Draft 2004 - Rev01

GOVERNMENT OF THE PUNJAB
COMMUNICATION AND WORKS DEPARTMENT
REVISED
STANDARD SPECIFICATIONS
FOR
ROAD AND BRIDGE CONSTRUCTION
December 2004
DRAFT
Revision 01
PUNJAB HIGHWAY DEPARTMENT

2-LAKE ROAD, LAHORE, PAKISTAN
Punjab Highway Department Standard Specifications for Road & Bridge Construction
Draft 2004
PREFACE
The revision and updating of Standard Specifications for Road and Bridge
Construction (1971) has since long been due. Highway Engineering practices have developed
a great deal over the period owing to improved technology, more of mechanization, better
construction equipment and more knowledge about materials. Demand for better facilities
and trend of using larger and heavier vehicles by the transporters also necessitated review of
standards. With the replacement of Composite Schedule of Rates, 1998 with Market Rates
System with effect from July 1, 2004, it became all the more necessary to address the new
requirements of General Specifications.
Pursuant to a summary initiated by the Finance Department Government of
the Punjab, on 24.06.2004 regarding adoption of market rate system, review of Specifications
and Rate analysis standardized by Finance Department was also contemplated. Accordingly, a
Sub Committee comprising Chief Engineers (Highway) North and South and Directors of the
three support Directorates was constituted by the Secretary to Government of the Punjab,
Communication & Works Department, Lahore for updating the specifications in a meeting
held on 1.10.2004.
The sub committee held a series of meetings at Road Research & Material
Testing Institute, Lahore and consulted various Standards and Specifications of different
agencies. Some of the Executive Engineers / Deputy Directors were also associated for
necessary assistance. While amendments in various sections of the existing specifications
have been made and standards updated, new items have also been added to cater for the
future needs of the Communication & Works Department. Suggestions and comments for
further improvement will, however, be particularly welcome and will be carefully considered.
Thanks are expressed to all members of the Sub Committee for squeezing time
out of their busy schedules and making consistent efforts in completing the assignment by the
target date. Director Bridges contributed considerably in updating the Standards for
Structures. An appreciation is also due to Director, Road Research Institute and to Mr. Sohail
Raza, Dy. Director, in particular, for the preparation and compilation of the Specifications.
It is hoped that this document will contribute effectively in improving the
standard of construction and quality control of Highway Projects in the Department.
(MOHAMMAD IQBAL KHOKHAR)

Lahore, Chief Engineer (North)
December, 2004 Punjab Highway Department, Lahore
( Chairman )
(RANA MOHAMMAD GHOUS) (CH.KHUDA YAR)

Chief Engineer (South) Director Bridges,
Punjab Highway Department, Lahore Punjab Highway Department, Lahore
( Member ) ( Member )
(MOHAMMAD YOUSAF KHAN) (KHAYYAM QAISER)

Director Road Research & Material Director Planning & Design Cell, Punjab
Testing Institute, Lahore. Highway Department, Lahore
( Member ) ( Member )
Draft 2004
CONCISE TABLE OF CONTENTS
DESCRIPTION PAGE
CHAPTER 100 GENERAL 1
CHAPTER 200 CONSTRUCTION EQUIPMENT AND 22

LABORATORY
CHAPTER 300 SITE CLEARANCE 30
CHAPTER 400 EARTH WORK AND RELATED 38

OPERATIONS
CHAPTER 500 SUB-BASE AND BASE CONSTRUCTION 70
CHAPTER 600 BITUMEN BASE AND SURFACING 99
CHAPTER 700 CEMENT CONCRETE 129
CHAPTER 800 HIGHWAY STRUCTURES 169
CHAPTER 900 INCIDENTAL CONSTRUCTION 296
CHAPTER 1000 ROADWAY CONSTRUCTION 367

MATERIALS
CHAPTER 1100 MISCELLANEOUS 410
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DETAILED TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
CHAPTER 100 GENERAL 1

