Vinyl
d)
Chlorinaied rubber
e)
Bituminous
1)
Epoxy
g)
Polyurethane
h)
Zinc rich
one pack type (ready for use) and two pack type (mixed
Drying time
Consistency
1904. FABRICATION
1904.1. General
All work shall be in accordance with the drawings and as per
these specifications with care being taken that all parts of an assembly fit accurately together. All members shall carry mark number and
item number and, if required, serial number.
Unless specifically required under the contract, corresponding parts
need not be interchangeable, but the parts shall be match marked as
required under Clause 1904.7.
Templates, jigs and other appliances used for ensuring the accuracy
of the work shall be of mild steel; where specially required, these shall
be bushed with hard steel. All measurements shall be made by means
of steel tape or other device properly calibrated. Where bridge materials
have been used as templates for drilling, these shall be inspected and
passed by the Engineer before they are used in the finished structure.
All structural steel members and parts shall have straight edges and
blunt surfaces. If necessary, they shall be straightened or flattened by
<<
458
Structural
Steel
Section
1900
b)
c)
Sheared edges of plate not more than 16 mm thick with subsequent grinding
th smooth profile, which are for secondary use such as ssiffeners and gussets.
to
smooth edge.
<<
a)
b)
HV30.
c)
d)
e)
Edge is suitably heat treated by approved method to the satisfaction of the Engineer
and shown that cracks had not developed by dye penetrant or magnetic particle
test.
459
Section 1900
f)
Structural Steel
Thickness of plate is less than 40 mm for machine flame cutting for snateriak
confomiing to l&226 and IS:2062, The requirement of hardness below 350 IN
30 of flame cur edges thould be specified by the Engineer.
b)
c)
d)
Edges of ~ingte shaped plates over 25 mm thick not capable of being machined
by ordinary method may be machine flame cut and the and surface ground.
e)
Edges of universal plates or flats of the same nominal width used in tiers may
be left unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12 mm thick and over shall
be machined and those less than 12 mm thick may be sheared and
ground.
The ends of plates and sections forming the main components of
plate girders or of built~upmembers shall be machined, machine flame
cut, sawn or hand flame cut and ground.
Where ends of stiffeners are required to be fitted, they shall be
machined, machine flame cut, sawn, sbeared and ground, or hand flame
cut and ground.
The ends of lacing bar shall be rounded unless otherwise required.
Other edges and ends of mild steel parts may be sheared and any
burrs at edges shall be removed.
1904.3. Preparation of Boles
1904,3.1. Drilling and punching Holes for rivets, black bolts, high.
strength bolts and countersunk bolts/rivets (excluding close tolerance
and turn fined bolts) shall be either punched or drilled. The diameter
460
<<
Structural Steel
Section 1900
<<
461
Structural Steel
TABLE 1900-i
ma of Holes (mm)
12
14
16
18
20
22
24
27
30
33
13.5
15.5
17.5
19.5
21.5
23.5
25.5
29.0
32.0
35.0
1904.3.4. Close tolerance bolts and barrel bolts : Holes for close.
tolerance and turn fitted bolts. The diameter of the holes shall be
equal to the nominal diameter of the bolt shank minus 0.15 mm to
0.0 mm.
The members to be connected with close tolerance or tum fitted
bolts shall be firmly held together by service bolts or clamped and
drilled through all thicknesses in one operation and subsequently
reamed to required size within specified limit of accuracy as specified
in 15:919 tolerance grade H8.
The holes not drilled through all thicknesses at one operation
shall be drilled to smaller size and reamed after assembly.
1904.3.5, Holes for high strength friction grip bolts : All holes
shall be drilled after removal of burrs. Where the number ofplies
in the grip does not exceed three, the diameters of holes shall be 1.6
mm larger than those of bolts and for more than three plies in grip,
the diameters of hole in outer plies shall be as above and dia of holes
in inner plies shall not be less than 1.6 mm and not more than
3.2 mm larger than those in bolts, unless otherwise specified by the
Engineer.
1904.3.6. Removal of burrs : The work shall be taken apart after
drilling and all burrs left by drilling and the sharp edges of all rivet
holes completely removed.
1904.4. Rivet and Riveting
The diameter of rivets shown on the drawings shall be the size
before heating. Each rivet shall be of sufficient length to form a head
of the standard dimensions as given in IS handbook on Steel Sections,
Part I. It shall be free from burrs on the underside of the head.
<<
462
Section 1900
Structural Steel
When countersunk heads are required, the heads shall fill the
countersunk. The included angle of the head shall be as follows
a)
For plates over 14 mm thickness
90 degrees
b)
120 degrees
<<
463
Section 1900
Structural Steel
heads, shall be free from scale, dirt, loose scale, burrs, other foreign
materials and defects that would prevent solid seating of parts.
All loose or burnt rivets and rivets with cracked or badly formed
defective heads or with heads which are unduly eccentric with the shanks,
shall be removed and replaced. In removing rivets, the head shall be
sheared off and the rivet punched out SO as not to injure the adjacent
metal and, if necessary, they shall be drilled out. Recupping or
recaulking shall not be permitted. The parts not completely riveted
in the shop shall be secured by bolts to preventdamage during transport
and handling.
1904.5. Bolts, Nuts and Washers
1904.5.1. Black bolts (black all over) : Black bolts are forged bolts
in which the shanks, heads and nuts do not receive any further treatment
except cutting of screw threads. They shall be true to shape and size
and shall have the standard dimensions as shown on the drawings,
1904.5.2. Close tolerance bolts : Close tolerance bolts shall be faced
under the head and turned on the shank.
1904.5.3. Turned barrel bolts: The diameter of the screwed portion
of turned barrel bolts shall be 1.5 mm smaller than the diameter of
the barrel unless otherwise specified by the Engineer. The diameter of
the bolts as given on the drawing shall be the nominal diameter of
the barrel. The length of the barrel shall be such that it bears fully on
all the parts connected. The threaded portion of each bolt shall project
through the nut by at least one thread. Faces of heads and nuts bearing
on steel work shall be machined.
1904.5.4. High strength friction bolts and bolted connections: The
general requirement shall be as per relevant IS specifications mentioned
in clause 5.3 of (Fasteners) of IRC:24. Unless otherwise specified by
the Engineer, bolted connections of structural joints using high tensile
friction grip bolts shall comply with requirements mentioned in IS:4000.
1904.5.5. Washers : In all cases where the full bearing area of
the bolt is to be developed, the bolt shall be provided with a steel
washer under the nut of sufficient thickness to avoid any threaded portion
of the bolt being within the thickness of the parts bolted together and
to prevent the nut when screwed up, from bearing on the bolt.
For close tolerance or turned barrel bolts, steel washers whose faces
give a true bearing shall be provided under the nut. The washer shall
have a hole diameter not less than 1.5 mm larger than the barrel and
<<
464
Structural Steel
Section 1900
a thickness of not less than 6 mm so that the nut when screwed up,
will not bear on the shoulder of the bolt.
Taper washers with correct angle of taper shall be provided under
all heads and nuts bearing on bevelled surfaces.
Spring washers may be used under nuts to prevent slackening of
the nuts when excessive vibrations occur.
Where the heads or nuts bear on timber, square washers having
a length of each side not less than three times the diameter of bolts
or round washers having a diameter of 3h/~ times the diameter of
bolts and with a thickness not less than one quarter of diameter shall
be provided.
1904.5.6. Studs : Ordinary studs may be used for holding parts
together, the holes in one of the parts being tapped to take the thread
of the stud. Counter-sunk studs may be used for making connections
where the surfaces are required to be clear of all obstruction, such
as protruding heads of bolts or rivets, studs may also be welded on the
steel work in the positions required.
1904.5.7. Service bolts: Service bolts shall have the same clearance
as black bolts and where it is required that there should be no movement
prior to final riveting, sufficient drifts or close tolerance bolts shall be
used to locate the work.
1904.5.8. Tightening bolts: Bolted connection joints with black bolts
and high strength bolts shall be inspected for compliance of codal
requirements.
The Engineer shall observe the installation and tightening of bolts
to ensure that correct tightening procedure is used and shall determine
that all bolts are tightened. Regardless of tightening method used,
tightening of bolts in a joint should commence at the most rigidly fixed
or stiffest point and progress towards the free edges, both in initial
snugging and in final tightening.
The tightness of bolts in connection shall be checked by inspection wrench, which can be torque wrench, power wrench or calibrated
wrench.
Tightness of 10 per cent bolts, but not less than two bolts, selected
at random in each connection shall be checked by applying inspection
torque. If no nut or bolt head is turned by this application, connection
can be accepted as properly tightened, but if any nut or head has turned
all bolts shall be checked and, if necessary, re-tightened.
465
<<
Section 1900
Structural Steel
<<
466
Section 1900
Structural Steel
<<
467
Structural Steel
Section 1900
<<
a)
b)
The peening should be carried out after weld has cooled by light blows from
468
Section 1900
Structural Steel
a power hammer using a round nose tool. Care shall be taken to prevent
scaling or flaking of weld and base metal from over peening.
1904.8.5. Where the Engineer has specified the butt welds are to
be ground flush, the loss of parent metal shall not be greater than
that allowed for minor surface defects. The ends of butt joints shall be
welded so as to provide full throat thickness. This may be done by use
of extension pieces, cross runs or other means approved by the Engineer.
Extension pieces shall be removed after the joint has cooled and the
ends of the weld shall be finished smooth and flush with the faces of
the abutting parts.
The joints and welds listed below are prohibited type, which do
not perform well under cyclic loading.
a)
b)
Groove welds made from one side only without any backing grip
c)
d)
e)
Bevel-grooves and J-grooves in butt joints for other than horizontal position.
f)
One pair of ~run-onand one pair of nm-off plates prepared from same
thickness and profile as the parent metal shall be attached to start and finish
of all butt welds preferably by clamps.
(ii)
When nm-on and run-off plates shall be removed by flame cutting, it should
be rut at more than 3 mm from parent metal and remaining metal shall be
removed by grinding or by an~ other method approved by the Engineer.
<<
469
Section 1900
Structural Steel
The procedural trial for welding the stud shall be carried out when
specified by the Engineer.
1904.9. Tolerances
Tolerances in dimensions of components of fabricated structural steel
work shall be specified on the drawings and shall be subject to the
approval of the Engineer before fabrication. Unless specified, all parts
of an assembly shall fit together accurately within tolerances specified
in Table 1900-2.
A machined bearing surface, where specified by the Engineer,
shall be machined within a deviation of 0.25 mm for surfaces that can
be inscribed within a square of side 05 in.
TABLE 1900.2
FABRICATION TOLERANCES
A.
INDIVIDUAL COMPONENTS
1.
Length
a)
Member with both ends finished for
contact bearing
b) Individual components of members with
end plate conneution
c)
Other members
I)
Upto and including 12 M
ii) Over 12 M
2.
4.
+ 0 mm
-
~3 mm
+0 mm
-3 mm
Depth
Deviation in the depths of solid
web and open web girders
+3 mm
-2 mm
Straightness
a)
Deviation from streighiness of
columns
1)
In elevation
ii)
In plan
1./3000 subject to a
maximsin of 15 mm
where L is length of
member
+5 rum
-0mm
5.
470
<<
2 mm
2mm
3.5mm
Width
Width of built-up girders
b)
3.
1 mm
111000 subject to a
maximum of 10 mm
mm
Section 1900
Structural Steel
6.
0.005 d to a maximum
of 2 mm where d is depth
of the member
7.
0.005 b to a
minimum of 2 mm where b
is width of the member
b)
0.015 b
to a
maximum of 4 mm where
b is width of the member
at other places
8,
111000. where
L is nominal length
of the diagonal
9.
D/500,
10.
D/1000, where D is
as defined in 9 above
11.
D/1000, where D is
as defined in 9
above
12.
1/600 of depth of
member subject to
a maximum of 1.5 mm
where D is
from
the column axis to
the point under
consideration on
the base plate
the distance
1905. ERECTION
1905.1. General
The provisions of this item shall apply to erection of steel bridge
superstructures or main members of bridge superstructures, composed of
steel, which span between supports.
If the sub-structure and the superstructure are built under separate
contracts, the department will provide the substructure, constructed to
correct lines, dimensions and elevations properly finished and will
establish the lines and the elevation required for setting steel.
<<
471
Structural Steel
Section 1900
The Contractor shall erect the structural steel, remove the temporary construction, and do all the work required to complete the
construction included in the contract in accordance with the drawings
and the specifications and to the entire satisfaction of the Engineer.
1905.2. Organisation and Equipment
The Contractor shall submit erection plans prepared by the fabricator,
showing a method and procedure of erection, compatible with the details
of fabrication.
A detailed scheme must be prepared showing stage-wise activities,
with complete drawings and working phase-wise instructions. This should
be based on detailed stage-wise calculation and take into account
specifications and capacity of erection equipment machinery, tools,
tackles to be used and temporary working loads as per Coclal provisions.
The scheme should be based on site conditions e.g. hydrology,
rainfall, flood timings and intensity, soil and sub-soil conditions in the
river bed and banks, maximum water depth, temperature and climatic
conditions and available working space, etc.
The scheme should indicate precisely the type of temporary fasteners to be used as also the minimum percentage of permanent fasteners
to be fitted during the stage erection. The working drawings should
give clearly the temporary jigs, fixtures, clamps, spacer supports, etc.
Unless otherwise provided in the contract, the contractor shall supply
and erect all necessary falsework and staging and shall supply all labour,
tools, erection plant and other materials necessary to carry out the work
complete in all respects.
The Contractor shall supply all rivets, bolts, nuts, washers, etc.
required to complete erection at site with an allowance for wastage,
etc., of 12 1/ per cent of the net number of field rivets, bolts, washers
required, or a minimum of five number of each item.
Service bolts and nuts, ordinary platters, washers and drifts for use
in the erection of work shall be supplied at 60 per cent (45 per cern
bolts and 15 per cent drifts) of the number of field rivets per span
in each size (this includes wastage). A reduction in the quantities of
service bolts, etc., may however, be specified by the Engineer if more
than one span of each type is ordered.
Prior to actual commencement of erection all equipment, machinery,
tools, tackles, ropes, etc. need to be tested to ensure their efficient
-
<<
472
Section 1900
Structural Steel
<<
473
Section 1900
Structural Steel
<<
Structural Steel
Section 1900
<<
475
Section
1900
Structural Steel
<<
476
Structural
Steel
Section 1900
<<
477
Section
1900
Strucunal Steel
<<
Visual Inspection All welds shall be visually inspected, which should cover
all defects of weld such as size, porosity, crack an the weld or in the HAZ
(Heat Affected Zone) etc. Suitable magnifying glass may be used for visual
inspection. A weld shall be acceptable by visual inspection if it shows that
a)
b)
Through fusion exists between weld and base metal and between adjacent
layers of weld metal.
c)
d)
The weld shall be of full cross section, except for the ends of intermittent
fillet welds outside their effeclive length.
e)
When weld is transverse to the primaay stress, undercut shalt not be more
than 025 mm deep in the part that is undercut and shall not be more than
0.5 mm deep when the weld is parallel to the primary stress in the part that
is undercut.
1)
The fillet weld in any single continuous weld shall be permitted to under
nan the nominal fillet weld size specified by 1.6 mm without correction
provided that undersize ponion of the weld does not exceed 10 per cent
of the length of the weld. On the web.to..flange welds on girders, no undernan is permitted at the ends for a length equal to twice the width of the
flange.
g)
The piping porosity in fillet welds shall not exceed one in each 100 mm
of weld length and the maximum diameter shall not exceed 2.4 mm, except
for fillet welds connecting ssiffeners to web where the sum of diameters of
piping porosity shall not exceed 9.5 mm in any 25 mm length of weld and
shall not exceed 19 mm in any 300 man length of weld.
h)
The full penetration groove wetd in butt joints transv~rseto the direction
of computed tensile stress shall have no piping porosity. For all other groove
welds, the piping porosity ~haIi not exceed one in 100 mm of length and
the maximum diameter shall not exceed 2.4 mm.
478
Structural Steel
(ii)
Section 1900
Magnetic Particle and Radiographic Inspection: Welds that are subject to radiographic or magnetic particle testing in addition to visual inspection shall have
no crack.
Magnetic particle test shall be carried out for detection of crack and other
discontinuity in the weld according to IS:5334.
Radiographic test shall be carried out for detection of intemal flaws in the weld
such as crack, piping porosity inclusion, lack of fusion, incomplete penetration,
etc. This test mat be carried out as per 15:1182 and 15:4853.
Acceptance Criteria The weld shall be unacceptable if radiographic or magnetic
particle testing shows any of the type of discontintrities indicated in the code.
(iii) Ultrasonic Inspection : The Ultrasonic testing in addition to visual inspection shall
be carried out for detection of internal flaws in the weld such as cracks, piping
porosity inclusion, lack of fusion, incomplete penetration, etc. Acceptance criteria
shall be as per 15:4260 or any other relevant IS Specification and as agreed
to by the Engineer.
iv)
Liquid Penetration Inspection The liquid penetrant teat shall be carried out for
detection of surface defect in the weld, as per 15:3658, in addition to visual
inspection.
The non-destnjctive testing of following welds be carried out using one of
the method or methods described at (ii),(iii) and (iv) above, as may be agreed
to by the Engineer.
a)
b)
10 per cent of the length of longitudinal and transverse butt welds in tension
flanges.
c)
ci)
<<
479
Structural Steel
Section 1900
<<
481
Section 1900
Structural Steel
b)
<<
482
Structural Steel
Section 1900
Drying time
Flexibility and Adhesion
Consistency
<<
483
Section 1900
Structural
Steel
b)
c)
F1an~ecleaning
ii)
60 micron Total
<<
484
Structural
Steel
Section 1900
Priming Coat
One heavy coat or ready mixed paint, red lead primer conforming
to IS:102
or
One coat of ready mixed zinc chrome primer conforming to IS: 104
followed by one coat of ready mixed red oxide zinc chrome primer
conforming to IS:2074.
or
Two coats of zinc chromates red oxide primer conforming to IS:2074
Finishing Coats
Two cover coats of red oxide paint conforming to IS:123 or any
other approved paint shall be applied over the primer coat. One coat
shall be applied before the fabricated steel work leaves the shop. After
the steel work is erected at site, the second coat shall be given after
touching tip the primer and the cover coats if damaged in transit.
c) Conventional Painting System for areas where corrosion is
severe
Primh~gCoat
Two coats of ready mixed red lead primer conforming to IS:102
or
One coat of ready mixed zinc chrome primer conforming to IS: 104
followed by one coat of zinc chromate conforming oxide primer to
IS:2074.
Finishing Coats :
Two coats of aluminum paint conforming to IS:2339 shall be applied over the primer coat. One coat shall be applied before the
fabricated steel work leaves the shop. After the steel work is erected
at site, the second coat shall be given after touching up the primer and
the cover coats if damaged in transit.
1906.4. Painting in the Shop
All fabricated steel shall be painted in the shops after inspection
and acceptance with at least one priming coat, unless the exposed surfaces
are subsequently to be cleaned at site or are metal coated. No primer
shall be applied to galvanised surfaces.