101 GENERAL 2
CHAPTER 200 CONSTRUCTION EQUIPMENT AND 22
LABORATORY
201 CONSTRUCTION EQUIPMENT - 23
GENERAL REQUIREMENTS
202 FIELD TEST LABORATORY FOR 26
QUALITY CONTROL
211 MAINTENANCE OF TRAFFIC 27
CHAPTER 300 SITE CLEARANCE 30
301 CLEARING AND GRUBBING 31
302 REMOVAL OF TREES 33
303 STRIPPING 35
311 REMOVAL OF EXISTING STRUCTURES 36
CHAPTER 400 EARTH WORK AND RELATED 38
OPERATIONS
401 SCARIFICATION OF EXISTING 39
ROAD/BREAKING OF ROAD
PAVEMENT STRUCTURE
402 STRUCTURAL EXCAVATION AND 40
BACKFILL
403 ROADWAY EXCAVATION/BORROW 47
EXCAVATION
409 SUB-GRADE PREPARATION 50
410 IMPROVED SUB-GRADE 54
411 MAKING EMBANKMENT 58
CHAPTER 500 SUB-BASE AND BASE 70
CONSTRUCTION
501 MECHANICALLY STABILIZED SUB- 71
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BASE
515 GEOTEXTILES 78
521 SUB BASE COURSE BRICK PAVEMENTS 84
541 DRAINAGE LAYER UNDER 86
SHOULDERS
551-A WATER BOUND MACADAM BASE 88
COURSE
551-B AGGREGATE BASE COURSE 93
552 BRICK EDGING 98
CHAPTER 600 BITUMINOUS BASE AND SURFACING 99
601 BITUMINOUS PRIME COAT 100
611 BITUMINOUS TACK COAT 103
621 PLANT MIX BITUMINOUS BASE 105
COURSE
631 BITUMINOUS SURFACE TREATMENT 112
AND SURFACE DRESSING
651 BITUMINOUS PLANT MIX SURFACE 119
COURSE/BINDER COURSE/WEARING
COURSE
652 HOT RECYCLING OF ASPHALT 126
CONCRETE
CHAPTER 700 CEMENT CONCRETE 129
701 CEMENT CONCRETE 130
711 CEMENT CONCRETE PAVEMENT 155
721 PLUM CONCRETE 167
CHAPTER 800 HIGHWAY STRUCTURES 169
801 BRICK MASONRY 170
802 STONE MASONRY 176
803 GABIONS 190
821 REINFORCING STEEL WORK 201
831 STRUCTURAL STEEL WORK 207
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841 WELL FOUNDATION 216

851 DRILLED/BORED PILES 223
852 DRIVEN FOUNDATION PILES 235
861 GUIDE BANK 251
872 PLASTERING AND POINTING 255
891 PIPE CULVERTS 259
892 BED TO CONCRETE PIPE CULVERTS 268
893 UNDER DRAIN 270
894 HEADWALLS, WINGWALLS, PARAPETS 272
895 MANHOLES 274
896 DROP INLETS AND CATCH BASINS 278
897 SLOPE PROTECTION 281
898 CURB AND GUTTER 288
899 CEMENT CONCRETE SIDE WALK 293
CHAPTER 900 INCIDENTAL CONSTRUCTION 296
901 METAL BEAM GUARD RAIL 297
902 CEMENT CONCRETE BEAM 300

GUARDRAIL
903 TRAFFIC ROAD SIGNS 302
904 PAVEMENT MARKING 308
905 REFLECTORIZED PAVEMENT STUDS 321
906 FENCING 325
911 BEARINGS 328
921 BRIDGE DECK JOINT SEALS 359
931 RAIN WATER OUTLETS FOR BRIDGE 362
DECK SLAB
941 KILOMETER STONES AND RIGHT OF 363
WAY MARKERS
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CHAPTER 1000 ROADWAY CONSTRUCTION 367

MATERIALS
1001 PORTLAND CEMENT 368
1011 BITUMINOUS BINDERS 374
1031 COARSE AGGREGATE FOR CEMENT 382
CONCRETE
1032 FINE AGGREGATE FOR CEMENT 385
CONCRETE
1033 MORTAR SAND 389
1034 MINERAL FILLER 391
1041 CLAY BRICKS AND CLAY TILES 392
1046 STONE FOR MASONRY 395
1051 WATER 398
1052 ADMIXTURES FOR CONCRETE 400
1061 HIGH TENSILE STEEL 405
1081 PAINTS (OTHER THAN ROAD 407
MARKING)
CHAPTER 1100 MISCELLANEOUS 410
1101 STANDARD BID SCHEDULE FORM 411
Annexure-1 RECOMMENDED MAJOR 429