<<
485
Section
1900
Structural
Steel
<<
Section 1900
Structural Steel
Environment
i)
ii)
iii)
130
iv)
<<
150 pm
487
Section 1900
v)
vi)
Structural Steel
350
ix)
<<
488
Stnsctural Steel
Section 1900
or
1900-4
WEIGHT OF RIVET
Rivet as manufactured
mm
HEADS
12
1.3
14
16
2.1
3.4
18
4.45
20
22
6.1
8.1
24
10.5
27
30
33
15.0
20.5
27.2
The Contractor shall supply detailed calculation sheets for the weight
of the metal in the fabricated structure.
No additions shall be made for the weight of protective coating
or weld fillets.
Where computed weight forms the basis for payment, the weight
shall be calculated for exact cut sizes of members used in the structure,
deductions being made for all cuts, except for rivet holes. Additions
shall be made for the rivet heads as mentioned above.
When specially agreed upon, the basis for payment may be the
bridge weight complete, according to specifications included in special
provisions of the Contract.
1909. RATE
The contract unit rate for the completed structural steel work shall
include the cost of all materials, labour, tools, plant and equipment
required for fabrication, connections, oiling, painting, temporary erection,
inspection, tests and complete final erection as shown on the drawings
and as specified in these Specifications.
<<
489
Bearings
2000
Bearings
<<
Bearings
Section 2000
2001. DESCRIPTION
This work shall consist of furnishing and fixing bearings in position
in accordance with the details shown on the drawings, to the requirements
of these specifications or as directed by the Engineer.
2002. GENERAL
i)
Bearing plates, bars, rockers, assemblies andother expansion orfixed devices shall
be constructed in accordance with the details shown on the drawings.
ii)
The beanngs may either be supplied directly to the Engineer by the manufacturer
to be installed by the Contractor or the Contractor is to supply and install she
bearings as part of the contract. In the former cue, the manufacturer shall be
associated with the installation of the bearings to the full satisfaction of the
Engineer, whereas in the latter case, the Contractor shall be solely responsible
for the satisfactory supply and installation of the bearing, Inthe detailed description
of the specification, a general reference shall be made to the Contractor or
manufacturer and the interpresarion shall be as per terms of contract.
iii)
The Contractor shall exercise the utmost care in setting and fixing all bearings
in their correct positions and ensuring that uniformity is obtained on all bearing
surfaces.
iv)
v)
When bearing assemblies or plates are shown on the drawings to be placed (not
embedded) directly on concrete, the concrete bearing area shall be constructed
slightly above grade (not exceeding 12 miss) and shall be finished by grinding.
vi)
It shall be ensured that the bearings are set truly level and in exact position
as indicated on the drawings so as to have full and even bearing on the
seats. Thin mortar pads (not exceeding 12 miss) may even be made to meet
with this requirement.
vii) It shall be ensured that the bottoms of girders to be rtceived on the bearings
are plane at the locations of these bearings and care shall be taken thatthe bearings
are not displaced while placing the girders.
viii) MS. bearings sliding on M.S. Plates shalt not be permitted. For sliding plate
bearings stainless, steel surface sliding on stainless steel plate with mild steel matrix
shell be used. The other option shall be to provide PTFE surface sliding on
stainless steel.
ix)
Some types of bearings which have been successfully used in various bridges
in India have been covered by these Specifications. For innovative types of
structures or in special cases, special types of bearings to suit the requirements
may have to be provided for which special specifications may be laid down by
the Engineer.
<<
493
Bearings
Section 2000
Railway axles (R 19) are also acceptable as forged steel for rollers.
b)
For the purpose of checking the soundness of cast steel components, castings
shall be ultrasonically examined following procedures as per 15:7666 with
acceptance standard as per IS:9565. The castings may also be checked by any
other accepted method of non..destnsctive testing as specified in 15 1030.
Quality level of castings shall be level 3 as per iS:9565.
All work shall conform strictly to the drawings and shall be in accordance with
the provisions of this section. Care shall he taken to ensure that all parts of an
assembly fit accurately together. The workmanship shall satisfy all relevant
provisions laid down in Section 1900.
b)
Knuckle pins, rolling surfaces of the rollers and bearing surface of the bearing
plates shall be machined and all bolt holes shall be drilled. The whole bearings
shall be fitted and finished as required for good quality machined work to the
satisfaction of the Engineer. However, in case of bearings which are to be groused
or bedded on a suitable yielding material on any surface which is to be in
permanent contact with the grout or the yielding material may be left unmachined.
c)
d)
e)
In prestressed precast girders, where recesses are left on the underside of girders
to receive the anchor bolts, grout holes extending to the beam sides or to the
deck level shall be provided. The cement sand grout shall have a mix of 1:1.
2003.3. Workmanship
<<
a)
h)
c)
Castings shall be tnse to the forms and dimensions shown on the drawings and
shall be free from pouring faults, sponginess, cracks, blow holes and other defects
on position, affecting their appearance or strength. Warped or distorted castings
will not be accepted. Exposed surfaces shall be smooth and dense.
494
Section 2000
Bearings
d)
All castings shall be cleaned by sand or shot blasting to remove sand or scale
and to present a clean uniform surface.
e)
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.
1)
imperfections which are not located in bearing surfaces shall be cleaned out,
filled with weld metal of the appropriate composition and ground flush.
g)
All surfaces of major components like top plates, saddle plates, base plates, rollers
of the bearings shall be machined all over for correct alignment, interchangeability,
proper fitting, etc.
2003.4, Tolerances
Tolerances for its individual components or of the assembled bearings
shall be as shown on the drawings or subject to the approval of the
Engineer.
Unless otherwise specified, the following tolerances shall be maintained
Diameter of Rollers, Knuckle Pins and Bores
Tolerances on diameter of rollers and all convex surfaces shall
conform to K7 of IS:919.
Tolerances on diameter of a]] concave surfaces shall conform to
D8 of IS:919.
Height of Bearings
Tolerances on height of any component casting shall not exceed
+0.5mm. No minus tolerance shall be allowed. The edges of all ribs
shall be parallel throughout their length.
Base Plate
Tolerance on length and width of the base plate shall not exceed
+1.0 mm, tolerance on the thickness of the plate shall not exceed
+0.5 mm. No minus tolerance shall be allowed. All rocking, rolling and
sliding surfaces shall have a machine smooth finish to 20 micron
maximum mean deviation as per IS:3073.
Castings
No minus tolerance shall be allowed in the thickness of any part
of the castings. The edges of all ribs shall be parallel throughout their length.
<<
495
Bearings
Section 2000
Bearings shall be placed in the positions as shown on the drawings with all
bearing surfaces in full contact and to the tolerances as specified.
b)
Roller and rocker bearings shall be placed so that their axles of rotations are
horizontal and nomial to the direction of movement of the members they support.
Upper and lower bearing plates shall be set horizontal in both directions.
c)
During installation the bearings shall be pre.set with respect to the bearing
axis to account for the movement due to the following
d)
i)
ii)
For bridges in gradient, the beanng plates shall be placed in a horizontal plane.
2003.5.2. Placing
<<
a)
b)
c)
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.
d)
All concrete surfaces to be in contact with the mortar shall be thoroughly cleaned
and kept saturated with water for a period not less than 24 hours before placing
mortar and operations are to be carried out when the surface temperatures of
the exposed bearings are the minimum practical.
e)
No ntortar that is more than 30 minutes old after completion of mixing, shall
be used.
f)
After placing and finishing the mortar, the bearing shall be checked for position
and shims or other temporary supports removed and the mortar made good. If
the bearing has moved, it or the plate shall be lifted, the mortar removed and
the whole procedure repeated.
g)
Exposed
days.
h)
Placing of the bearing and mortar shall only be carried out in the presence of
the Engineer.
faces
Section 2000
Bearings
<<
i)
ii)
iii)
a)
b)
c)
d)
The Engineer shall reserve the right to witness such inspection at manu~
facturers works with or without prior permission of the manufacturer, For
this, the beating manufacturer shall have in.plant testing facilities as far
as possible and practicable.
e)
g)
In case the lot size of similar bearings exceeds 12 sets as per the direction
of the Engineer, one extra set of bearings for each 24 sets of beatings
or part thereof, shall be manufactured and the cost of such extra bearings
shall be borne by the user.
h)
The Engineer shall select the extra bearing(s) at random and shall perform
various tests including destructive testing on it at his discretion, either at
the manufacturers works or at any other approved test laboratory, notwith.
standing the test reports submitted.
497
Section 2000
Bearings
i)
j)
k)
(3) above
shall be binding on
<<
Bearings
Section 2000
Copolymer Poly Tr~r*Fluora Ethylene (FIFE) unfitted quality shall have required
properties as per BS:5400 and thickness shall be as specified.
Anchor Bolts shall be as per relevant IS specifications.
<<
499
Bearings
Section 2000
2004.5. Seating of Pin Bearing
i)
Backing plate with studs welded on the face opposite to the seating of manufacture
shill be delivered by the mannfacnner.
ii)
the
iv)
v)
The mund base of the pot (bottom) of the pin beating assembly shall be connected
to the backing pLates by anchor screws after concreting of tier cap/pedestal.
vi)
2.
All bearings shall be load tested to 1.25 limes design vertical load
3.
4.
2.
ALl bearings shalt be load tested (if required, for design horizontal load only)
<<
500
Section 2000
Bearings
60 per cent by its weight. The ash content shall not exceed 5 per cent.
(as per tests conducted in accordance with ASTM D-297, sub-section
10).
EPDM and other similar candidate elastomers for bridge bearing use
shall not be pennitted.
Properties
The elastomer shall comform to the properties specified in Table
2000.1
TABLE 200e.l. PROPERTIES
Propcrtly
UnIt
OF
ELASTOMER
Test Method, IS
spedftcatlcsa
reference
Value of the
cbaracteristk
spedfled
Physical Prupesties
1.1.
12.
1.3.
2.
Hardness
Minimum Tensile
Strength
Minimum Elongation
atbreak
IRHD
IS:3400
60
(Past Ii)
IS:3400
(Pan I)
IS:3400
(Part!)
Mls
Per cent
17
400
Set
Per cent
IS:3400
(PartX)
duration
temperature
(h)
+Oto
(deg C)
1001
35
242
3.
Accelerated Agemg
IS:3400
(Pastry)
duration
(h)
70
CR
3.1
Max change in
3.2.
Hardness
Max change in
temperature
(dcgC)
l00~1
IRHD
Percent
+15
Per cent
-40
.15
Tensile Strength
3.3.
Max change in
Elongation
<<
501
Section 2000
Bearings
Identification of polymers
b)
c)
(tub-section 15)
d)
(sub-section 10)
The Engineer shall invariably get the test (a) performed within his
presence or in the presence of his authorised representative to satisfy
the requirement. In case of any disputes regarding interpretation of results
the Engineer may carry out test as per ASTM S-3452-78 (Chromatography
test) at the manufacturers cost in a recognised test house.
The elastomer specimen to conduct the Lest shall be obtained from
the bearings selected at random for destructive test. Remaining part
of the test bearing shall be preserved by the Engineer for any Lest to
be done in future, if required.
502
<<
Section 2000
Bearings
2005.2. Fabrication
Bearing with steel laminates shall be cast as a single unit in a mould
and vulcanised under heat and pressure.
Casting of elements in separate units and subsequent bonding
shall not be permitted, nor shall cutting from large size cast be permitted.
Bearings of similar size to be used in particular bridge project shall
be produced by identical process and in one lot as far as practicable.
Phased production may only be resorted to when the total number of
bearings is large enough.
The moulds used shall have standard surface finish adequate to
produce bearings free from any surface blemishes.
Steel plates for laminates shall be sand blasted, clean of all mill
scales and shall be free form all contaminants prior to bonding by
vulcanisation. Rusted plates with pitting shall not be used. All edges of
plates shall be rounded.
Spacers used in mould to ensure cover and location of laminates
shall be of maximum size and number practicable. Any hole at surface
or in edge cover shall be filled in subsequently.
Care shall be taken to ensure uniform vulcanising conditions and
homogeneity of elastomer through the surface and body of bearings.
The bearings shall be fabricated with the tolerances specified in
Table 2000-2.
TABLE ~.2
TOLERANCES
TOLERANCES
ITEMS
Overall
-0, + 6 mm
3.
a)
Parallelism
Of top surface of bearing with
respect to the bottom surface as datum
Of one side surface with
respect to the other as datum
Thickness of individual internal
layer of elastomer
Thickness of individual outer layer
Plan dimensions of laminates
Thickness of laminates
Parallelism of laminate with
respect to bearing base as datum
b)
4&
b)
5a.
b)
c)
<<
plan dimensions
2.
-0,
503
5 mm
I in 200
1 in 100
20 per cent (max. of 2 mm)
.0, + 1 mm
-3mrn,+0
Beatings
Section 2000
<<
504
Section 2000
Bearings
ii)
24 bearings
<<
505
Section 2000
Bearings
surface
2.
All bearings of the lot shall be checked for tolerances specified in Table 2DO0~
2.
3.
b)
c)
d)
e)
Low stiffness
Deflection under loads between om=5 MPa and ~m=l 5 MPa shall
be measured and recorded for all bearings with sufficient accuracy (~
5 per cent), Variation in stiffness of any individual bearing from the
mean of the measured values for all such bearings of the lot shall not
be larger than 20 per cent (of the mean value).
Tests on specially moulded test pieces
1.
2.
Test pieces offered for inspection shall be identified by suitable markings and
duly certified by the manufacturer.
3.
<<
506
Section 2000
Bearings
Specific Gravity
0.2
Ash Content
0.5 per cent
Hardness (Table 2000-1 1.1)
Tensile strength (Table 2000-1 1.2)
Elongation at Break (Table 2000-1 1.3)
Compression Set (Table 2000-I 2)
Accelerated Ageing (Table 2000-1 3)
Adhesion Strength (Clause 2005.1)
Note 2.
,
<<
Two bearings thall be selected at random from the lot as test bearings. These
bearings shall be excluded from the lot accepted.
507
Section 2000
2.
Bearings
for
for
for
for
for
determination
detennination
determination
determination
determination
of
of
of
of
of
shear modulus
elastic modulus
shear modulus (short teim loading)
adhesion strength
ultimate compressive strength
agency
with separate or
2.
Acceptance testing on test pieces prepared from the surface or body of the test
bearings instead of specially moulded test pieces.
3.
Acceptance tests not covered by these specifications but according to the specifications laid down by the Engineer.
b)
<<
508
Bearings
Section 2000
<<
509
Section 2000
Bearings
<<
510
Bearings
Section 2000
<<
511
Section 2000
Bearings
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 fined
to the templates with the anchor screws but with MS washers in place of elastomer
washers. The above template assembly shall be fitted in the fomtwork at its
proper location and in a vertical plane.
iii)
After casting of the pedestal and removal of the fonnwork, the template is to
be removed.
The sub-assembly of elastomeric bearing wish the MS backing plate shall be fitted
to the embedded anchors with anchor screws and elastomeric washers replacing
the steel washer.
ii)
A clearance is required between the stainless steel face of the eleazomenc beating
and that of the vertical face of the face plate with stainless steel top installed
on the projection below the soffit. This shalt be achieved by inserting removable
steel sheeting of thickness as per the drawing, during preparation of the formwork
before casting of the superstnremre.
iii)
The face plate with stainless steel top and pack plate shall be assembled with
the anchors with elastomeric washers and anchor screws. The assembly shall
be fined in the formwork at its proper location and in a vertical plane. The
removable steel shims shall be removed at an appropriate time after the casting
of the super-strocture.
<<
i)
Template of 6 mm MS plate and of size same as face pimp with stainless steel
top and matching holes for the anchor screws shall be used. Anchors shall be
fitted to the templates with the anchor screws but with MS washers in place
of elastoiner washers. Separate screws may be used in case of inconvenience
of in the length of original anchor screws. The above template assembly shall
be fitted in the fonnworic for the super-strocture at its proper location and in
a vertical plane.
ii)
512
Section 2000
Bearings
iii)
The face plate with the required thickness of pack plate shall be loosely fitted
to the anchors embedded in the projection below the superstmcture, with elastomer
washers and anchor screws.
iv)
v)
The required clearance between thettainless steel face of the elastosneric bearing
and that of the vertical face plate installed on the projection below the soffit
shall be checked. After adjustment of the required working clearance the small
gap between the vertical face of the prcpection below the soffit and the back
of the face plate (with pack plates, if any) shall be grouted with epoxy grout.
Ru~atlon
Element
Sliding
Element
Generally for
Pot
Pot
None
Vertical Load
Elastomer
Elastomer
None*
Horizontal Buffer
Pot PTFE
Pot
l9?E-SS~
Spherical
Knuckle PiPE
Spherical
Knuckle
PTFE.SS~
Elastoiner PTFE
Elastomer
FT?E-SS~
Transverse Guide
Elastomer SS~
Elastomer
SS.SS
Transverse Guide
**
<<
Horizontal Load
513
Section 2000
Bearings
The surface mating with the FIFE in the sliding pair shall be corrosion resistant
stainless steel, Normally, the stainless steel shall form the upper component.
The stainless steel shall overlap the PTFF after full movement on all sid~.If
stainless steel sheet is used, it should be bonded by continuous welding tong
the edges. Adhesive or any other bonding can be approved by the Engineer. The
surrace shall be prepared by thorough cleaning to remove grease, dust or any
other foreign substance.
ii)
PiPE modular sheets of the sliding pair shall be located by confinement assisted
by bonding. Confined PTFE shall be recessed into the metal backing plate. The
shoulders of the recess shall be sharp and square to restrict the now of PTFE.
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 must slide along the wall and alter its shape according to the angle of tilt
At the same time, it must be sufficiently rigid to bridge the gap between
the piston and the wall of the pot. However, the percentage of plan area of
the lubrication cavities to the gross area shall not exceed 25 per cent. The
depth of the cavity shall not exceed 2.0 mm.
iv)
The diameter to thickness ratio of the confined elastomer shall not exceed 15.
The surface of the confined elastomer shall be smooth.
v)
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 very 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 supersirueturt
viii) The extemal surfaces of the assemblies shall be completely cleaned by sand
blasting. After sand blasting, dust shall be removed from the swface using clean
and dry compressed air or a clean brush after which suitable coating shall be
applied.
ix)
<<
Pot bearings including all parts as shown on the drawings shall be fully shop
assembled at the manufacturers works to ensure proper fitting of all parts.
514
Bearings
Section 2000
2006.3. Materials
a)
b)
Steel
i)
ii)
Cast steel shall conform to Cr 280-520W of 15:1030. 0,3 to 0.5 per cent
copper may be added to increase the corrosion resistance properties.
ii)
PTFE
PTFE (poly tetra fluoro ethylene) shall be of unfilled pure virgin quality. It shall
be free sintered. The mechanical properties of unfilled PiPE shall comply with
Grade A of BS:3784.
c)
Elastomer
ftc
confined
a)
Hardness
50
h)
Mm tensile
strength
MPa
TS:3400 (Part 1)
15.5
c)
Mm elongation at break,)
Max compression set and
Accelerated ageing
following properties
+
<<
515
Section 2000
Bearings
Overall height
-0 to +3 mm
iii)
Height of elastomer
5 per cer~t
iv)
.0 to + I mm
Class 2 of lS:4897
a)
b)
v)
Machined
Unmachined
Flatness
b)
Surface Finish
2006.4.5. Painting
<<
i)
All non-working surfaces shall be coated with two coats of epoxy primer and
one or more coat each of epoxy intermediate and finish, total thickness ~g0.150
p.m or any other painting scheme as approved by the Engineer.
ii)
Silicon
iii)
516
Section 2000
Bearings
2006.5. Test
2006.5,1. Raw materials Necessary test certificates for all
raw materials as in Clause 2006.3 above shall be furnished by
manufacturers. Reference may also be made to Clause 2005.1 for tests
on elastomers.
2006.5.2. Test on casting : Tests specified in IS:1030 shall
be performed. Castings shall
be ultrasonically
tested and
certificates submitted. Quality level of castings shall be level 3 as per
IS:9565.
2006,5.3. Test on welding
All welding shall be tested by
Dye Penetration method. But welding shall be tested by Ultrasonic
method. Soundness of welding shall be certified by the manufacturer.
2006.5.4. Acceptance test on bearing
I)
ii)
iii)
iv)
<<
i)
Care shall be taken during installation of the bearings to permit their correct
functioning in accordance with the design scheme.
ii)
iii)
The load shall be transferred onto the bearings only when the bedding material
has developed sufficient strength. The props for the forrnwork shall only be
removed after lapse of appropriate time. In special cases, this can be ensured by
suitable devices like jacks, etc.
iv)
v)
vi)
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
517
Section 2000
Bearings
a)
h)
c)
d)
e)
ii)
Sliding plates shall be fully supported and care taken to prevent tilting, dis.
placement or distortion of the bearings under the weight of wet concrete.
iii)
Using Template
i)
Template with required rigidity and matching holes corresponding to the base
of the bearing shall he used.
ii)
All the anchors shall be fitted to the tower face of the template using the
anchor screws but with steel washer replacing the elastomer washers,
Separate screws may be used in case of inconvenience in the length of the
original anchor screws.
iii)
The. template assembly shall be located with regard to level and alignment.
It shall be ensured that the sop of the anchors lie in a horizontal plane at
the required elevation. Ihe anchors shall be tied/welded so reinforcements
to avoid displacement during concreting.
is)
s)
vi)
The gap below the bearing assembly shall be grouted with cement based
grout. Reference may be made to Clause 2006.6.1 (vi).
<<
i)
Pockets commensurate with the sizes of the anchors shalt be kept in pedestals
during concreting of the same. The pedestal shall be cast approximately 25
mm shon of the required finished level.
ii)
Anchors shall be fitted to the bearing bettom with elastomer washers and
anchor screws. The bearing assembly shalt be seated in the location on
steel chairs/packs. flat anchors fitted below the bearing shall go into pockets
in the bed block. Level and alignment of the bearing shall he checked. it
shalt be ensured that the bearing sits in a horizontal plane.
518
Bearings
Section 2000
iii)
The gap below the bearing assembly including anchor pockets shall be
grouted with cement based grouL Reference may be made so Clause 2006.6.1
(vi).
<<
519
Section 2000
Bearings
bolts, the cost of all tests prescribed in the specifications and shown on
the drawings.
Where the Department supplies the bearings, the rate for fixing them
shall include the cost of anchor bolts, their fixing, transport of bearings
from the place of supply to the site, handling and placing them in position
as per direction of the Engineer.
<<
520
Open Foundations
2100
Open Foundations
<<
Section 2100
Open Foundations
2101. DESCRIPTION
Sources of Materials
ii)
iii)
iv)
v)
vi)
Equipment details
<<
523
Open Foundations
Section 2100
<<
524
Open Foundations
Section 2100
ii)
iii)
Use of steellconcrese caissons or sheet piling for creating an enclosure for the
foundations, which can subsequently be dawatered,
system or
other methods.
The work shall conform to these Specifications and shall meet the
prescribed standards of acceptance.
No point of the surface of the lean concrete in the case of foundation
on soil or the surface of hard rock in the case of foundation of hard
rock, shalt be higher than the founding level shown on the drawing
or as ordered by the Engineer. Levels of the surface shall be taken
at intervals of not more than 3 metres centre to centre, subject to a
minimum of nine levels on the surface.
<<
525
Section 2100
Open Foundations
2106. TOLERANCES
a)
Variation in dimensions
50mm
b)
15 mm
c)
5 mm
ci)
25mm
10 mm
<<
526
Sub-structure
2200
Sub-structure
<<
Sub- structure
Section 2200.
2201. DESCRIPTION
Sources of Materials
ii)
iii)
iv)
v)
vi)
Equipment details
<<
529
Sub- Structure
Section 2200
<<
530
Section 2200
Sub- structure
to relevant
joint shall
in cantilever
ballast wall.
For gravity type masonry and concrete return and wing wall, the
st face of foundation shall be prepared in the same manner as prescribed
for construction of abutmeni No horizontal construction joint shall be
provided. If shown on drawing or directed by the Engineer, vertical
construction joint may be provided. Vertical expansion gap of 20 mm
shall be provided in return wall/wing wall at every 10 metre intervals
or as directed by the Engineer. Weep holes shall be provided as
prescribed for abutments or as shown on the drawings.
Formwork, reinforcement and concrete in dirt/ballast wall shall
conform to relevant sections of these specifications.
The finish of the surface on the earth side shall be rough while the
front face shall be smooth finished.
Architectural coping for wing wall/return wall in brick masonry shall
conform to section 1300.
2207, TESTS AND STANDARDS OF ACCEPTANCE
The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria.
The work shall conform to these specifications and shall meet the
prescribed standards of acceptance.
2208. TOLERANCES IN CONCRETE ELEMENTS
(a)
+10 mm, -5 mm
10 mm
(c)
10mm
<<
5 snm
(0
5 mm
Bearing areas
3 mm
531
10mm
(e)
Section 2200
Sub- Structure
2209. MEASUREMENTS FOR PAYMENT
2210. RATE
The contract unit rates for masonry, concrete, reinforcement and
weep holes shall include all works as given in respective sections of
these specifications and cover all incidental items for furnishing and
providing substructure as mentioned in this Section.
<<
532
Concrete Superstructure
2300
Concrete Superstructure
<<
Section 2300
Concrete Superstructure
2301.
DESCRIPTION
The work shall cover furnishing and providing of concrete superstructure in accordance with the drawings as per these specifications or
as directed by the Engineer.
2302. MATERIALS
Materials shall conform to Section 1000 of these Specifications.
2303. GENERAL
2303.1. A method statement for construction, indicating the following, shall be submitted by the Contractor for approval of the Engineer,
well in advance of the commencement of the construction of superstructure
i)
Sources of Materials
ii)
iii)
iv)
v)
vi)
2303.2. Dimensions, lines and levels shall be set Out and checked
with respect to permanent reference lines and permanent bench mark so
that the final product is in accordance with the drawings or as directed
by the Engineer.
2303.3. The work shall conform to the following sections besides
stipulations in this section with regard to specific type of construction:
i)
ii)
iii)
iv)
Formwosk
Strel Reinforcement
Structural Concrete
Prestressing
Section
Section
Section
Section
1500
1600
1700
1800
Additionally, some of the common types of superstructure construction shall have features as discussed in this Section.
2304. REINFORCED CONCRETE CONSTRUCTION
2304.1. Solid Slabs
Where adjacent span of slab has already been cast, the expansion
joint and filler board shall be placed abutting the already cast span which
535
<<
Concrete Superstructure
Section 2300
shall form the shutter on that side of the new span to be cast. The
whole of the slab shall be cast with reinforcement embedded for the
road kerb and railings. No other construction joint shall be allowed except
with the express permission of the Engineer.
Where wearing coat is required to be provided, after the deck
slab has been cast, the surface of the slab shall be finished rough,
but true to lines and levels as shown on the drawings, before the
concrete has hardened. The areas of construction joints shall be treated
in the prescribed manner.
The top of the slab shall be covered with clean moist sand as soon
as the top surface has hardened. Curing shall be carried out as per Section
1700.
Where the slab is resting on bearings, the same shall be placed
in position in accordance with the drawings, before casting of deck slab.
2304.2. RCC 1-Beam and Slab
Provision of construction joint shall conform to the drawings or as
per directions of the Engineer. No construction joint shall be provided
between the bottom bulb and the web. If not indicated on the drawing,
construction joint m~aybe provided at the junction of the web and the
fillet between the web and the deck slab with the permission of the
Engineer.
The portions of deck slab near expansion joints shall be cast
alongwith reinforcements and embedments for expansion joints. For this
purpose, the portion of deck slab near expansion joints may be cast
in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true
to lines and levels as shown on the drawings before the concrete
has hardened. Care shall be taken for setting of bearings as indicated
on the drawings.
2305. PRESTRESSED CONCRETE CONSTRUCTION
<<
536
Section 2300
Cuncrete Superstructure
In case of cast-in~~situ
construction, the sequence of construction including side shifting of girders, if applicable, and placing on bearings
shall be in accordance with the drawings.
The PSC girder constituting the top flange, web and the bottom
flange shall be concreted in a single operation without any construction
joint.
The portions of deck slab near expansion joints shall be cast alongwith reinforcements and embedments for expansion joints. For this
purpose, the portion of deck slab near expansion joints may be cast
in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but
true to lines and levels as shown on the drawings before the concrete
has hardened, Care shall be taken for setting of bearings as indicated
on the drawings.
2305.2. Box Girder
Box girders may be simply supported or continuous. Simply
supported box girders shall have minimum construction joints as
approved by! the Engineer. In the case of continuous box girders the
sequence of con~tructionand location of construction joints shall strictly
follow the drawings.
The box section shall be constructed with a maximum of one construction joint located in the web below the fillet between the deck
slab and web. If permitted by the Engineer, one additional construction
joint may be permitted and this construction joint shall be! located
in the web above the fillet between the soffit slab and web.
The portions of deck slab near expansion joints shall be cast
alongwith reinfotcements and embedments for expansion joints. For this
purpose, the portion of deck slab near expansion joints may be cast
in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true
to lines and levels as shown on the drawings before the concrete
has hardened. Care shall be taken for setting of bearings as indicated
on the drawings.
2305.3. Cantilever Construction
Continuity~of untensioned reinforcement from one segment to the
next must be ensured by providing full lap length as necessary.
<<
537
Section 2300
Concrete Superstructure
The design of the superstructure shall take into account the following
aspects which form an integral part of the construction operations
a)
Stability against overturning for each statical condition through which the
assembly passes, shall be checked.
b)
Stresses at each preceding segment joint with the addition of evesy segment or
change of statical conditions shall be checked, The load of equipment as well
as construction live load shall be taken into accotmL
c)
2306. TOLERANCES
2306.1. Precast Concrete Superstructure
Variation in cross-sectional dimensions
a)
b)
c)
5 mm
5 mm
shall not exceed 10mm
or 0.1per cent of the
span length, whichever
is lesser
5 mm
-5 mm to +10 mm
b)
-5
c)
5 mm
d)
e)
mm to +10 mm
<<
538
Concrete Superstructure
Section 2300
<<
2400
Surface and Sub-surface
Geotechnical Exploration
<<
Section 2400
Reconnaissance
ii)
Preliminary Explorations
iii)
Detailed Explorations
2401.2.1. Reconnaissance includes a review of available topographic and geological information, aerial photographs and data from
previous investigations and site examinatiorr.
2401.2.2. Preliminary investigation shall include the study of
existing geological information, previous site reports, geological maps,
air photos, etc. and surface geological examination. For large and
important structures the information may be supplemented by geophysical
methods. In some cases where no previous sub-strata data are available,
exploratory geophysical investigation may need to be supplemented
by resorting to a few bore-holes. These will help to narrow down the
number of sites under consideration and also to locate the most desirable
location for detailed sub-surface investigation like bore or drill holes,
sounding probes, etc.
2401.2.3. The scope of detailed investigation for bridges may be
decided based on data obtained after preliminary investigation. Based on
data obtained after preliminary investigations, the bridge site, type of
<<
543
Section 2400
structure with span arrangement and the location and type of foundations,
shall be tentatively decided. Thereafter, the scope of detailed investigation including the extent of exploration, number of bore-holes,
type of soundings, type of tests, number of tests, etc., shall be decided,
so that adequate data considered to be necessary for the detailed
design and execution, are obtained.
2401.2.4 The width of exploration One purpose of detailed
exploration for high embankments is to ascertain the average shear
strength of each strata. The other purpose is to ascertain the
compressibility of the clayey strata. It is, therefore, necessary that
detailed and well illustrated description of the characteristics of
stratification should be prepared. After the general shape and trend of
the boundaries of the various soil deposits have been determined and
rough assessment of their strength has been made by sUb-surface
sounding, with or without sampling in exploratory boring, the location
of bore-hole(s) for undisturbed sampling shall be decided. At least
one representative undisturbed sample should be collected from each
strata, When the homogeneous strata is very thick, one representative
sample shall be collected for each 3 m thickness of the strata.
2401.3. Soil investigation for foundations shall contain a programme
for boring and retrieval of samples. The field work shall consist of
excavation, drilling of bore-holes for the purposes of collection of
undisturbed and disturbed samples, standard penetration tests, in-situ vane
tests, static and dynamic cone penetration tests, other field tests, as
specified by the Engineer and preparation of bore-logs. Collection and
preservation for testing of disturbed and undisturbed samples from boreholes, borrow pits, etc., as specified by the Engineer shall form a part
of the above. All in-situ tests shall be supplemented by laboratory
investigations. Relevant Indiab Standards such as 15:1498, IS:1888,
IS: 1892, 15:2131, IS:2132, IS:2720, 15:4434 and IS:4968 and Appendix
I of IRC:78, etc., shall be followed for guidance.
2401.4. The soundings by dynamic method shall be carried out
in bore-holes using a standard sampler as specified in IS:2131.
2402. PRELIMINARY INVESTIGATION
2402.1. Foundations
2402.1.1. Preliminary exploration shall be carried out to determine
the soil profile showing the boundaries between the different soil types
and between loose and dense parts in the same type of deposits.
<<
544
Section 2400
<<
545
Section 2400
<<
Section 2400
ii)
the l~cationand extent of soft layers and gas pockets, if any, under the hard
founding strata,
iii)
the geological condition like type of rock, faults, fissures or sabsidence due to
mining, porosity etc.,
iv)
v)
vi)
a)
xi)
ii)
Stmcnue of rock. including bedding planes, fauks, fissures, solution cavities etc.,
v)
Properties of rock m
vi)
<<
547
Section 2400
<<
548
Section 2400
Visual identification for texture, stmctuie, composition, colour and grain size.
ii)
Laboratory tests shall be done for specific gravity, porosity and moisture content.
<<
549
Section 2400
Auger Boring
ii)
W.jh Boring
v)
Rotary Boring
<<
550
Section 2400
Agency
b)
c)
Pit1Bor~-ho1enumber
d)
Reduced
e)
Name of supervisor
g)
It)
i)
j)
Position and ahitude of contaas, faults, strong joint, slidcen sides, etc.
k)
I)
m)
n)
o)
Results of field tests e.g. SPT, in-situ vane shear test etc.
p)
<<
551
Section 2400
Type of Sample
Method of Sampling
Soil
Disturbed
Hand Samples
Auger San~ples
Shdl Samples
~
Undisturbed
Rock
Hand Samples
Tube Samples
Disturbed
Undisturbed
Cores
<<
552
Section 2400
I.
Soil identification,
natural moisture
content tests,
mechanical analysis
and index properties,
WEIGW.1 OP SAMPLE
REQUIRED Kg
Cohesive soils
Sands and
Gravels
chemical tests
2,
Compression testS
3.
Comprehensive
examination of
construction material
and borrow area soil
including soil
Cohesive soils
and sand
Cohesive soils
and sands
Gravelly soil
12.5
25 - 50
50
100
stabilisaticn
2408.2.3, While taking out disturbed soil samples, Standard Penetration Test may also be conducted to find out the bearing capacity
of the sub-soils at specified levels.
2408.3. Undisturbed So Samples
24083.1. The location of the bore-hole shall be as indicated
on the drawing or given by the Engineer.
The depth of the bore-hole shall be as indicated on the drawing
or shall be governed by the criteria given therein or as directed by the
Engineer.
24083,2. Samples shall be obtained in such a manner that their
moisture content and structure do not get altered. This may be ensured
by careful protection and packing and by use of correctly designed
sampler.
2408.3.3. Standard Penetration Test may have to be conducted in
each case to obtain additional data as directed by the Engineer. In soft
clay, in-situ vane shear test as per JS:4434 may have to be conducted.
Where all the three operations have to be carried out in one layer, the
sequence shall be undisturbed soil sampling followed by in-situ vane
shear test, followed by Standard Penetration Test.
2408.3.4. For compression test samples, a core of 40 mm diameter
and about 150 to 200 mm length may be sufficient, but for other
laboratory tests, a core of 100 mm diameter and 300 mm length
<<
553
Section 2400
<<
554
Exploration
Section 2400
Tube number
b)
Job designation
c)
Sample location
d)
Boring number
e)
Sample number
f)
Depth
g)
Penetration
h)
<<
555
_&...
Section 2400
b)
Field tests.
-
c)
Laboratory tests : Sharing strength test - triaxial or box shear test - in case of
the possibility of rise of water table, the tests shall be done on sawrated samples.
b)
Field tests
-
c)
Note
between bed level and upto anticipated maximum scour depth (below H.F+L.)
ii)
iii)
from foundation level to about P4 times the width of the foundation below it.
<<
Section 2400
(a)
During construction
or immediate
post-construction
(b)
Strength
Parameters
do
cuu, ~uU
Shear Test
Type of
Analysis
Unconsolidated undrained
triaxial shear test on
undisthibed samples
and on compacted
embankment material
Total
Unconlined compression
S~
stress
analysis
do
test in laboratory or
(c)
During construction
or immediate
c~
Consolidated undrained
Effective
test with pore-pressure
stress
measurement on as
analysis
compacted soil samples of
embankment materials and on
undisturbed samples
post-construction
2.
C~
557
<<
do
do
Section 24(X)
TEST
TEST METHOI)
I)
15:2720 (Part 4)
IS:2720 (Part 5)
IS:2720 (Part 7)
15:2720 (Part 2)
ii)
iii)
iv)
<<
558
Section 2400
<<
559
2500
River Training Work
and Protection Work
<<
Section 2500
2501
DESCRIPTION
<<
563
Section 2500
<<
Section 2500
Quarry stones are preferable to round boulders as the latter roll off
easily. Angular stones fit into each other better and have good interlocking
characteristics.
Where the required size stones are not economically available,
cement concrete blo~ksin Ml 5 grade conforming to Section 1700 or
stones in wire crates in combination may be iLsed in place of isolated
stones of equivalent weighL Cement concrete blocks will be preferred,
wherever practicable.
25032. Laying Boulder Aproth
The size of stone should conform to clause 5,3,7,2 of IRC:89.
The size of stone shall be as large as possible. In no case any
fragment shall weigh less than 40 kg. The specific gravity of stones
shall be as high as possible and it shall not be less than 2.65.