CONSTRUCTION EQUIPMENT
Annexure-2 SCHEDULE FOR SAMPLING AND 432

TESTING OF VARIOUS MATERIALS
Annexure-3 CONVERSION FACTORS 441
REFERENCES 443
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CHAPTER 100
GENERAL
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SECTION 101
GENERAL
101-1 INTRODUCTION
101-1.1 Preamble
The Specifications have been formulated for road and bridge

construction keeping in view that following types of activities are
being carried out in the Department.
i) Construction of limited access roads, new Highways, Bridges

and allied works.
ii) Rehabilitation and Improvement of existing road network.
All the above aspects of construction and rehabilitation have been

covered in these Specifications. Subsequent chapters would give a list
of such items of work with an indication of their probable use, in case
of the above two categories of works.
101.1.2Standards
These Specifications describe the requirements and procedures for

execution of work items to achieve required workmanship and quality.
The materials to be used shall conform to specifications and testing
procedures as per American Association of State Highway and
Transportation Officials (AASHTO), the American Society for Testing
and Materials (ASTM) or British Standard (BS) as indicated in their
latest editions. Samples of materials for laboratory tests and their
subsequent approval shall be utilized according to these references.
101.1.3Manpower
Contractor shall also provide skilled manpower in adequate number,

who can perform execution with quality and workmanship control in
accordance with the requirements of the work item.
101.1.4Equipment
Number and kind of Equipment required for different items of work

shall be planned by the contractor keeping in view the workmanship
required by a particular item and the quantity of finished item required
to be carried out in eight hours shift. The Engineer Incharge shall
approve such planning or any changes shall be proposed for guidance
of the Contractor. However, this procedure shall not relieve the
Contractor of his contractual obligations pertaining to performance and
maintenance of project.
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101.1.5Alternative Equipment
While a few of these specifications may provide that equipment of a

particular size and type is to be used to perform portions of the work, it
is to be understood that the deployment and use of new or improved
equipment is to be encouraged.
The Contractor may request, in writing, permission from the Engineer

Incharge to use equipment of a different size or type in place of the
equipment specified or recommended in these chapters.
The Engineer Incharge before considering or accepting such request

may require the Contractor to furnish, at his own expense, evidence to
satisfy him that the equipment proposed for use by the Contractor is
capable of producing work equal to or better in quality than, that which
can be produced by the equipment specified.
If such permission is granted by the Engineer Incharge, it shall be

understood that such permission is granted for the purpose of testing
the quality of work actually produced by such equipment and is subject
to continuous attainment of results which, in the opinion of the
Engineer Incharge, are equal to or better than that which can be
obtained with the equipment specified. The Engineer Incharge shall
have the right to withdraw such permission at any time when he
determines that the alternative equipment is not producing work of
equal quality, to that which can be produced by the equipment
specified. Upon withdrawal of such permission by Engineer Incharge,
the Contractor will be required to use the equipment originally
specified and shall, in accordance with the directions of the Engineer
Incharge, remove and dispose off or otherwise remedy, at his own
expense, any defective or unsatisfactory work produced with the
alternative equipment.
Neither the Employer nor the Contractor shall have any claim against
each other, for either the withholding or the granting of permission to
use alternative equipment, or for the withdrawal of such permission.
Nothing in this clause shall relieve the Contractor of his responsibility

for furnishing materials or producing finished work of the quality
specified in these specifications.
101.1.6Storage of Materials
Articles or materials to be supplied or incorporated in the work shall be

stored in such a manner as to ensure the preservation of their quality
and fitness for the work, and to facilitate inspection, with no or
minimum hazard to road users.
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101-1.7 Defective Materials
All materials which the Engineer Incharge has determined as not

conforming to the requirements of the drawings and specifications will
be rejected whether in place or not. They shall be removed
immediately from the site of the work. No rejected material, the
defects of which have been subsequently corrected, shall be used in the
work, unless approval in writing has been given by the Engineer
Incharge. Upon failure of the Contractor to comply with any order of
the Engineer Incharge made under the provisions in this clause, the
Engineer Incharge shall have authority to cause the removal of rejected
material and to deduct the cost thereof from any payments due or to
become due to the Contractor.
101-1.8 Trade Names and Alternatives
For convenience in designation on the plans or in the specifications,

certain articles or materials to be incorporated in the work may be
designated under a trade name or the name of a manufacturer and the
catalogue information. The use of an alternative article or material that
is of equal quality and of the required characteristics for the purpose
intended will be permitted, subject to the following requirements.
The responsibility of proof as to quality and suitability of alternatives

shall be upon the Contractor and he shall furnish all information
necessary as required by the Engineer Incharge. The Engineer Incharge
shall be the sole judge as to the quality and suitability of alternative
articles or materials and his decision shall be final.
Whenever the specifications permit the substitution of a similar or

equivalent material or article, no tests or action relating to the approval
of such substitute material will be made until the request for the
substitution is made in writing by the Contractor accompanied by
complete data as to the quality of the material or article proposed. Such
request shall be made well in time to permit approval without delaying
the work.
101-1.9 Frequency of Tests & Test Designation
Frequencies of tests for the items of construction have been given in

subsequent chapters. Test designation and procedure will be used as
given in the latest version of relative publication. Schedule for
sampling and testing of various materials is given at Annexure-2.
101-1.10 Testing
Unless otherwise specified, all tests shall be performed in accordance

with the methods used by AASHTO/ASTM/BSS and shall be arranged
by the contractor under the supervision of the Engineer Incharge or his
designated representative at site or in lab.
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Whenever the specifications provide an option between two or more

tests, the Engineer Incharge will determine the test to be used.
Whenever a reference is made in the specifications to a specification

manual, or a test designation either of the American Society For
Testing and Materials, the American Association of State Highway and
Transportation Officials, Federal Highway Specification, or any other
recognized organization, and the number or other identification
representing the year of adoption or latest revision is omitted, it shall
mean the specification, manual or test designation in effect on the day
30 days prior to the date for submission of bids. Whenever said
specification manual or test designation provides for test reports (such
as certified mill test reports) from the manufacturer, copies of such
reports identified as to the lot of material, shall be furnished to the
Engineer Incharge who may at his discretion, select random samples
from the lot for testing. Test specimens from the random samples
including those required for retest, shall be prepared in accordance
with the referenced specification and furnished by the Contractor at his
expense. The number of such samples and test specimens shall be
entirely at the discretion of the Engineer Incharge. Unidentified metal
products such as sheet plate, hardware, etc. shall be subject to the test
requirements prescribed by the Engineer Incharge.
When desired by the Engineer Incharge, the Contractor shall furnish,

without charge, samples of all materials entering into the work and no
material shall be used prior to approval by the Engineer Incharge.
Samples of material from local sources shall be taken by or in the
presence of the Engineer Incharge, otherwise the samples will not be
considered for testing.
101.1.11 Utility Lines.
The Contractor shall conduct his operations, make necessary

arrangements take suitable precautions and perform all required works
incidental to the protection of and avoidance of interference with
power transmission, telegraph, telephone and natural gas lines, oil
lines, water and sewerage mains and other utilities within the areas of
his operations in connection with his contract and the Contractor shall
save harmless and indemnify the Employer in respect of all claims,
demands, proceedings, costs, charges and expenses whatsoever arising
out of or in relation to any such interference.
101-1.12 Safety Precautions.
The contractor shall adequately provide for the safety, health and
welfare of persons and for the prevention of damage to works,
materials and equipment for the purpose of or in connection with the
Contract.
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101-1.13 Inspection
The Departmental Engineers and consultant (where employed) shall at