To ensure regular and orderly disposition of the full intended
quantity of stone in the apron, template cross walls in dry
masonry shall be built about a metre thick and to the full height of the
specified thickness of the apron at intervals of 30 metres aft along the
length and width of the apron. Within these wails, the stone then shall
be hand packed.
The surface on which the apron is to be laid shall be levelled
and prepared for the length and width as shown on the drawings. In
case the surface on which apron is to be laid is below the low water
level, the ground level may be raised upto low water level by dumping
earth and the apron laid thereon. The quantity of stone required in
the apron shall be re-worked out by taking the toe of pitching at higher
level.
2503.3. Laying Wire Crates and Mattresses in the Apron
Wire crates shall be made from hot dipped galvanized mild steel
wi:re of diameter not less than 4 mm in annealed condition having tensile
strength of 300450 ItPa conforming to IS:280. The galvanizing
coating shall be heavy coating for soft condition conforming to 15:4826.
The mesh of the crate shall not be more than 150 mm,
Wire crates for shallow or accessible situations shall be 3 metre x
1.5 metre x 1.25 metre in size. Where these have to be deposited
and there is a chance of overturning, the crate shall be divided into ii
metre compartments by cross netting.
<<
ccc
Section 2.5(X)
can be made
Wire dates built in~-situ, shall not he larger than 7.5 metres x 3
metres x 0.6 metre, nor smaller than 2 metres x 1 metre x 0.3 metre
Sides of
large
crates
shall
be
securely
stayed
at intervals of
Where the crates arc to be bid in deep water and have to be dumped and then
joined together.
ti)
Where depth of water is tow or dry bed is avaitabte, tn such cases, the crates
can be laid at site.
<<
Protection Work
Section 2500
may be. protected against ordinary wave splashing by 0.3M.6 metre thick
cover of clayey or silty earth and turfed.
2504.2. Pitching/Filter media
2504.2.1. Pitching : The pitching shall be provided as indicated in
the drawings. The thickness and the shape of stone pitching shall he
shown on the drawing.
The stone shall be sound, hard, durable and fairly regular in shape.
Quarry stone should be used. Round ho ulders shall not he. allowed. The
stone.s subje.ct to marked deterioration by water or weather shall not he
accepted.
Thes ize and weight of stone shall conform to clause 5.3.5.1 of
l.R,C:89. No stone, weighing les~sthan 40 kg shall, however, he used.
The s. izes of spalis ,sha,I I be a minimum of 25 mm and shall he suitable
to fill the. voids in the pitching.
Where. t.he required size stones are not economically available.,
cement concrete blocks in MIS grade conforming to Section 17(X) or
stone.s in.wire crates may be used in place of isolated stones of equivalent
weight. Cement concrete blocks will be preferred wherever practicable..
Use of geosynthetics has been dealt with in Section 700.
2504,2.2, Filter media : lhe material for the filter shall consist of
s.and, gravel, stone or coarse sand. To prevent escape of the embankment
material through the voids of the stone pitching / cement concrete blocks
as well as to allow free movement of water without creating any uplift
head on the pitching, one or more layers of graded materials, commonly
known as a filter medium, shall be provided underneath the pitching.
The gradation of the filter material shall satisfy the following re~
quircme.nts
Provision of a suitably designed filter is necessary under the slope
pitching to prevent the escape of underlying embanktnent material
through the. voids of stone pitching/cement concrete blocks when suh~
jected to the attack of flowing water and wave action, etc. In order
to achieve, this requiretnent, the filter may be provided in one or more
layers satisfying the following criteria
D 15 (Filter)
<5
D 85 (Base)
(Filter) < 20
D 15 (Base)
<<
567
Section 25(X)
D 50 (Filter)
<25
D 50 (Base)
Notes
I.
2.
tn the foregoing, 0 15 means the size of that sieve which attows 15 per
cent by weight of the fitter materiat to pass through it and simitar is
the meaning of t) 50 and 1. 85.
3.
tf more than one fitter tayer is required, the same requirement as atxsve
shalt be fottowed for each tayer. The finer fitter shatt be considered as
tsase materiat for selection of coarser fitter.
4.
<<
568
Section 2500
are minimum by packing with spalls, wherever necessary, and the top
surface is as smooth as possible.
When full depth of pitching can be formed with a single stone,
the stones shall be laid breaking joints and all interstices between
adjncent stones shall be filled in with spalis of the proper size and
wedged in with hammers to ensure tight packing..
When two or more layers of stones must be laid to obtain the
design thickness of pitching, dry masonry shall be use.d and stone.s
shall he well bonded. To ensure regular and orderly disposition
of the full intended quantity of stone as shown, template cross walls
in dry masonry shall be built about a metre wide and. to the full
he.ight of the specified thickness at suitable intervals and all along
the length and width of. the pitching. Within these walls the stones:
shall he hand packed us specified.
2504.4. Toe Protection
.
<<
569
.Sc.ctiots 250t)
The soit at the founding tevct is property compacted to tnie tines and level so
as to have an even bedding..
c)
<<
570
&.
Protection Work
Section 2500
the work shall conform to these Specificatkns and shall meet the
p~e.serihed standards of acceptance.
2509. MEASUREMENTS FOR PAYMENT
The protection
if
<<
Section 2500
River Training
dressing of the bed, Excavation beyond this depth shall be paid for
separately unless otherwise specified.
The contract unit rate for one ctibic metre of filter or sto.e/cement
concrete block pitching on slopes shall include the cost of preparing
the b:ases, putting to the profiles, laying and compacting the filter
and s.tone pitching of dry rubble/cement concrete block rivetment for
embankment slopes to the specified thickness, lines, curves, slopes and
ieve.is and all labour and materials as well as tools and plant required
for the work,
The contract unit rate for rubble stone/cement concrete b~ock
flooring shall include the cost of all material, labour and tools and plant
for completing the work as per these specifications.
<<
Expansion Joints
2600
Expansion Joints
<<
Expansion Joints
Section 2690
260!. DESCRIPTiON
h)
c)
The expansion ~omu shalt be designed and duty got approved try the Engineer.
It ehalI cater for expected movement and rotation of the ssmcture at the
~
and provide smooth riding surface, It shatt atso be easy for inspection,
snaintcnance and replacement.
hxpans~ossjoints shalt be robust, durabte, water~might and reptaceable. Site
fabricated expansion joints shall be prohibited. Expansion joints shatt be obtained
by the Engineer either directly or through the Contractor from approved
manufacturers and beof proven type.
For bridges with prestreesed concrete superstructure, with individual span length
snore than 2.0 m or built with innovative designfeonstruceion etastomeric e spansion
joints of slab seat or strip seat type shatt be provided..
Foe slab type of bridges of spans less than tO metres continuous surfacing
may tat provided across the expansion gaps, suppo:rted on a 20 mm thick plate
placed and fised at the level of the deck stab,
c)
1)
i
For brid,gcs other than ttsose ntentioned in (c) abeve with spares atseve 1
an alternative specification of stiding steet plate joint or filled joints with copper
plates may at so he adopted if approveat by the Engineer, apan 1mm elastosneric
expansion joint of stab seal or strip seat type.
Vctticular traffic shatt not he allowed over expansion joints after its constmc.tion
for such period as may be detemsirsed by the Engineer.
Proprietary type deck joints offered by the Contractor in tieu of the type speciliect
shall cossepty irs alt respects with the manufacturers specifications and meet
the required range of movements and rotations and be fit for the purpose of
ensur.ing satisfactory long tersrs performance its the bridge.
ii)
Dimensions and general details of mite joint including material tpeci fication.s,
ltotding down belt or anchorage details and instttation procedures.
iii)
575
<<
Expansion Joints
Section 2600
<<
a)
Withstand the imposesi toad inclusling the impact load frotn live toami anti other
sources.
h)
c)
Permit relative rotation in elevation and plan due to the causes as noted akove,
d)
Be waterproof. Bridge deck expansion joint seals play a critical role in preventing
the degradation of the stmctsaral components of the bridge system. Without
effective joint seals, water passes through the bridge deck and works harmfully
to corrode steel components and cause deterioration of the concrete. Rain water
gathers various corroding additives from the atmosphere and also from the
carriageway.
e)
Ensure seating. In case bridge deck joints are not seafed, apart from tots of
waterproofing, grit and other forms of road debria may enter the joint Debris,
when unpacted with the joint can seriously restrict the moventent instead of
facilitating the same, In the case of proprietary joint.s being accepted for
adoption, the sealing shall be as specified by them,
I)
g)
Be easy so install,
h)
i)
Be resistant to the materialt likely to collect/spill over the deck in its normal
service.
576
Expansion Joints
Section 2600
Provide smooth continuity at the top of the deck for riding comfort,
5)
c)
d)
e)
Ensure that animal paws and hooves should not gee entangled where bridges are
used by animal drawn traffic,
t)
g)
Permit transfer of generated forces without distress, i.e,, without getting uprooted.
The puwoae will not be served if the bonding is with the wearing coat only.
Anchorage must he provided with the deck atnicwral element,
b)
Ensure that surface in the transition zone stays undisturbed during long term
service,
<<
a)
In this type of buried joint, the wearing coat shall be made continuous over the
joint. The other altemative shall be to keep a gap in the wearing coat which
is filled up with a seal and filler, to be provided in extremely hot areas,
b)
Materials for steel plates shall conform to Section 1900. The exposed metallic
components ~hall be galvanised or coated with approved anti-corrosive painL The
thickness shall be 20 mm or so for obtaining satiafactory perfonnance.
c)
Plates shall be placed to the line, grade and expansion gap shewrs on the drawings
with any adjustment required for temperature, particular care being taken ~ith
the top of the plates.
d)
e)
Any temporary bolts or other fixings which prevent relative movement of the
adjacent pasts of the joint shall be removed as soon as the concrete has set
sufficiently so hold the expansion plates in their correct positions. In any case,
temporary bolts or other fittings shall be removed within 6 hours of placing
concrete unless otherwise directed by the Engineer.
Care shall be taken to prevent damage to expansion joint plates or its coating.
g)
if any damage occurs, the plates and coatings shall he restored by the Contractor
to the satisfaction of the Engineer.
h)
Plates shall be free ofoil, nan, loose paint or other similar material before coating.
577
Section 26(X)
Expansion Joints
2605,
FILLER JOINTS
a)
The components of this type of joint shall be at least 2 rem thick corrugated
copper plate placed slightly below the wearing coat, 20 mm thick compressible
fibre board to protect she edges, 20 mm thick pre-moulded joins filler filling the
gap upto the top level of the wearing coat, sealed with a joint sealing compound.
h)
The material used for filling expansion joins shall be bitumen impregnated felt.
elastotner or any other suitable material, as specified on the drawings.! impregnated
felt shall conform to the requirements of iS~1838, and shall be got approved
front the Engineer. The joint filler shall consist of large pieces and assembly of
small pieces to make up the required size shall be avoided,
c)
Expansion joins mttteriais shall be handled with care and stored under cover
by the Contractor to prevent damage.
d)
Any damage occurring after delivery shall be made good to the satisfaction of
the Engineer and at the expente of the Contractor.
e)
f)
Pte.mnoulded expansion joint filler shalt not be placed in position until immediately
prior to the placing of the abtrtting material. If the two adjacent surfaces of
the joint are to be placed at different times, this type of joint filler shall not
be placed until the second face is about so be placed.
g)
recommen-
h~i Sealants shall be finished approximately 3 runt below the upp.r surfaces of the
!joint.
i)
Joint materials spilt or splashed oito finished surfaces of the bridge during joint
filling operations shall be removed and the surfaces made good so the Engineers
approval.
No joins shall be sealed until inspected by the Engineer and approval is given
to proceed wish the work,
<<
a)
Steel inserts shall conform to IS ~226.Use of any other materials like fibre-glass
or similar material shall not he permitted.
b)
Elastomer for elastosnerie slab unit (11513) shall conform to clause 915.1 of
IRC:83 (Part Ii), compounded to give hardness IRIID 60 ~5, subject to the
following additional stipulations
i)
Chloroprene (CR) only shall be used in the manufacture of elastomeric expansion joints. No reclaimed/natural rubber or vulcsnised wastes shall be
used.
ii)
578
Expansion Jotnts
Section 2600
iii)
Chioroprene content of the compound shall tsot be lower than 6111 per cent
by weighs. The ash content shall not exceed 5 pr cent (as per tests cortducsed
in accordance with ASTM D.297 fin (1) and (ii) above.
iv)
EPDM, and other similar candidate etastoroers for etpansion joints shall
not be permitted.
c)
Elastomeric plugs.
d)
e)
11)
Anchor bars comprising hooked anchor stiffenert welded !with lower steel inserts
and sinusoidal anchor bars welded with horizontal leg of the edge steel inserts!,
ihe elaborate anchoring arrangements of steel inserts shall be pennanently welded]
tied witlt the steel reinforcetnenL
to
2606.2. Fabricatkyn
a)
Steel inserts shall be grit blasted and provided with epoxy paint.
b)
c)
Expansion joints shalt be fully moulded to the required size in one single
vulcanising operation including the encasing layers! ~t integral and homogeneous
part
st)
Plan dimension
.>
ii)
Total height
3 mm
->
5 mm
ii)
Expansion joins material shall be handled wish care and stored under cover by
the Consractor to prevent damage. Any damage occurring after delivery shall
be made good at site expense of the Contractor so the satisfaction of the Iin!gineer.
2606.4. Installation
<<
Steel inserts
i)
Deck casting shall be done leaving pockets or recess For steel inserts
and anchors of the expansion joint as per drawing.
ii)
Steel insetis shall be towered as the appropriate locasion inside !the pocket.
iii)
The sop of the inseti shall be flush with the finished level of wearing course
maintaining the camber,
iv)
579
Section 2600
b)
v)
Anchor rods shall be tied/welded with the existing deck main reinforcement,
mainsaining level and alignment
vi)
Spacer Bar
i)
Spacer bars shalt be used to ensure proper positioning of bolts and also
levelling of the steel inserts during fixing of the same with the deck
reinforeemens and catting second stage concreting in the pocket thereafter,
ii)
iii)
c)
d)
<<
Expansion Joints
a)
h)
While removing the spacer bar after concreting, one must take care so see
that the concrete is not datnaged during withdrawal of spacer bar. If the
spacer bar happens to be snugly fisted, it shall not be pulled by any means;
it shall he gas cut in two pieces and then removed.
Concreting of Pocket
i)
Concreting of pocket shall be done with greas care using proper mix
conforming so grade similar to that of the deck casting besides ensuring
efficient bonding besween deck and steel insert. Also proper r.are shalt be
given for ensuring efficient bonding with the already cast concrete.
ii)
Needle vibrasors shall be used. Care shall be saken so thas the position of
steel insert is not disturbed during vibration.
iii)
Spacer bar shall he resnoved within an appropriate time before the joint
is required to pennis nsovenaent
ii)
ESU
580
Section 2600
Expansion Joints
iii)
iv)
v)
vi)
ESU shall he tightened with stainless steel nuts and lock washers in
position. Tightened nuts shall be locked with lock washers,
vi)
vii) The etastotneric plugs shall be pressed in position after applying adhesive
on the appropriate surface.
viii) ESU shall he fined in position after completion of wearing course. While
completing this part of the wearing course, adequate care shall be taken to
ensure a waterproof joining with she already existing wearing course.
e)
[re-Setting
i)
The main purpose of presetting of the steel insens as the time nf its
installation is to ensure as closely as possible the condition that in the
long nsn as the mean average annusl temperature, the ESU remains at
its nominal stare.
a)
b)
Changes due
c)
d)
to
shrinkage of concrete~
Resultant changes in expansion gap due to first factor can occur in both
directions from any pre-selected mean position whereas changes due to
creep and shrinkage are unidirectional
such that the expansion
gap continuously increases with passage of time,
<<
i)
ii)
581
and fixing of
Section 261X1
Expansion Joints
[nor to csnistnction of bridge deck area adjacent to the joint, the supplier
shall provide detailed working drawings showing the location of all bolts, recesses
and holes necessary for the installation of the joint. Reinforcing bars in
.supenstntcsume shall be amended as required to ensure that there will be no
interference in the installation of she joint.
ii)
All bearing surfaces and recesses which are in contact with the joint assembly
shall he checkesl with a straight edge to ensure flatness of profile.
ins)
No boles shall he sIn lIed for firing bolts within 7 days of concreting Holes for
the bolts shall he drilled to the size and depth shown on the drawitigs
iv)
s)
lhe. fi sing, hulLs shall not lxi placed in a position sntil at least 4 weeks after
stressing is completed in pose-tensioned box or beam and slab stmctures.
Prior to placing sections of joinsing, contact surfaces shall he cleaned to remove
all grease, tar, paint, oil, mud or any other foreign material that may affcos
adhesion of the sealant.
ci)
Sealsnt shall only he applied to dry contact surfaces. Sufficient sealant shall he
applied to the contact surfaces so cause extrusion of sealant when the jointing
is fised in position.
vii)
joint
sin) Bolt cavities shall he cleaned and plugged wish neoprene cavity plugs Prior
to placing the plugs sufficient sealant shall he placed in the cavities to cause
extrusion of the sealant by the plugs.
ix)
All
escess sealant shall be removed from the jointing and adjacent areas.
<<
582
Section 2600
Expansion Joints
Routine test.. Each expansion joint shall be tested for at least 100 cycles for
a teas movesnent which shall be 10 per cent more than the design expansion)
contradion mowesnent.
ii)
In addition to routine test, one out of every 20 expansion joints shall he subjected
to the teat movement for 40(X) cycles.
The. lot shalt be rejected if the elastomer material shows signs of fatigue or
pesananent set or distress in the teat. The test piece shall not be used in the
bridge.
iii)
The type test for abrasion resistance shall be carried out for one joint out of
every 20 not. as per 15:34(X) (Part 3) and the standard deviation shall be within
20 per cent
Edge beams This special claw leg profiled member shall be of extruded roiled
steel section combining good weldability with notch toughness.
b)
Strip seal
This shall be of dhloroprene with high tear strength, insensitive
to oil, gasoline, and ozone. It shall have high resistance to aging. This component,
provided to ensure water tightness, shalt have bulbous shape of the pan of the
seal which is inserted into the groove, provided in the edge beam, The seal shotsld
be vulc.anised in single operation for minimum full length of joint..
c)
Rigid Anchorage - This shall be welded to the edge beam at staggered distance,.
toops - This shall be made of weldable steel connecting the rigid
Anchor
anchorage
with deck reinforcement.
ct)
2607,2. Material
<<
a)
Edge beams of this special section are at present being directly imported
in India. The steel shall conform to steel grade Rst 37-2 of German Standard
or eqtaivalenL
h)
Chloroprene of strip seal shalt conform to clause 915.1 of D.C:83 (Past Ii). The
propertiea of chtoroprene ahait conform to Table 26OO~i.
c)
d)
583
Section 2600
Expansion Joints
SPECIFIED VALUE
Hardness
63 5 Shore A
Tensile Strength
Mm
Ii MPa
Elongation at fracture
Mm
350 per
Mm
Mm
Mm
Mm
10 N/rnnt
10 N/mm
25 per cent
3
220 mm
cent
Max 5Shore A
Max -20 per cent
Max -20 per cent
No cntcks
<<
a)
Rolled steel profiles for edge beams shall be long enough so cater for a 2-lane
carriageway. These shall be cut to size of actssal requirements by means of a
mitre box saw~Alignment of the cut-to-size steel profiles shall then be made in
accordance with the actual bridge cross~sectionon work tables. For this purpose,
the contour of bridge cross-section shall be sketched onto these tables. After
the steel profiles are aligned, they will be chucked to the tables by means of
screw clamps and tacked by arc welding.
h)
c)
Anchor loops shall be bent to the required shape and welded to anchor plates!!
d)
The finally assembled joints shall then be clamped and transported to the work
site.