all times, have safe access to the work during its construction, and shall
be furnished with every reasonable facility for ascertaining that the
materials and the workmanship are in accordance with the
requirements and intentions of these Specifications, the Special
Provisions, and the plans / drawings. All works done and all materials
furnished shall be subject to inspection by Engineer Incharge.
The inspection of the work or materials shall not relieve the Contractor
of any of his obligations to fulfill his contract as prescribed. Work and
materials not meeting such requirements shall be made good and
unsuitable work or materials may be rejected, notwithstanding that
such work or materials have been previously inspected by the Engineer
Incharge or that payment therefore has been included in a progress
estimate.
101-1.14 Removal of Rejected and Unauthorized Work.
All works, which have been rejected, shall be remedied, or removed

and replaced by the contractor in an acceptable manner and no
compensation, will be allowed to him for such removal, replacement or
remedial work.
Any work done beyond the lines and grades shown on the plans or
established by the Engineer Incharge or any extra work done without
written authority will be considered as unauthorized work and will not
be paid for.
Upon order of the Engineer Incharge, unauthorized work shall be

remedied, removed, or replaced at the Contractor’s expenses, if he
refuses or delays.
Upon failure of the Contractor to comply promptly with any order of

the Engineer Incharge made under this item, the Employer may cause
rejected or unauthorized work to be remedied, removed, or replaced
and to deduct the costs from any payment due or to become due to the
Contractor.
101-1.15 Alternative Methods of Construction.
Whenever the plans or specifications provide that more than one

specified methods of construction or more than one specified type of
construction equipment may be used to perform portions of the work
and leave the selection of the method of construction or the type of
equipment to be used up to the Contractor, it is understood that the
Employer does not guarantee that every such method of construction or
type of equipment can be used successfully throughout all or any part
of any project. It shall be the Contractor’s responsibility to select and
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use the alternative or alternatives, which will satisfactorily perform the

work under the conditions encountered.
101.1.16Conformity with Contract Documents and Allowable Deviations.
Work and materials shall conform to the lines, grades, cross sections,
dimensions and material requirements, including tolerances, shown on
the plans or indicated in the specifications. Although measurement,
sampling and testing may be considered evidence as to such
conformity, the Engineer Incharge shall be the sole judge as to whether
the work or materials deviate from the plans and specifications, and his
decision relating to any allowable deviations there from shall be final.
101.1.17Trial Section
Contractor shall submit complete methodology of trial section for

approval of the Engineer Incharge. Trial sections shall be prepared for
each type of road pavement layer. Inspite of the approval of Engineer
Incharge for trial section, contractor shall be responsible for the quality
of work. Contractor will provide minimum of following information in
the methodology.
i) Equipment to be used
ii) Layer thickness adopted
iii) Per day production
iv) Results of tests.
101.2 SCOPE
The Standard Specifications is a part of contract documents which

shall be read in conjunction with the following contract documents
which are mutually explanatory to one another and mentioned
hereunder, with the order of precedence as given in the Condition of
Contract.
(i) Contract Agreement (Latest Edition)

(ii) Addenda.
(iii) Letter of acceptance
(iv) Additional conditions
(v) Drawings.
(vi) Specifications.
(vii) The bid and Appendices as Annexures.
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101-3 DEFINITION OF TECHNICAL TERMS
Whenever in these specifications or in other documents pertaining to the contract,

the following terms and abbreviations appear, their intent and meaning shall,
unless specially stated otherwise, be interpreted as given below:-
Aggregate Inert material such as sand, shingle, broken stone, or

broken bricks which, when bound together by an
added matrix, forms a conglomerated mass, as in
concrete or bituminous paving mixtures. The term
coarse aggregate is employed for aggregate retained
on US Standard Sieve No. 4 (4.75 mm) for concrete
and sieve No. 8 (2.38 mm) for bituminous paving
mixtures.
Alignment The position and direction given to the centerline of

a road in plan or profile.
Alignment (Horizontal) The position and direction of centerline of a road in

plan.
Alignment (Vertical) The position and direction of centerline of a road in

profile.
Alignment The alteration to the alignment of an existing road.