584
Section 2600
Expansion Joints
For transportation and storage, auxiliary brackets shall be provided to hold the
joint assembly together.
h)
the
supply of
either
to incltading
the Ergmeer
to the
Bridgemanufacturer
Contractor allshall
the materials
stripdirectly
seal joints
sealantsor and
all
other accessories for the effective installation of the jointing.
c)
Expansion joint, material shall be handled with care. It shall be stored under
cover on suitable lumber padding by the Contractor to prevent damage. Any
damage occurring after delivery shall be made good at the Bridge Contractors
expense to the satisfaction of the Engineer.
2607.5. Installation
26073.1. The width of the gap to cater for movement due to thermal
effect, prestress, shrinkage and creep, superstructure deformations (if
any) and sub-structure deformations (if any) shall he determined and
intimated to the manufacturer. Depending upon the temperature at wttich
the joint is likely to be installed, the gap dimension shall be preset.
26073.2. Taking the width of gap for movement of the joint into
account, the dimensions of the recess in the decking shall be established
in accordance with the drawings or design data of the manufacturer.
The surfaces of the recess shall he thoroughly cleaned and all dirt
and debris removed. The exposed reinforcement shall be suitably
adjusted to permit unobstructed lowering of the joint into the recess.
2607,5.3. The recess shall be shuttered in such a way that
dimensions in the joint drawing are maintained, The formwork shall
he tight.
2607,5.4, Immediately prior to placing the joint, the presetting shall
be inspected. Should the actual temperature of the structure be different
from the temperature provided for presetting, correction of the presetling
shall be done. After adjustment, the brackets shall be tightened again.
2607.5.5. The joint shall be lowered in a pre-determined position.
Following placement of the joint in the prepared recess, the joint
shall be levelled and finally aligned and the anchor loops on one side
of the joint welded to the exposed reinforcement bars of the structure.
Upon completion, the same procedure shall be followed for the other
side of the joint. With the expansion joint finally held at both sides,
the auxiliary brackets shall be released, allowing the joint to take up
the movement of the structure.
2607,5.6. High quality concrete shall then be filled into the recess.
The packing concrete must feature low shrinkage and have the same
<<
585
Section 2600
Expansion Joints
slrengl.h as that of the superstrnctnre, hut in any case not less than M
35 grade. (kxxl compaction and earefttl curing of concrete is particularly
irnportanl.. After the cnncrete has cured, the movable installation brackets
slill in place shall be removed.
2.607,5,7, Rolled up neoprene strip seal shall he cut into the required
length and inserted between the edge beams by using a crow bar pttshing
the bulb of the seal into the steel grooves of the edge beams. A landing
to a bead shall he formed in the thickened end of the edges of the
seal which would force the thickened end against the steel beam due
to wedge effect when the strip seal is buttoned in place.
26073.8. As soon as the concrete in the recess has become inttially
sel., a sturdy ramp shall be placed over the joint to protect the exp..sed
steel beams and neoprene seals from site traffic. Expansion joint shall
not he expose.d to traffic loading before the carriageway surfacing, is
placed.
26073.9. The carriageway surfacing shall he finished flush with the
top of the steel sections. The actual junction of the surfacing/wearing
coat with the steel edge section shall be formed by a wedge shaped
joint with a sealing compound. The horizontal leg of the edge beam shall
he cleaned beforehand. It is particularly important to ensure thorough
and careful compaction of the surfacing in order to prevent any
pretnature depression forming in it,
Acceptance Test
<<
i)
ii)
For neoprene seal, the acceptance test shall conform to the requirements stipulated
srs Table 2600-1. It shall also be stretch tested, If a manufac.tnrer ia to supply
this type ofjoint, they will have to produce a test certificate accordingly conducted
in a recognised laboratory in India or abroad.
iii)
iv)
The manufacturer shall produce test certificates indicating that anchorage system
had beers seated in a recognised laboratory to detennine optimum configuraSn of anchorage assembty under dynamic loading.
s)
lhe manufacturer shall satisfy the Engineer that water tightness test for
the type of joint has been carried out in a recognired laboratory so check the
water tightness under a water pressure of 4 bars.
vi)
586
Expansion joLrtt.~
ty ~ the
Section 2600
manufacturer
2608.
2609.
<<
587
2700
Wearing Coat and
Appurtenances
<<
Section 2700
2701. DESCRIPTION
lhis work shall include wearing coat and bridge appurtenances.
such as railing, approach slab, drainage spouts, weep holes in
conformity with details shown on the drawing and these peciftcations or as approved by the Engineer.
2702. WEARING COAT
2702.1. Bituminous Wearing Coat
Specifications for bituminous concrete/bitumen mastic in wearing
coat shall conform to Section 500 except for the special require.mnents as stated hereinafter.
.2702.1.1. Principles of bituminous wearing coat shall comprise.
the. following
i)
A layer of mastic asphalt, 6 mm thick after applying a prime coat over the
top of the deck before the wearing coat is laid. The prime coat and the layer
of mastic asphalt shalt be laid as per Clauses 503 and 515 respectively.
ii)
of 25 rum each as
<<
591
Section 2700
The cross slope in the deck shall be. kept as 2.5 per cent for
decks, level in longitudinal profile.
2702.3. For providing cross camber no variation in thickness of
wearing coat shall be permitted.
2703. RAILINGS
2703.1. General
a)
Bridge railing includes the portion of the structure erected on and above
the kerb for the protection of pedestrians and traffic.
h)
Railings shall not be cortstnicted until the centering falsewonlc for the
span has been released and the span is self-supporting. For concrete with steel
re:inforcenient, specifications of the items ofcontrolled concrete and reinforcement
mentioned under relevant sections of this specifications shall be applicable.
c)
The type of railing shall be carefully erected true to line and grade. Posts shall
be vertical with a tolerance not to exceed 6 mm in 3 metres. The pockets left
for posts shall be filled up with non-shrinkable mortar
d)
e)
g)
<<
592
Section 2700
<<
593
Section 2700
l)s am tv&
don g km ~ ludt n il cIt ftt tson shall lx
n suet ci by
.suUicicnt number of drainage fixtures embedded in the deck slab, The
spouts shall he of not Ie.s.s than 100 mm in diameter and shall he of
corrosive resistant material such as galvanise.d steel with suitable. cleanout fi,x owes. The spacing of drainage spouts shall not exceed 10 m.
the. discharge from drainage s-pout shall he kept away from the deck
structure, In case. of viaduco in urban areas, the drainage spouts should
be connected with suitably located pipelines to clischarge the surface
run -off to drains provided at ground level.
2705.2. Fabrication
The. drainage assemh]y shall be fabricated 1.0 the dimensions shown
on the drawings; all rn ateri ~Js shall he corrosion resistant; stee
components shall he. of mild stee conforming to IS:226, The drairtage.
asse.mhly shall be. seam welded for uate.r tightness and then hofidip
galvanised.
2705.3. Placement
The galvanised assembly shall be given two coats
painting befOre placenient. The whole assembly shall he
position, lines and. levels as shown in the drawing
cut-out i.n the shuttering for deck slab and held in
Where the reinforcements of the deck are required to be
of bituminous
placed in true
wit.h.oece.s.sary
place Firmly.
cut, equivalent.
reinforcements shall be placed at the corners of the assembly.
2705.4. Finishing
Aflersetling
cr.acks
or bituminous sealant as pe.r IS: 1834 and the excess sealant trimmed
to receive the wearing coat. After the wearing coat is completed, similar
<<
594
.1] 1115.
Section l7tX)
on the wearing
concrcte(retnli.irced
is I
Asphalt Ic
in cubic metres.
2709. RATE
The contract tinit rate for wearing coat shall include the cost of all
labour, material, tools and plant and other cost necessary for completion
of the work as per these Specifications.
Ihe contract unit rate of railings shall include the cost of all labour,
<<
595
Section 2700
material, tools and plant required for completing the work as per these
Specifications..
the contract unit rate for approach slab shall include the cost ol
all labour, tnate.rial, tools and plant required for completing the work
as per these Specifications. The rate for base shall include cost of
all labour, material, tools and plant required, including preparation of
surface and consolidation complete in all respects.
the contract unit rate for each drainage spout. shall include the cosl
of all labour, material, tools and plant required for completing
the,: work as per these Specifications. It shall also include the cost of
providing flow drain pipes with all fixtures upto the point of ground drains
wherever shown on the drawings.
The contract unit rate for weep hole shall include the cost of
all labour, material, tools and plant required for completing the work
as per these Specifications.
<<
596
Repair ofStructures
2800
Repair of Structures
<<
Repair of Structures
Section 2800
2801. DESCRIPTiON
Repair of structures shall be carried out in accordance with the repair
plans and these specifications or as directed by the Engineer. Where
repair work is not covered by these specifications, special specifica~
tion may he framed.
Implementation of repair schenes shall also conform to provisions
of IRC:SP:40.
2802. GENERAL
2802.1, Environmental Aspect
Care shall be taken to ensure suitable mitigation measures against
noise and dust, pollution and damages to the environs whether temporary
or permanent and shall be taken as incidental to work.
2802,2. Phasing
The sequence of work shall be in accordance with the drawings or
as directed by the F.~~ngineer.
2802.3. Traffic Management
Traffic management, signage, signalling arrangement, barricading,
and lighting arrangement shall be in accordance with Section 100 and
with t.hese specifications and shall be considered as incidentals to work.
2802.4. Safety Precautions
Adequate precautions shall be taken for safety .of personnel, road
users and existing services, which, during execution, shall be considered
as incidentals to work.
Persons working should wear safety helmets and rubber gloves.
2802,5, Dismantling and Removal of Material
t)is.mantling of any bridge component and removal of materials
shall conform to Section 200 and this section and as shown on the
drawings or as directed by the Engineer.
2803. SEALING OF CRACKS BY INJECTION
OF EPOXY RESIN
2803,1. General
The work of epoxy adhesive utilising the Structural Concrete Bonding
Process shall conform to these specifications.
599
<<
Repair of Structures
Section 2800
2803.2. The Contractor shall furnish detailed methodology of constntction including sotirces of supply of material, tools, equipment and
appliances to be used on work, details of personnel and supervision.
2803.3. Personnel
The Contractors personnel shall be qualified and experienced in
epoxy injection process.
2803.4. Material
The mixing ratio of resin and hardener shall generally be between I to I and
2 to I by volume subject to manuracturers recommendation.
Neither the mixed epoxy adhesives nor their individual components shall contain
solvents and thinners,
iii) The
iv)
Consistency requiremeni
Standard
VersIon
cpa
Low Viscosity
Version
cpa
(200-300)
(t0O-t90)
1 hour 15minutes
<<
600
Repair of Stnictures
Section
2800
<<
601
Section 28(X)
Repair of Structures
exceeds 2 litres for a particular entry port, the work shall be stopped
t.Jntess otherwise. specified, components A and B, i.e., resin and hardener, shall
be at a temperature between tO degrees Celsius and 35 degrees Celsius at the
time of mixing.
is)
c.)
d)
Any heating of the adhesive components shall he. done by application of instirect
heat in case the work is to he done in cold climate,
c)
Just before use, the two components shall be thoroughly mixed in. the ratios
specified by the manufacturer, The length of mixing time shall he in strict
accordance with manufacturers recommendations, When mixed, all ad.i.csives
with different coloured components shall have a uniform colour without streaks.
~fl
The use of sulvents and thinners will not he permitted except for cleaning
of equipment.
2803.9. Testing
2803.91, Mateilal Testing. Prior to approval of the material, the
following tests shall be carried out at site or in an authorised laboratory
for each batch of resin and hardener and each combination thereof at
the. co:st of the Contractor.
i)
Viscosity test for resin and hardener and the mix - three specimens each.
ti)
iii)
Bond test
is)
Shear test - six specimens each, 3 after 24 hours and the other three aftet 72
hours of curing
i)
500
ii)
With
602
<<
Section
2800
One pot life test shalt he performed on commencement of work and the
sattte shalt be repeated even four hostrs..
iv)
Wttese the resin and hardener get mixed at point of injection, the pot life is r.oi
irrtportant and no teats may be required.
Ls,t
Bond Test
.A standard ISO snm diameter and 300 mm long concrete cylinder shalt he east
in 2. pieces by providing a separating media at an axis of 45 degrees Celsius
to tlse longer axis of the cylinder (refer to Fig. 2.800/1).
Ihree sets of such split cylinders shall he prepared in advance, Two pieces of
each set shall be joined wir.h epexy rnorear at four p. mrs to give a clear gap
of shout 0.2 mnns, which will be injected with epoxy resin at site, After epoxy
has been cured, load test is esrried out on the cylinder which shall not he test
than Sf) per cent of the cube strength of the concrete mix and the failure shalt
not take place at she ,joint injected with epoxy resin,
~e)
Sttear Tests
Two steel plates, minimssm 3mm thick, shall be bonded with epoxy at site using
the same resin mix as used/proposed to he used for injection. The assembly shalt
he kept in mechanical clamp till epoxy is cured, A total of six specimens shall
be prepared for each hatch of materials. Three test specimens shalt then he
subjected to a shear force along the axis after 24 hours and the minimunt shear
strength before failure shalt nut be less than 1 MPa, (refer Fig. 2800/2).
Penetration/Visual Examination
be full of epoxy adhesive,
603
<<
Section 2800
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E
Repair of Structures
E
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<<
Section 2800
Repair of Structures
b)
Bond Strength : Concrete failure before adhesive failure or 40 MPa with no failure
of either co~xcreLeor adhesive
Pres~areTest
The mixing head of the injection equipment shall be disconnected and the two
adhesive component delivery lines shall be attached to the pressure check device,
which shall consist of two independent vatved nozzles capable of sensing the
pressure. The cheek device shall be closed and equipment operated until the
gauge pressure in each tine reads 5 MPa, The. pumps shall be stopped and
the gauge pressure shall not drop below 4 MPa within 2 minutes.
The
preasure test shall be run for each injection unit at the beginning and
after break of every shift.
b)
Ratio Test
The mixing head of the injection equipment shall be disconnected and the two
adhesive components shall be pumped simultaneously through the ratio check
device, which shall consist of two independent valved nozzles. There shall
be a pressure gauge capable of controlling back pressure by opening or closing
valved nozzles capable of sensing the back pressure behind each valve. The
discharge pressure shall be adjusted to read 5 bar for both adhesive components,
<<
605
Repair of Structures
Section 2800
Bond Strength
:
12 MPa
Tensile Strength :
16 MPa
The Contractor shall carry out tests on the samples made out or
requirements indicated above.
The sand content in the mortar shall be in accordance with the
desired consistency.
2804.2. Proportioning and Mixing
The resin and hardener shall be mixed before adding the dry
filler. The mixed ready to use mortar should not contain lumps of
unwetted filler and should be uniform in colour. For a total weight
f 1 kg or less, hand mixing will be sufficient. For quantities in excess
of 1 kg, the component shall be mixed for 3 minutes with a slow speed
400-600 rpm - electric drill with a Jiffy mixer, The stirrer shall be
moved up and down and along the sides until an even streak free colour
is obtained. Whipping in an excessive amount of air shall be avoided.
If no power is available, a flat putty knife may be used to reach
into the corners of the can and hand mixing done for at least 5 minutes.
2804.3. Surface Preparation
Surface upon which epoxy is to be placed shall be free of rust,
<<
606
Repair of
Structures
Section 2800
grease, oil, paint, asphalt, loose material, unsound concrete, dust or any
other deleterious material.
Since cured epoxy does not provide adequate bond with any
material, all overlay, whether epoxy or cement based, shall be done
within pot life of the base epoxy layer.
2804.4. Contaminants, such as oil, grease, tar, asphalt, paint, wax,
curing compounds or surface impregnants like linseed oil or silicons,
including laitance and weak or loose concrete shall be removed. When
bonding to asphalt, the surface should be roughened so that clean
aggregate is exposed. Epoxy bonding agents shall not be applied when
ii rains, or in standing water. The surface must be dry.
Two general methods of surface preparation shall be followed
a)
Mechanical that includes grinding, grit blasting, water blasting and scarification.
b)
Chemical that includes acid etching with 15 per cent by weight of hydrochloric
solution, followed by repeated flushing with high pressure stream of water.
2804.5. Application
Epoxy primer coat shall be applied with the help of stiff nylon
bristle brushes or hard rubber rollers or spray gun depending upon
the nature of surface and extent of work area. As far as possible,
the coating shall be uniformly thick.
Before the primer coat is fully cured, epoxy mortar shall be
applied by means of !rowels and floats. The interval between the
application of primer coat 3nd epoxy mortar shall be approximately 15/30 minutes depending upon the ambient temperature.
Seat Coat shall be applied after 24 hours curing, after mild
roughening of the surface of the mortar,
2804.6. Coverage
The coverage of resin mix would depend on the system of resin
However, as a general guideline the coverage area shall be as
under
used.
a)
Primer Coat. One kg of resin-hardener mix covers an area of 3-6 square metres
per coal depending on the fmish of the concrete.
b)
Epoxy Mortar. One square metre of surface requires approximately 2024 kg of epoxy mortar when laid to a thicknest of 10mm.
c)
<<
607
Repair of Structures
Section 2800
<<
608
Repair of Structures
Section 2800
<<
Section 2800
LU
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LU
610
Repair ofStrucuires
a
0
(%4
L
I-
<<
Section 2800
Repair of Structures
flow freely into holes smaller than about three times the largest cement
particle. Except in large cavities where thick mortar can be placed,
the sand should all pass the 28-mesh sieve and have a large portion
passing the 50- and the 100- mesh sieves. The proportions of Ordinary
Portland Cement to sand Will depend upon the size of the spaces to
be filled and will vary from a neat grout to about 1:1 mix. The amount
of water to be added depends upon the consistency required. Orouts
with as little as 16 litres of water per bag of cement could be handled
and it shouldseldom be necessary to use more than 35 to 40 litres
of water per bag of cement.
Where necessary and approved by the Engineer, admixtures to
Portland Cement grout mixtures may be added for delaying the setting
time, increasing flow ability, minimising segregation~andshrinkage.
2806.2. Preparation
The surface shall be cleaned with wire brush and compressed air.
15 mm din and 150 to 200 mm deep hoLes along the length of
the cracks at a spacing of 500 mm may be drifted by wet drilling using
rotary percussion drills and nipples. inserted in these boles.
2806.3. Proportioning, MixIng, and Equipment for Grouting
The cement grout shall be mechanically mixed using a system
of power-driven paddles of high speed centrifugal pump. The grout
pump to be used shall permit close control of pressures to allow a flexible
rate of injection with minimum clogging of valves and ports The most
satisfactory equipment for injecting grout is a pump of the double-acting
flexible reciprocating type giving a steady flow. The grout pump shall
be so placed as to reduce the waste in cleaning lines. It is preferable
to add 50 per cent or mOre of the mixing water into the mixer before
adding the dry ingredients and then the remaining water. A continuous
supply of grout is preferable to an intermittent one. Consistency of
the grout may be determined by trials starting with thin grout i.e. about
40 litres of water per bag of cement and progressively decreasing
the water content to about 15 litres per bag of cemenL
Where the mixer and pump are combined in one unit1 the dry
material shall be screened before mixing. if the mixer and pump are
in separate uwis, the grout shall pass through a screen before it enters
the pump.
<<
611
Repair of Structures
Section 2800
2806.4. Application
Highest practical pressure within the limits 100-400 kPa should be
used in order to force the surplus water from the grout. As thb pressure
may be distributed hydraulically over considerable areas, vigilance must
be exercised to prevent damage or, the needless waste of grout. Orouting
is ~o be done by attaching a pscker (consisting of expansible tube
of rubber) to the end of the grout supply pump through the holes and
nipples.
Pressure shall be steady to ensure a continuous flow of grout.
Grouting shall not be continued till the hole consumes mix at the rate
of not less than 30 litres in 20 minutes or until refusal at the grouting
pressure of 400 kPa at any hole until iefhsaL Should the grout escape
from an adjacent nipple,it should be plugged or capped. Any seam,
crack or joint through which grout escapes shall be caulked with epoxy
ffiortar as soon as thick grout appears.
2806.& Cleaning o~Equipment
2807. GUNIT1NG/SHOTCRETE
2807.1. The gunite is a mixture of cement, sand and water. It
comprises 100 parts by weight of cement, 300 parts by weight quartz
sand, 35-50 parts by weight water and 2 parts by weight approved quick
setting compound. In general, dry mix shotcrete shall be used.
2807.2. Ordinary Poilland cement conforming to IS:269 shaft be used
in guniting.
28073. Sand for guniting shall comply with the requirements stipulated in IS:383. In general, sand should neither be zoo coarse to increase
the rebound nor too fine to increase the slump. Sand should preferably
have a moisture content between 3 to 6 per cent.
<<
612
Repair of Stmctures
Scc~ion2800
The grading of sand shall lie within the limits given below
IS Sieve
Designation
95. 100
4.75mm
2.36mm
1,18mm
600 microns
300 microns
150 microns
65.90
45.75
30
10
2
- 50
- 22
<<
613
Section 2800
Repair of Structures
<<
614
Section 2800
Repair of Structures
ii).
The existing expansion joint assemblies shall be removed carefully along the
entire width of the carriageway. The deck slab for a width of 400 mm on either
side should be removed for placing of reinforcement., anchor rods, anchor bolts
and other fixing assemblies for the new expansion joints and pouring of fresh
concrete. The gap between the girders over the piers should be cleared of all debris.
A temporary platform in the gap at the end of girders shall be erected to collect
the materials falling down during concreting and fixing of expansion joints
iii)
The service lines, if any, shall be disconnected/ diverted before the dismantling
work starts.
<<
615
Rcpair of Structures
Section 2800
<<
616
Section 2800
Repair of Structures
Anchorages
Depending upon the prestressing force, suitable anchorages and
wedges shall be used conforming to relevant codes and section 1800.
28103, Workmanship
a)
Stressing of cables shalt be earned out as per instructions given in the drawing,
and conforming to Section 1800.
b)
Care should be taken to avoid any damage to the existing sisucture, by way of
stress concentration orany other reason during fixing of the deviator blocks and
after stressing of cable. The deviator blocks shall be so fixed as not to allow any
movement due to prestressing forces. Radius of corvature of the surface of the
deviator block interfacing with the cable shall be minimum one metre.
c)
The anchorages shall be sealed with suitable epoxy mortar system after the
stressing of cables, A minimum cover of 50mm shall be provided for the anchor
plates and anchorages.
d)
Suitable grouting inlet points and vent points shall be provided by way of HDPE
1 vent connections to the sheathing.
e)
Grouting of cables shall be carried out as per provisions made in Section 1800.
<<
a)
b)
c)
d)
617
shall
Repair of Structures
Section 2800
e)
f)
g)
h)
2813. RATE
The contract unit rate for sealing of cracks and injection of cement
grout shall include cost of all materials, labour, toots and plant, placing
in position, testing, curing and other incidental expenses for the
satisfactory completion of the work as per these specifications.
The contract unit rate for application of epoxy mortar for
specified thickness shall include cost of all materials, labour, tools and
plant, placing in position, testing and other incidental expenses including
surface preparation for the satisfactQry completion of the work as per
these specifications and as shown on the drawings.
The contract unit rate for gunitinglshotcreting shall include cost
of all materials, labour, tools and plant, placing in position, testing,
curing, surface preparation and other incidental expenses including
the provision of nipples for the satisfactory completion of the work as
per these specifications.
The contract unit rate for replacement/rectification of bearings shall
include cost of all materials, labour, tools and plant, placing in position,
site welding/riveting/bolt connections, operation of jacks and other
incidental expenses for the satisfactory completion of the work as per
these specifications and as shown on the drawings.
The contract unit rate for dismantling of wearing coat shall include
cost of all jirnterials, labour, tools and plant, traffic management,
signages, safety precautions and other incidental expenses including
removal of existing expansion joints for the satisfactory completion of
the work as per these specifications.
The contract unit rate for external prest.ressing shall include cost
of all materials, labour, tools and plant, temporary works, testing, curing
and other incidental expenses including the careful monitoring of the
deflection of girders being externally prestressed for the satisfactory
completion of the work as per these specifications and as shown on
the drawings.
<<
618
Pipe Culverts
2900
Pipe Culverts
<<
Pipe Culverts
Section 2900.
2901. SCOPE
This work shall consist of furnishing and installing reinforced cement
concrete pipes, of the type, diameter and length required at the locations
shownon the drawings or as ordered by the Engineer and in accordance with
the requirements of these Specifications,
2902. MATERIALS
All materials used in the construction of pipe culverts shall conform to
the requirements of Section 1000.
Each consignment ofcement concrete pipes shall be inspected, tested,
ifnecessary, and approved by the Engineer either at the place ofmanufacture
or at the site before their incorporation in the works.
2903. EXCAVATION FOR PIPE
The foundation bed for pipe culverts shall be excavated true to the lines
and grades shown on the drawings or as directed by the Engineer, The
pipes shall be placed in shallow excavation of the natural ground or in
open trenches cut in existing enibankments, taken down to levels as shown
on the drawings. In case of high embankments where the height of fill is
more than three times the external diameter of the pipe, the embankment
shall first be built to an elevation above the top of the pipe equal to the
external diameter of the pipe, and to width on each side of the pipe of not less
than five times the diameter of pipe, after which a trench shall be excavated
and the pipe shall be laid.
Where trenching is involved, its width on either side of the pipe shall
be a minimum of 150mm orone~fourthofthediameterbf the ~ipe whichever
is more and shall not be more than one-third the diameter of the pipe.
The sides of the trench shall be as nearly vertical as possible.
The pipe shall be placed where the ground for the foundation is
reasonably firm. Installation of pipes under existing bridges or culverts
shall be avoided as far as possible. When during excavation the material
encountered is soft, spongy or other unstable soil, and unless other special
construction methods are called for on the drawings or in special
provisions, such unsuitable material shall be removed to such depth, width
and length as directed by the Engineer. The excavation shall then be
backlilled with approved granular material which shall be properly shaped
and thoroughly compacted upto the specified level.
Where bed-rock or boulder strata are encountered, excavation shall be
<<
621
Section 2900
Pipe Culverts
taken down to atleast 200 mm below the bottom level of the pipe with
prior permission of the Engineer and all rock/boulders in this area be
removed and the space filled with approved earth, free from stone or
fragmented material, shaped to the requirements and thoroughly
compacted to provide adequate support for the pipe.
Trenches shall be kept free from water until the pipes are installed
and the joints have hardened.
2904. BEDDING FOR PIPE
The bedding surface shall provide a firm foundation of uniform
density throughout the length of the culvert, shall conform to the specified
levels and grade, and shall be of one of the following two types as specified
on the drawings:
(i)
First Class bedding: Under first class bedding, the pipe shall be evenly bedded
on a continuous layer of well compacted approved granular material, shaped
concentrically to fit the lower part ofthe pipe exterior for atleast ten per cent of i t.s
overall heightor as otherwise shown on the drawings. The bedding material shall be
well graded sand or another granular material passing 5,6 mm sieve suitably
compacted/rammed. The compacted thickness of the bedding ~ yer shall be as shown
on the drawings and in no case shall it be less than 75 mm,
~ii) Concrete cradle bedding: When indicated on the drawings or directed t~,the
Engineer, the pipe shall be bedded in a cradle constructed of concrete having a mix
not leaner than M 15 confomiing to Section 1700, The shape and dimensions of the cradle shall be as indicated on the drawings. The pipes thafi be laid on the conere~e
bedding before the conrete has set,
<<
Section 2900
Pipe Culverts
upstream. The pipes shall be fitted and matched so that when laid in work,
they form aculvert with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed
at the cost of the Contractor.
290t JOINTING
The pipes shall bejointed either by collarjoint or by flushjoint. In the
former case, the collars shall be of RCC 150 to 200 mm wide and having the
same strength as the pipesto be jointed. Caulking space shall be between 13
and 20 mm according to the diameter of the pipe. Caulking material shall be
slightly wet mix ofcement and sand in the ratio of 1:2 rammed with caulking
irons. Before caulking, the collar shall be so placed that its centre coincides
with thejointand an even annularspace is leftbetween the collarand the pipe.
flush joint may be internal flush joint or external flush joint. In either
case, the ends of the pipes shall be specially shaped to form a self centering
jointwith ajointing space 13 mm wide. The jointing space shall be filled with
cement mortar, 1 cement to 2 sand, mixed sufficiently dry to remain in
position when forced with a trowel or rammer. Care shall be taken to fill all
voids and excess mortar shall be removed.
For jointing pipe lines under light hydraulic pressure, the recess at the
end of the pipe shall be filled with jute braiding dipped in hot bitumen or
other suitable approved compound.Pipes shall be so jointed that the bitumen
ring of one pipe shall set into the recess ofthe next pipe. The ring shall be
thoroughly compressed by jacking or by any other suitable method.
All joints shall be made with care so that their interior surface is
smooth andconsistent with the interior surface of the pipes. After finishing,
the joint shall be kept covered and damp for at least four days.
2907. BACKFILLING
Trenches shall be backfilled immediately after the pipes have been laid
and thejointing material has hardened. The backfill soil shall be clean, free
from boulders, large roots, excessive amounts of sods or other vegetable
matter, and lumps and shall be approved by the Engineer. Backfilling upto
300 mm above the top of the pipe shall be carefully done and the soil
thoroughly rammed, tamped or vthrated in layers not exceeding 150 mm,
particular care being taken to thordughly consolidate the materials under the
haunches of the pipe. Approved pneumatic or light mechanical tamping
equipment can be used.
<<
623
Section 2900
Pipe Culverts
<<
624
Maintenance of Road
3000
Maintenance of Road
<<
Section 3000
Maintenance of Road
3001. GENERAL
The Specificationsshall apply to all itemsofroad maintenance works as
required to be carried out under the Contract or as directed by the Engineer.
The works shall be carried out in conformity with therelevant Specifications
to the required level, grade and lines using approvM materials. The works
shall be carried out using light duty machinery or manual means provided
the quality of the end product does not suffer. In execution of maintenance
works, areference is made tothe IRC publications: Manual for Maintenance
of Roads and Code of Practice for Maintenance for Bituminous Surfaces
of Highways, IRC 82-1982 for guidance and compliance wherever applicable. Wherever the Specification is not clear, good engineering practice
shall be adopted in the construction to the satisfaction of the Engineer.
3002. RESTORATION OF RAIN CUTS
3002.1. Scope
The work shall consist of earthwork for restoration of rain cuts in the
embankment and shoulders, using suitable material, and compacting the
same.
3002,2. Materials
The material used for restoration of rain cuts shall consist of soil
conforming to Clause 305.2.
3002.3. Construction Operation
The area affected by rain cuts shall be cleared of all loose soil and
benched. The width of the benches shall be at least 300 mm and they shall
extend continuouslyfora sufficient length. Theheight of thebenches shall be
in the range of 150-300 mm.
Fresh material shall be deposited in layers notexceeding 250 mm loose
thickness and compacted so as to match with the benching at a moisture
content close to the optimum. Compaction shall be carried out using suitable
equipment such as platecompactors andrammers or by suitable implements
handled manually. The finished work shall conform to aligmnent, levels and
slopes as indicated in the drawing.
3002.4. Measurements for Payment
The earthwork foi~restoration of rain cuts shalt be measured in cubic
metres.
<<
627
Maintenance of Road
Section 3000
3002.5. Rate
The Contract rate for the item of earthwork for restoration of rain cuts
shall be payment in full for carrying out the required operation including
full compensation for:
(i) Supply ofmaterial including all leads and lifu and the costof arrangement of land;
(ii)
Setling out;
(i)
Making up ofthe earthen thoulderby adding extra soil and compacting rhesame; andl
or,
(ii) Stripping a layer of soil to achieve the required grade and level.
<<
628
Maintenance
of Road
Section 3000
hand tools. The resulting surface shall be uniform and have a field density
of atleast 94 per Cent of maximum density obtained in accorthnce with
IS : 2720 (Part 8). If the surface is not uniformly compacted, it shall be
excavated to a depth of 150 mm and the soil mixed with water if required
and compacted at a moisture content close to the optimum to achieve 94 per
cent of maximum density as stated above.
3003,4. Measurements for Payment
Maintenance of earthen shouldershall be measured in sq. metres.
3003.5. Rate
The Contract unit rate for maintenance of earthen shoulder shall be
payment in full compensation for:
(i)
furnishing earth required formaking up of shoulders including all leads and lifts,cost
of land and compaction;
(ii)
excavation of earth as required and disposal of the earth at the location approved; and
(iii) all tools, equipments and incidentals to complete the work in accordance with the
above Specification.
<<
629
Section 3000
Maintenance of Road
rectangle or square. The edges shall be cut vertically uptothe level where the
lowerlayer is stable without any loose material, The area shall be thoroughly
cleaned with compressed air or any appropriate method approved by the
Engineer to remove all dust and loS particles. The area shall be tacked or
primed with cutback or emulsion depending upon whether the lower layer
is bituminous or granular in nature. The sides, however, are to be painted
with hot tack coat material using a brush. The primecoal and tack coat shall
conform to Clauses 502 and 503 of these Specifications, respectively.
3004.1.4. Backfilling operation : The mix to be filled shall be either
ahot mix or a cold storable mix (using bituminous emulsion). Mixing shall
be done in a plant of suitable capacity. It shall be placed in thicknesses not
more than 100 mm (loose). It shall be compacted in layers with roller/plate
compactor/hand roller/ rammer. While placing the final layer, the mix shall
be spread slightly proud of the surface so that after rolling, the surface shall
be flush with the adjoining surface. If the area is large, the spreading and
levelling shall be done using hand shovel and wooden straight edge. During
the processof compaction with roller or other means, the surface level shall
be checked using a 3 m straight edge.
3004.1.5. Measurements for payment: Filling of pot-holes and patch
repair shall be measured in sq.m.
3004.1.6. Rate: The Contractunit rate for filling of pot-holes and patch
repair shall be in full compensation for
(i)
(ii)
(iii) all labour, tools, equipments and incidentals to complete the work inaccordancewith
the Specifications.
<<
630
Section 3000
Maintenance of Road
tank, flexible hose and spraying bar or lance. Traffic shall be allowed on the
surface after the seal has set to a non-tacky and firm condition so that if is
not picked up by the traffic.
3004.2.4. Measurements for payment: The fog seal work shall be
measured in sq.metres.
3004.2.5. Rate : The Contract unit rate for application of fog seal shall
be in full compensation for:
(i)
supplying of fog seal material and all the operations for applying it; and
(ii)
all the labour, tools,equipments and incidentals to complete the work in accordance
with this Specification.
<<
631
Maintenance of Road
Section 3000
processed fine aggregate or fine stone chips to produce a dry mix forrepairing
spalled or damaged edges.
3005.1.3. Repairing Procedure: Spalled or broken edges shall be
shaped neatly with a vertical cut with chisels into the shape of rectangle.
Small pneumatic chisels also may be used, provided the cutting depth can
be controlled. The depth of the cut shall be the minimum to effect repair.
After shaping the spalled area, it shall be cleaned and primed. The epoxy
mortar/concrete is then applied using hand tools like trowels, straight edges,
brushes etc. The repaired edge shall be in line with the joint groove and shall
be flush with the concrete slabs. During the repair work, any damagenoticed
to the joint sealant shall be made good by raking Out the affected portion
and resealiag.
3005.1,4. Traffic: Although the epoxy mixes set in 2-3 hours time, it is
desirable to divert the traffic for 12 hours or as per the recommendation ofthe
manufacturers.
3005,1.5. Measurements for payment: Repair of joint grooves shall
be measured in linear metres.
3005.1.6. Rate: The Contractunit rate for repair of joint grooves with
epoxy mortar or epoxy concrete shall be in full compensation for~
(i) supply and application of epoxy primer, epoxy mortar or epoxy
concrete;
(ii) all tools, equipment and incidentals to complete the work in accordance with the above Specification.
3005.2. Repair InvolvingRemoval of OldJoint Sealant and Sealing
with Fresh Sealant in Cement Concrete Pavements
3005.2.1. Scope: The repair of sealant of contraction, longitudinal or
expansion joints shall include removal of the existing sealant and resealing
the joint with fresh sealant material.
3005,2,2. Material: Sealant material to be replaced shall be either hot
poured rubberised bitumen or polysulphide type of sealant as per Clause
602.2.8. As per the recommendation of the manufacturer, appropriate type of
primer also shall be applied.
3005.2,3. Repairing procedure: The existing sealant shall be raked out
with the help of a metal raker such that most of the sealant is removed.
Subsequently, the sealant stuck to the sides of the grooves shall be removed
thoroughly either by using saw cutting machine so that grooves may be
widened by one mm or by sand blasting. In no case the old sealant shall be
<<
632
Maintenance of Road
Section 3000
<<
(i)
removal of old sealant, regrooving or sand blasting the sealinggroove and placing of
debondmg strip or tape.
(ii)
all tools, equipments and incidentals to compkte the work in accordance with the
above Specification.
633
Appendices
Appendices
<<
Appendices
Appendsxl
LIST OF IRC PUBLICATIONS REFERRED TO IN THE
SPECIFICATIONS, CODES & STANDARDS
NumbeT Designation
<<
TItle
IRC : 21965
IRC : 5-1985
[RC :6-1966
IRC : 8-1980
IRC
10-1961
LRC : 14-1977
IRC : 16-1989
IRC : 17-1965
IRC : 18-1985
IRC : 19-1977
Standard Specifications and Code of Practice for Water Bound Macadam (Second Revision)
IRC : 20-1966
IRC : 21-1987
[RC : 22-1986
1RC : 23-1966
IRC : 24-1967
IRC : 25-1967
[RC :26-1967
mc
: 27-1967
IRC : 29-1968
IRC :30-1968
637
(Post-
Appendices
Number Designation
Title
IRC : 35-1970
IRC :36-1970
IRC : 37-1984
IRC : 40-1970
IRC : 45-1972
IRC : 47-1972
IRC
48-1972
IRC : 49-1973
1RC : 50-1970
IRC :51-1973
IRC : 56-1974
IRC : 63-1976
Tentative Guidelines for the Use of Law Grade Aggregates and Soil
Aggregate Mixtures in Road Pavement Construction
IRC :67-1977
IRC
72-1978
IRC : 75-1979
IRC : 78-1983
IRC : 79-1981
IRC : 82-1982
IRC : 83-1982
IRC : 83-1987
IRC : 87-1981
Guidelines for the Design & Erection of False Work forRoad Bridges
1RC : 89-1985
IRC : 90-1985
IRC : 93-1985
<<
638
Appendices
Number Designation
<<
Title
IRC :94-1986
IRC:SP:1l-1977
IRC : SP :31-1986
IRC : Special
Report 11, 1992
IRC Highway Research Board, State ofthe Art: Granular and Bound
Bases and Sub-Bases
639
Appendices
Appendix 2
LIST OF INDIAN AND FOREIGN STANDARDS REFERRED
TO IN THE SPECIFICATIONS
(A) INDIAN STANDARDS
Number Designation
Title
IS : 5-1978
IS : 73-1992
Paving bitumen
IS : 164-1981
IS : 210-1978
IS : 215-1961
Road tar
IS : 217-1988
CUtbaCkbitumen
IS : 226-1975
IS
269-1989
IS : 278-1978
IS : 280-1978
IS : 334-1982
IS : 383-1970
IS : 432-1982
Mild steel and medium tensile steel bars andhard-drawn steel wire for
concrete reinforcement
(Part I)
(Part 11)
IS : 443-1975
IS = 454-1961
IS : 455-1989
IS : 456-1978
IS : 458-1988
IS : 460-1985
Test sieves
IS : 508-1973
IS : 516-1959
IS : 702-1988
IS ~:736 -1986
IS : 814-1974
<<
Appendices
Number Designation
Title
IS : 823-1964
IS : 961-1975
IS : 1002-1956
IS : 1030-1974
IS :1077-1976
IS :1124-1974
IS :1129-1972
IS :1139-1966
Hot rolled mild steel and medium tensile sleet deformed bars for
concrete reinforcement
Rivet bars for structural purposes
IS : 1148-1973
IS :1149-1973
IS :1195-1968
IS: 1199-1959
IS : 1201 to
1220- 1978
iS : 1239-1979
(Part I)
IS : 1239-1979
(Part II)
IS : 1364-1967
Mild steel tubular and other wrought steel pipe fittings (second revision)
Precision and semi-precision hesagon boks,sctnwa,nutsandlocknsts
(diameter range 6 to S9tnm) (first revision)
IS : 1367-1984
IS : 1387-1967
IS : 1398-1960
15: 1442-1964
Covered electrodes for metal arc welding ofhigh tensile structural steel
1St: 1448
IS : 1477
(Pan I)-1971
IS : 1489-1991
Portland-pozzolana cement
IS : 1498-1970
purposes
IS : 1514-1959
IS : 1732-1971
Dimensions for round and square steel bars for structural and general
engineering pwposes
IS :1785
(Part I)-1966
641
<<
Appendices
Number Designation
IS : 1786-1985
IS : 1838
IS : 1888-1982
IS :2004-1978
15 :2062-1980
IS :2116-1980
IS 2131-1981
IS :2250-1965
15 :2386-1963
(Paul)
(Part 2)
(Part 3)
(Part 4)
Mechanical properties
(Part 5)
Soundness
(Past 6)
(Part 7)
(Part 8)
Petrographic examination
IS : 2720
<<
Title
(Part 2)4973
(Part 3)-I980
Section 1
Section Il
(Past 4)-1985
(Part 5)-1985
(Part 7)4980
(Pan 8)-I983
(Part 10)-1973
(Part 13)-1985
(Part I4)-l983
(Part 16)-1987
(Part 27)-1977
642
Appendices
Title
Number Designation
(Part 28)-1974
(Part 29)-1975
IS :3117-1965
IS : 3466-1967
Masonry cement
iS : 3764-1992
IS : 4138-1977
ES : 4332
IS
(Part 1)4967
(Part 3)4967
(Part 4)4968
(Part 7)4973
(Part 8)-1969
4434-1978
IS 4826
IS :5317-1969
IS : 5435 (Revised)
IS : 5640-1970
IS :6006-1970
IS :6241-1971
IS :6909-1991
Supersulpbated cement
IS :6925-1973
IS : 7537-1974
IS :8041-1978
IS :8112-1989
ES : 8887-1978
IS :9103-1979
IS : 10262-1982
643
<<
Appendices
TItle
Number DesIgnation
iS: 12269-1987
IS: 12330-1988
IS : 13321
(Part 1)-1992
IS: 13325-1992
propetties
Determination of tensile properties of extruded polymer geogrids
using the wide strip-test method
iS : 13326
Evaluation of interface friction between geo-synthetics and soilmethod of test part 1: Modified threct shear technique
(Part l)-l992
IS: SP23-1982
ASTM :D-36
Thennoplastie material
ASTM : D-395
ASTM :D-412
ASTM : D-429
ASTM : D-573
ASTM : D-624
ASTM : D-664
ASTM : D-797
ASTM
1075
ASThI D-1149
ASTM D-1559
ASThI D-2172
ASTM
D-2240
ASTM D-3625
boiling water,
ASTM : D-4533
ASTM : fl-li
ASTM:E-S10
AASFETO: DM283
<<
AASI-ITO : DM 17-77
AASHTO: DR 5-80
644
Appendices
Number Designation
Title
AASHTO: DM 81-75
AASHTO: DM 7-10
AASHTO: DM282.80 Joint sealants,hot poured, elastometic type. (or ASTM : D3406) for
portlandcement concrete pavements
BS ~~10-1969
Test sieves
BS 729-1971
Hot dip galvanized coatings on iron and steel articles
ES
812-1975
Testing aggregates
Part 2-
1154-1970
BS : 1377-1975
ES : 1447-1973
BS : 1449-1956
Part 1-1972
Part 2-1967
BS : 1470-1972
IS :2630
Preformedjoint filler
BS : 2870
BS : 3262
Part-i
Part-2
Part-3
BS : 5212
Part 2-1975
<<
645
Appendices
Number Designation
Title
BS : 6044
B.S : 6088
ES : 6906
Past I
Part 4
Part 7
Part 2
Pail 3
ES : 7542
CR111 and ICC,
New Delhi
Asphalt institute
GRI-GGI
GRI-GG2
GRU3G3
(GRI denotes standards for test prepared by Geosynthetic Research Institute at Drexel
University Philaddphia, USA)
<<
646
Appendices
Appendix 3
(Clause 4023.2 and 403.3.2)
METHOD OF SIEVING FOR WET SOILS TO
DETERMINETHE DEGREE OF PULVERISATION
I.
A sample of pulverised soil approximately 1kg in weight should be taken and weighed(W
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 (Wi).
Lumps offiner soils in the retained material should be broken until all the individual
particulars finer than the aperture size of the sieve are separated.
The soil should again be placed on the sieve and shaken until sieving is complete. The
retained material should be weighed (W,).
3.
4.
1).
WeIght of roil by per cent passing the sieve can than he calculated from the expression:
(W1W2)x 100
(W1-W,)
<<
647
Appendices
Appendix 4
GUIDELINES ON SELECTiON OF THE GRADE OF BITUMEN
(Source Bituminous Road Construction Handbook, Indian OilCotporation and Central Road
Research Institute)
A
For bituminous premix carpet, choice is governed by climatic conditions and intensity of
traffic.
(I)
Grade 30/40 for areas where difference between maxtrnutn and minimum
airnospheric temperatures is less than 25 C and traffic intensity is greater than 150(1
commercialvehicles per day. For traffic intensityteas than 1500 commercial vehicles
per day, Grade 50/60 is preferred.
(ii)
(iii) Grade 80/100 may be used in high altitude and snow-bound regions, irrespective of
traffic intensity cotlaideration.
B
For bituminous macadam and penetration macadam as also built-up spray grout, Grade
30/40 (for hot climates) and 60/70 or 801100 for other climates are suggested.
For a dense-graded bituminous concrete, a more viscous grade like 60170 can withstand
stresses of heavier wheel loads better than a less viscous grade of 80/100. Similarly
pavingbitumen grade 60/70 isrnore advantageous for roadswith largenumberofrepetitions
ofwheel loads like expressways, urban roads, factoryroads etc. High stability requirement
cannot be meteffectively by less viscous bitumen.
<<
648
Appendices
tt~
AR.
100
AR.
SO
AC. LU
C,
0
>4
2000
;c. 2.5
10
~1ooo
<<
649
and
viscosity
Appendices
Appendix 5
ANTI-STRIPPING AGENTS USED FOR BITUMINOUS
MATERIALSAND MIXES
I. Scope
1.1. Anti-stripping agents are used for bituminous materials and mixes to ensure adhesion
between aggregates (hydrophilic in nature) and bitumen, even under submergence in water.
Prior approval of the Engineer shall be taken in respect of both qualitative and quantitative
use of a particular product.
2. MaterIals
2.1. The anti-stripping agents shall be fatty acid amines having a long hydrocarbon
chain.
2.2. PhysIcal and Chemical Requirements : The anri.stripping agents shall conform to
the physical and chemical requirements as detailed in Table AS-I.
2.3, Storage and Handling : Anti-stripping agents shall be properly stored in closed
containers made of steel or aluminium. Containers made of zinc, copper, polythene PVC and
most types ofrubber are not suitable for use. A~most of the anti-stripping agents cause irritation
when in contact with human skin and are also irritating to the eyes, protective gloves for
hands and goggles forthe eyes shall be used while handlingthem, specially in caseof liquid antistripping agents.
3. Use in Sprayed Work
3.1. AdditIve Dosage: The dosage shall be determined depending on the nature
(stripping value) of the aggregate and the size of aggregate. While the recommended minimum
dose of anti-stripping agent for sprayed work is given in Table A5-2, the actual dosage shall be
determined in the laboratory as directed by the Engineer.
3.2. MixIng Procedure During Construction: The anti-stripping agent supplied in
liquid, solid or concentrate form shall be thoroughly mixedwith liquid bituminous material or
with straight rim bitumen. Whenused with straight run bitumen, the correct dose of anristripping
agent shall be mixed in a hot bitumen tank boiler.
The two constituents shall be agitatedtill the anti-stripping agent is thoroughly mixed. The
doseofanti-stripping agenishall suitably be increased ifthe binderis to remain in bitumen boiler
tots longerperiod.
4. Use in Premix Work
4.1. Additive Dosage: The dosage shall be determined depending on the nature
(stripping value) ofthe aggregate and the percent voids in the mix~Whilethe recommended
minimum doses fordifferent types of bituminous premix materials in terms of voids content are
given in Table A5-3, the actual dosage shall be determined irs the laboratory as directed by the
Engineer.
<<
650
Appendices
Method
Litelt
1.
Appearance
Visual
Liquid/Solid
2.
Odour
Smelling
Agreeable
3.
IS: 1202-1978
0.860-1.03
4.
IS: 1448
42
5.
IS 1448
150
6.
IS: 1448
1.0
7.
Solubility in diesel
As given at
Complete
oil (HDOorLDO) in
theraiioof298at
end of
Appendix
50C
8.
9.
ASTM 1)664
200
Elemental
Analyser
7,0
IS : 6241
As given at
No stripping
Wt. minimum
10.
Strippingvalue with
bitumen containing
lpercentWLantiatripping
compound at 40 C
theendof
Appendix
24 hours
11.
do -
<<
Complete
Coating
test
12.
Thermal stability at
163C 5 hours
13.
ASTM D 3625
95
14.
Retained Marshall
Stability per cent minimum
As given at
the end of
appendix
75
do -
651
Should not
lose its efficacy
Appendices
Penetration
Macadam!
Built up
spray grout
Surface
Dressing
with
Liquid
seal
coat
uncoated
aggregate
0-25
0,5
0.6
0.7
08
25-50
0.6
0.7
0.8
1.0
50-100
0.75
1.0
1.0
1.0
4.2. Mixing Procedure During Construction : The required dose of the anti-stripping
agent shall be poured into th~hot bitumen tank and allowed 15 to 30 minutes of circulation
or stirred to ensure a homogeneous mix. It is necessary to use a stable antismripping agent or
increase the dose according to expected degradation. Alternatively, the correct dose shalibe
injected intothe bitumen line by means ofa pump. The agent isfed into the bitumen first before
it is sprayed on the aggregate in the mix; thus, no separate mixing time for mixing the agent
with bitumen is required. In rolled asphalt and bitumen mastic surfacing works, precoated
chippings are pressed intothe hard surfacewhile the mix isstill hot to makethe newly laid surface
skid resistant. These chippings shall be precoated with bitumen treated with antistripping
compound. TABLE AS-3. TENTATIVE RECOMMENDED MINIMUM DOSE OF
ANTISTRIPPING COMPOUND IN BITUMEN PREMIX WORKS
Stripping
value ol
<<
aggregate
Voids content
3-5 percent
VoIds content
5.10 per cent
Voids content
10-15 per cent
0-25
0.3
0.4
0.5
25.50
0.4
0.5
0.6
50-100
0.6
0.8
1.0
652
..
..
...
. ..
Appendices
236mm
100
1.18mm
600mic.
300mic.
80
75
45
weight of stone dust. The stopper shall be replaced and the bottle shall be vigorously shaken
for two minutes.The water shall be then drained off and the stone dust shall be transferred to a
piece of paper and examined visually forsatisfying complete coating. The minimusn per cent
content of antistripping agent at which the stone dust sample is thoroughly coated shall be
recorded. The test shall be repeated at 60Cin water as well as 1 per cent solution of Sodium
Chloride in water for both the testing temperatures.
653
<<
Appendices
(b)
The under water coating test shall further be conducted with coarse aggregate,
passing 19 mm sieve and retained on 13.2 mm sieve. In this case the per cent
content of she cuthack-antistripping agesn blendshall be kept at 5 per cent by weight
of coarse aggregate. In order to take care of contamination in water, the test shall
also be carried out in the I per cent Sodium Chloride in water.
The minimum per cent contentof antistripping agent atwhich stone dust/coarse aggregate
Procedure: Blends of antistripping agent and bitumen of 80/100 grade shall be prepared
with 0.00,0.25,0.50, 0.75 and 1.00 per cent consents of antistmipping agent and kept in oven at
163Cfor five hours. After the heat exposure, she blend samples are fluxed with kerosene oil
so obtain the consistency of MC 3 and tested for under water coating test
Reporting of test results: An antistripping agent ahall be deemed to be beat resistant if the
dose requirement before and after beat exposure remains unchanged.
QUANTITATIVE EVALUATION OF RETAINEDMARSHALL STABILITY
VALUES AFTER IMMERSION IN WATER
Procedure: For quantitative evaluation, the tests shall be carried out as stipulated in
ASTM D1075 (Effect ofWater on Cohesion ofcompactedBisuminous Mixtures). Thegradasion
of aggregates shall be such as to give sufficient voids in the compacted bituminous mix to bring
out the effects of stripping. The gradation of aggregates shall be as under:
Steve Size
19.00mm
13.20 mm
9.50mm
4.75mm
2.36mm
600 mic
300 mic
lSOmic
75 mic
100
75-100
60-80
35-55
20-35
10-22
6-16
4-12
2-8
The Marshall test specimens shall be prepared using Sper centbitumen of80/100 grade by
weight of aggregates blended with varying percentages of anristripping agents from 0 to I per
ient in steps of 0.25 per cent The test samples shall give a void content of about 6per cent. At
least 8 standard Marshall specimens for each of the varying antistripping agent percentages shall
be prepared. Bath set of 8 test specimens shall be sorted out in two groups of4 each so that the
average specific gravity of the specimen in group I shall be essentially the same as in group IL
Group-I shall be tested for Marshall Stability in the usual procedure ASTM D1559. Group-Il
specimens shall be immersed in water for 24 hours at 60C 1C.and then shall be teased
immediately for Marshall stability as per ASTM D 1559.
CalculatIon: The numerical index of resistance of bituminous mixtures to the detrimental
effect of water shall be expressed as the index of retained stability:
Average Marshall Stability ofGroup-Il
Average Marshall Stability of Group-i
654
<<
Appendices
Appendix 1000-1
DRAFT DOCUMENT ON IS : 9077-1979 CODE OF PRACTICE
FOR CORROSION PROTECTION OF STEEL REINFORCEMENT
IN RB AND RCC CONSTRUCTION (REVISED)
FOREWORD
This Indian Standard has been revised taking into consideration the experience gained
over the years, developments thote have taken place subsequently and also considering the
need for evolving suitable acceptance tests for quality control. In this regard, the electrochernical
tests developed at the Central Electrochemical Research Institute, Karaikudi, and also the tens
specified in ASTMA775(A775 M-90 for powder epoxy coating have been considered.
This revised standard supersedes earlier standard namely 15:9077-1979. While revising
this standard, is was decided so cover the various test procedures required to ensure the quality
of individual product as well as the finished products. Is was also decided that this standard
should include very stringent test procedures particularly for finished products so that these
procedures can be used to evaluate not only the corrosion resistance of a particular finished
product covered by this standard but also any other finished product such as galvanising,
powder epoxy etc.
1. SCOPE;
1.1. This standard (revised) specifies the recommended practice for surface preparation,
surface pretreatment and anti-corrosive treatment based on inhibited and sealed cement slurry as
an in-situ process forcorrosion protection ofmild steel reinforcesnent/ IIYSD bars in conventional
reinforced concrete structures and conventional reinforced brickwork, constructions This
practice is alto applicable for non-prestressing steels (mild steel reinforcement/HYSI) bart) used
in prestressedConcrete ssmcture.
1.2. This standard applies only for in-situ corrosion pmtecsicn of rn:ild steel reinforcement)
HYSD bars after all bending and shaping operations are completed. However, this does not
preclude the possibility of using this practice as a factory process.
2. ANT1CORROSIVE TREATMENT PROCFSS SEQUENCES
The anticorrosive treatment should necessarily include the following sequential steps~
(a)
Since presence of oil, grease, dirt, heavy scale and rust will adversely affecttheperformance
of any anticorrosive treatment, it is essential to adopt suitable surface preparation technique,
Surfacepreparation can be either by acid pickling or by sand blasting.
(b)
Surface pretreatment
Sealing treatment
Sealing treatment should make the coating harder and less permeable.
<<
655
Appendices
A typical flow diagram is shown in Fig. 1000/1.
3. PROCEDURE FOR SURFACE PREPARATION
3.1. Sand Blasting
Sand blasting of the steel surface to SAE 2 1/2 standards can be done
3.2. De-rusting by Pickling
The pickling weld should be preferably based on hydrochloric acid and should include an
efficient inhibitor so prevent base metal attack.
A typical dc-mating solution should have the following characteristics:
(a)
(b)
(c)
Specific gravity when tested using a standard specific gravitybottle should be around
1.12.
Coating weighs when tested as per test procedure A given hereunder should be around
4.5 gsns./sq.m.
(b)
(c)
Presence of fungicide shall be tested by dissolving the jelly in deionized water, the
resulting solution shall be yellow incolour.
(d)
(e)
(I)
It should in liquid form ready for mixing with the ordinary portland cement
(ii) Specific gravity when tested using a standard specificgravity bottle should be 1.04
+0.02
(iii) pH when tested using a pH meter should be 12.75 ~0.25
(iv) Tolerable limit for chloride in inhibitor - admixture when tested using anodic polarisation technique (as per test procedure H) should be 300 25 ppm
5.2. OrdInary Portland Cement
This should conform to lS:269 and should be sieved topaaa through 75 microns IS sievc.
656
<<
STEPS
DURATION
(For iOns length
Rebar)
STORAGE YARD
PICKLING
TANK
15
30 stirs
RINSING
-f
PHOSPHATING (brushing)
(Brushing)
~iiiiiiiiii~
(Brushing)
SOLUTION
(Brushing)
sin
rain
12
24 rain
sin
sin
12
24 h
sin
2-4
(Brushing)
2-4
[I~I~~1
657
sin
h
<<
main
AIR DRYING
STACKING YARD
~i~ixiiiiiiiii~
AIR DRYING
B
2-4
AIR DRYING
B SOLUTION
~iiiiixiiiii~
SOLSYTION (Brushing)
B SOLUTION
sin
40 sin
~-Ii~~IiIII]
RINSING
REACTION TIME
A SOLUTION
sin
sin
h
Appendices
5.3. Cement and inhibitor admixture shouldbemixed inspecified proportionso have suitable
consissency. Coating should be appliedpreferably by brushing. However, underspecific circurn~
stances spraying or dipping is also allowable.
5.4. Sufficient time lag should be allowed in between successive coatings to ensure final
setting of theundercoat. A minimum of6 to 12 hours may be necessary.
5.5 A minimum oftwo coats with sufficient time lag in between should be applied.
6. SEALING TREATMENT
The sealing treatment should be performed over the coated surface immediately after final
setting of the sop coat. Sealingtreatment can be applied by brushing. spraying or dipping.
6.1. A typical sealing solution should have the following characteristics:(a)
Specific gravity when tested using a standard specific gravity bottle should be 1.09
+0.02
(b)
(c)
Tolerable limit for chloride in sealing solution using anodic polarisation technique
should be 450 25ppm (as per test procedure B).
7.5 cm a 2.5 cm or 7.5 cm a 5 cm mild steel polished and degreased specimens are to be
used for this test. First the blank loss of unphospbated specimen is to be found out. For this,
the initial weighs (W,) is accurately weighed. The specimen is kept immersed in the Clarks
solution or patented inhibitedde-russing solution for 1 minute. The specimen is removed, rinsed
658
<<
Appendices
in distilled water and dried using hotairblower. The specimen is immediately weighed (W
2) The
<<
659
HEIGHT OF (~UT~ING
EDGE
RI. OFTCP
OF SlEININU
BEIORI
CASTING
MEFRE
3
INITI,\1,
GAUGE
RI Al )1N
FOUNDING LEVEL
_____________
FINAL
(,AU( I
RI ADIM
SINKING
DL RIM
I UI DM
~LUI 9 LU] ~
RI. OF
BOFIOM
UI C I I I IL.(
I IX,1
(COI..7 C )E.K~
DEPTH OF
STJMP
Bit OW
CLTIING
EDGE
STRATA
MI ~
\\ Ii H
wEIGHT
ECCENTRICIIY
Al UNG X
AXIS
ECUEN]RI
~
Al ONG
Y AXJ~
QUANTITY
OF [MU[Xii I)
MAIl RIM
MEIRE
MITRE
10
METRE
METRE
II
12
TONNF
Ii
14
METRE
MEfl~E
REPORT
ANY SPU( tAt
MI tHUD 01
SINKING
EMPLOYED
REMARKS
SIGNATURE
01
SUPFR\~ISING
Oil ICLR
660
METRE
17
I~
~____-_
<<
REPORT
RIG \RDINC
OBS I
I S OR
SAJI) I~I1 ()\V
DURING SINKING
MUIRI-.
METRE
120041-I
KENTLEDGE
SINKING
RL. OF.
RI. OFTOP
HEIGHTOF
TOTAL
OF STFINING
511 INING
HFICH1 UI
RI Fl RI N( I
Al [I R
C \S1
SF1 INING
LI VII
LASTING
(CCII 4 CCII 3) (IN(I I DING) (Al WHICH
CUllING
CURB ANI)
CUFFING
EDGE IS
EDGEPt ACE1))
(COI~$..C0L3)
_______
SThINING
REDUCED
LVI I ~RI )
I3UTIDM
t UI UNG
EDGE
AIPENJ)JX
IS
E)
20
21
APPENDIX 1200/1-2
(PLACE)
(PLACE)
WELL ELO -
Us
- TftAHC DW5~
PLAN OF WELL NO
C)
CD
<<
TOTAL
SmINING
TOTAL
SINKING
MFFRF
Mfl1~I
(PLACE)
ENI)
(PLACE)
ENI)
ALON(JY-AXIS
DIFFERFNCE
(COL.5
(U!S)
(1)15>
(COL.8
COL;)
~
4
DIFFERENCE
TILT ALONG
X~AXIS
COLUMN
6
TILT ALONG
RESULTANT
YAXIS
TiLT
COLUMN
9
J(COL, l0+
COL,
DIVIDED BY
DIVIDEF) 1W
WLLLDIA
WI] I )I~
II)
Ii
-_________.~_________
652
<<
12
.H~
AJONG
X-AXIS
WITH
DIRECTh)N
\U RI
13
ALONG
Y-AXIS
WITH
DIRECTION
MFIRJ
II
1.~ThNT
ACTION
~S(COL. I3)~*
TAKEN FOR
RCOL, 1~jV~ REC11FICAT1ON
MI FRF
15
REMARKS
SIGNATURE
OF
SUPERVISING
OFFICER
Appendices
Appea4fr
15%/f
GENERAL
LI. The ifonnation atidi the manufacturer is required so supply shall be in such
desail as to obviate 1515515 use of the equipnens due to Ut intention of the manufacturer
not hawing been snide clear or disc to wn~gassumptions on Ut past of the user.
Li. The user shall refer unusual problem or aoblesns of erection/assembly not
in keqir!g with the Seeded use of Ut equipom too she manufacturer of the equipment.
2. INFORMAl ION REQUIRED
ii, The masssiifaetusen of Ivopsiesary syssons shall sqiy the following information:
a)
b)
List of kans of equ~pmu*svailable, giving singe of sizes, spans and such like,
with the snassufacussers idasti1~casionnusnbers or other references.
c)
The basis on whkls Ut safe wosking loads have beets determined and
whether the factor of safety given ~pp4ies so collapse or yield.
d)
e)
[nstnscaions for use and maintenance, including any points whAck require special
attention during eressioss, especsally where safety is concerned.
I)
Sizes of mats,
0)
(ii)
fr)
<<
663
Appendices
(vi)
<<
664
Appendices
Appendix
1700/i
(ii)
Joints should be positioned where they are readily accessible for preparation and
concreting, such as location where the cross section is relatively small, and where
reinforcement is not congested.
(iii) In beams and slabs, joints should not be near the supports. Construction joints
between slabs and ribs in composite beams should be avoided,
(iv) For box girders, it ia preferable so cast the sofia sod the webs without any joint.
(v)
location of joints shall minimise the effects of the discontinuity on the dunsbility,
structural integrity and the ar.. arsnce of the stnicture.
<<
665
Appendices
The joint surface shall not be contaminated with release agents, dust
or curing membrane.,
Concreting of Joints
The old surface shall be thoroughly cleaned and soaked with water,
Standing water shall he removed shortly before the new concrete is placed
.iui.d the new concrete shall be thoroughly compacted. Concreting shall
be carried out continuously upto the construction joints.
Surface retarders may be used to improve the quality of construction
joints.
For a vertical construction joint, a stopping board shall be fixed previously at the predetermined position and shall be properly stayed to
prevent its displacement or bulging when concrete is compacted against
it, Concreting shall be continued right upto the board,
<<
666
,r)
0
(it
ii
<<
667
n
rn
-~
rn
rn
rn
x
z
at
0
0
Appendices
Appendices
Appendix
TESTS ON SHEATHING DUCTS
1800/I
All tests specified below shall be carried out on the same sample in the order given
below.
At least 3 samples for one lot of supply (not
be tested.
exceeding
The tests are applicable for sheathing transported to site in straight lengths where
the pressressing cable is threaded inside the sheathing prior to concreting. These tests are
not applicable for sheathing tsar for coiled cable and transported to site as an assembled
unit, nor for sheathing ducts placed in position without threading of prestressing cable
prior to concreting.
(A) WORKABILITY TEST
A tett sample 1100 mm long is soldered to a fixed base plate with a soft solder (Fig.
1800(1-I). The sample is then bent so a radius of 1800 mm alternately on either tide to
complete 3 cycles.
Thereafter, the sealing joints will be visually inspected to verify that no failurel
opening has taken place.
(B) TRANSVERSE LOAD RATING TEST
The lest ensures that stiffness of the sheathing is sufficient to prevent permanent
distortion during site handling.
The sample i~placed on a horizontal support 500 mm long so that the sample is
supported at all points of outward comagations.
A load as specified in Table I is applied gradually at the centre of the supported
through a contact surface 12 mm long. It shall be ensured that the load is applied
approximately at the centre of two corrugations, Fig. 1800/1-2. The load as specified is
applied in increments.
portion
TABLE 1
dia (mm)
load
(N)
25.35
35-45
45-55
55-65
65-75
75-85
85-90
250
400
500
600
700
800
1000
per
<<
dia (mm)
25-35
35-45
45-55
55-65
65-75
75-85
85-90
load (N)
300
500
800
1100
1400
1600
1800
668
Appendices
(D) WATER LOSS TEST
The sample is sealed at one end. The sample is filled with waler and after sealing,
the end is connected to a system capable of applying a pressure of 0.05 MPa, Fig. 180W
1-4, and kept constant for 5 minutes using a hand pump with pressure gauge or stand pipe
system can be used.
The
<<
669
~
~
as
-o
Appendices
<<
0
C)
n
670
I~S PLATE
153
Appendices
~53
l5O~15C)a()tr.m
-...
L25s25a4
--.~
Cd~L~.)
ELEVATION
I.
--
...
500
TIMB ER
PAC KING
4
LFRAME
25 x 25 x 4
A
PLAN
VIEW
A-A
<<
671
Appendices
-SHEATHING
PIPE
1100mm LONG
SHEATHING
SOLDERED
JOINT
1W
I 0~
49
M.SPLATE
100*100*10mm
PAN
fig. 1890/13
<<
flin1cn~ionsare in mm.
672
Appendices
H S FL. ATE
so oso~0mm
~OL.DERNO
NI 5 pEAT L
lOOxlOOx 3 mm~
--100
I SHEATHING SAMPLE LENGTH I
Fig 1800/1 4
<<
673
PJ.~STRESSINGREPORT:
NUMIIER OR NAME OF THE BRIDGE:
2
kglcni
APPEN[)JX I 800/U
kg/cm2
Pumps:
Cube Strength :
kg/cm
DATh OF PRESTRESSING______________
Gauges
at
28 days
Cable
Stressing
Secjuence
Calculated
Elongation
mm
Gauge Mark
Readings cii extens~on
in mm it the pressure
of200k~/cm ~
11
12
13
kg/cm2
14
15
16
I.x,ckiog
~
~E
~
~3
~E
z~
2
<~
~<
~1
<
~e
..
<~
-.~
~~
~3
<<
~
~
~
~
674
22
23
24
25
kiter
Total
24Ht~ Drawmn
26
-~~J
<r
>~
>
~
~<
~
,
.
~
Contrntor
~20~211
<
Client
19
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Appendices
Appendix
1800/Ill
<<
675
Appendices
All ducts should have grout openings at bnt.h ends. For this porpose special
openings should be provided where such openings are not available at end anchorages. For draped (curved) cables vents shall be provided at all crown and
valley points. 0 is a good practice so provide additions] air vents at suitable
intervals not exceeding 20 m. All grout openings or vents should include provisions
for preventing grout leakage.
h)
Standard details of fixing couplers, inlets, outlets and air vents to the duct!
anchorage shall be followed as recommended by the supplier of the prestressing
systetn.
23,3. Ducts should be securely fastened at close intervals. All unintended holes or openings in the duct must he repaired prior to concrete
placing. The joints of the couplers and the. .sheathing should be made
water proof by use of adhesive tape or similar suitable sy~itemcapable
of giving leak proof joints. Groin openings and vents must be securely
anchored to the duct and to either the forms or to reinforchig steel
to prevent displacement during concreting operations due to weight,
buoyancy and vibrations.
2.5.4. Ducts require very careful handling as, being of thin metal,
they are susceptible to leakage due to corrosion in transit or storage,
by It lnng/nppLno in handl ng parttc til irl) ~slu_n p1 KL d adjotn tng to
reinforcing steel, by pulling apart at j.oints while insertin,g tendons
prior to concreting, or by accidental punctur~ng while drilling for form
ties/inserts. Duels are also liable to damage by rough use of internal
vibrator and sparks from welding being done. close by.
3. EQuIPMENT
3.1, Grout Mixer and Agitator
It is ~ssentialthat the. grout is maintained in a homogeneous state
and of uniform consistency so that there is no separation of cement.
Use of grout niixers to obtain a colloidal grout is essential. The mixer
should ha.ve an additional storage device, with an agitator to keep the
groifi moving continuously before it is pumped in the duct. Positive
reciprocating type grout pumps should be used.
<<
676
Appendices
<<
677
44.nendice.s
Grouting shall be carried out as early as possible hut not later than 2 weeks
of stressing a tendon. Whenever this stipulation cannot be complied with for
unavoidable reasons, adequate temporary protect~onof the steel against corrosion
by methods or products which will not impair the tsltintate adherence of the
iejected grout should he ensured till grooting. The sealing of the anchorage ends
after concreting is considered to he a good practice to prevent ingress of water.
For structores in aggressivc environment, sealing of the anchorage ends is
mandatory.
Notes
i)
<<
Application of some patented water soluble oils for coating of sieel/VPI powder
injection! sending in of hot, dry, oilfree compressed air through the vents at frequent
intervals have shown some good results.
67:.
Appendices
ii)
iii)
Some of the method.t recommended for sealing of anchorages are to seal the openings
with h:itstmen impregnated gunny bag or water proof pape:r or by building a brick
l:)edestal plastered on all faces enclosing the exposed wirea outside the anchorages.
Aey traces of oil if applied to steel for presenting corrosion should he removed
before grouting operation..
iv)
Ducts shall be flushed with water for cleaning as well as for wtttiog the surfaces
of the duct walls. Water used for flushing should be of same citsslity as used for
grousing. Is may, however, contain about I per cent of staked lime or quick lime.
All water should he drained thorough the lowest vent pipe or by blowing compressed
air through the duet
v)
The
water in the duct shoukl he 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)
lhe connection between the noxate of the injection pipe and duct should be such that
air cannot he ssteked in.
vii) All outlet points including vent openings should be kept open prior so commencement
of injection grout
viii) Before grousing, all air in the pump and hose tlsould be expelled..
circuit of the pump should be air-tight
ihe suction
<<
a)
h)
c)
For vertical cable or cables inclined more than 60 degrees to the hori~.,.ontal,
injection should be effected from the lowest anchorage or vent of she duct
d)
The method of injection should ensure complete filling of the ducu, To verify
this, it is advisable to compare the volume of the space to be fitted by the injected
grout with the quantity of grout actually injected.
e)
I)
In the case of cablea draped downwards e.g. in cantilever constnsction simultaneous injection from both ends may be adopted Fig. lSOO!lII- 1.
g)
1* in continuous movement.
679
Appendices
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<<
for (houtin,f
680
Appendices
Appendix 1800/IV
C ROUTING
,loh Naistc:
Span No.
~_.._.
.__._.__
Cable No:
__~_
_____.
Date of Grouting:..
W!C
RECORD
11501k.
Ratio:
Grout
Finish
_.
jisrte:
Start,.
tLC~SJip.rtteStt
(;rout mixer
Cable dues:
Diarrteter
...,~
1_englls
_._....
...__._.~.
._
___________.~.
__________
Grout ptsmp
._......
________________
.........
..._..____.
Regrouting ___________________.______________
Grouting pressure
(~crnentconsu sp~iort: 1)seoresseal
._........_..
Aetu:sl
outlet
Yes/No
Cable duct
Yes/No
Sealed
Yes/No
________________________________
5re~gtoutitigebeUks:
Free
of
blockaee
Inlet:
Yes/No
Vents:
Yes/No
Yes/No
Yes/No
i~sss~:
ge of grout througlt i:sutlet
Yes/No
______________ .____________
_______________
_____________
________
<<
(Tontractor
681
Systerts Supplier
1:spendiees
Li)
Disconnec Lion is facitiutted if a short length of tles.thie tube connects the duct
and injection pipe. This can be squeezed and cut off after she grout has hardened
<<
si
h)
lbe temperature of the grout shall not exceed 25 degrees Celsius. For increasing
the workability of grout, tts temperature may be lowered by use of chilled water
or by putting ice outside she grout storage container.
c)
When the cahlcs are threaded after concreting, the duct must be tetnporaril~
stiffened during cond.sct ing by insertmg bunch of strandt, wires or reinforcemen
or a rigid PVC pipe or any other suitable method.
d)
Duruig concreting, case shall be taken to ensure that the sheathing is not damaged.
Needle vibrators shall be used with extreme care by well experienced staff
only, to ensure against such damage.
e)
It is A gsrod prsctic:e to sstose she cables in h:rsh iti rections dursng the c:oncreting
opemations. This can easily he done by light hammering she ends of the wtresf
stndnds during concreting It ts also advisable that 3 to 4 hours after cdncreung
the cable should be moved bosh ways through a distance of about 20 ems. With
such movement, any leakage of tnorumr svhich has taken place in spite of all
precautions, loses bond with the cables, thus reducing the chance of blockages
This operation can also be clone by fit irig prestresssng jacks, at one end pulling
the entire cable and then repeating she ot.Teration by fixing the jack at the other
esid.
5)
g)
In ease. sif stage pmest nr ssing, cables tsTnsioncd in tbe. first stage should not rr.mnain
usigrosite.d till all cables are stressed Is is good pmacttce, while grouting any
duct in stage prestressing, to keep all the remaining duets filled up with watem
containing I per cent time or by running water through such dtsete till the gn:tut
has set. After grouting the particular cable, the water in the other cables
should be draineit and removed wish compressed air so prevent corrosion
hi
Care should he t:tkemt so avoist leaks frnm one duct to atsother at joints of precast
metnbers in pamntettlar
i)
End faces whese anchorages are located are vulnerable points of entry of water.
thisy hase io he necessarily protected with an effective harrier. Recesses shosild
be packed with mortar concrete and should preferably be painted with water
proof paint.
.ti
682
should
he