(Re-alignment)
Apron A layer or layers of concrete brick or stone masonry

or stone, placed at the entrance or outlet of culvert or
waterway or along the toe of an embankment etc, to
prevent scour.
Asphalt A dark brown to black cementitious material in

which the predominating constituents is bitumen
which occur in nature or are obtained in petroleum
processing
Axle Load The total load transmitted by all wheels whose

centers may be included between two parallel
transverse vertical planes 1.02 meter (40 inches)
apart extending across the full width of the vehicle.
Back Fill Material used to replace or the act of replacing

material removed during construction, also may
denote material placed or the act of placing material
at the back of abutments, retaining walls or similar
structures.
Ballast Gravel, Broken stone, Broken Brick etc.
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Base Course The layer or layers of specified or selected material

placed in designated thickness on a sub-base or
subgrade to support a surface course.
Batching Plant The mechanical equipment for measuring either by

weight or by volume, the quantities of different
ingredients required to make up each complete
charge of mixer.
Bid It is priced offer by the contractor to accomplish

specific items of work or the entire project, in
accordance with terms and conditions of the contract
documents.
Bid Schedule It is a priced bill of quantities containing rates

offered by the contractor for completion of various
items according to drawings and specifications of the
projects.
Binder A material used for the purpose of holding solid

particles together as a coherent mass.
Binder Course A mix of graded aggregate and bituminous material

mixed in a plant which constitutes the lower layer of
the surface course.
Bitumen The by-product of the distillation of or evaporation

of crude petroleum either by natural process or in a
refinery; the basic constituents of an Asphalt
essentially consist of hydro-carbons. It is
characteristically solid to semi solid, black to dark
brown in colour, is adhesive, and melts or softens on
the application of heat.
Bitumen Bitumen obtained after the final stage of distillation

(Straight Run) of petroleum of suitable type.
Bitumen (Cut Back) Bitumen whose viscosity has been reduced by the
addition of some suitable volatile diluent.
Bitumen (Emulsion) An emulsion in which bitumen is suspended in a

state of minute sub-divisions in water or in an
aqueous solution with the aid of suitable emulsifying
agents.
Bituminous Concrete A designed combination of dense graded mineral

aggregate, filler and straight run bitumen mixed in a
central plant, laid and compacted while hot.
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Bleeding A road condition in which free binder exudes in

(of bituminous roads) liquid form from the surface of a bituminous road in
hot weather.
Blinding The application of a loose layer of specified fine
material to reduce bleeding.
Borrow Suitable material used primarily for road

embankment.
Borrow area A place, outside the right of way, unless otherwise

specified, from which fill material will be obtained
for construction of embankment etc.
Box culvert A culvert constructed of rectangular cross-section.

Bridge A structure designated to secure passage over an
obstacle or waterway of more than 6 meters ( 20
linear feet)
Breast wall A retaining wall on the hill side.

By-pass road A road so constructed as to enable through traffic to
avoid congested areas or other obstructions to
movement.
Calendar day Every day shown on the calendar.

C.B.R. An empirical measure of the bearing capacity of a
(California Bearing sub-grade, sub-base, base or pavement expressed as
Ratio) a percentage of the bearing capacity of a standard
sample of crushed stone.
Camber The convexity given to the curved cross-section of a

carriage way or foot path.
Carpet See bituminous concrete.

Carriage way That portion of a highway intended primarily for
vehicular traffic.
Causeway A paved waterway slightly raised above normal bed

of the water channel.
Chipping Crushed angular stone fragments of single size

materials having nominal size between 2 mm (0.08
in) and 25 mm ( 1 inch)
Contract and Contract The written agreement between the Department and
Documents the contractor setting forth the obligations of the
parties there under, including, but not limited to, the
performance of the work, the furnishing of labour
and materials, and the basis of payment. The
Contract Documents include the invitation for
tenders, the tender, notice of award, form of contract,
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contract bond, general conditions and special

conditions, general specifications, supplemental
specifications, special specifications plan, addenda,
directives, change orders and supplemental
agreements that are required to complete the Work,
all of which constitute one instrument.
Contract Item A specifically described unit of work for which a

(Pay Item) unit price is provided in the tender.
Contract time The number of working days or calendar days

allowed for completion of the contract, including
authorized time extensions. In case a calendar date of
completion is shown in the tender, in lieu of the
number of working in calendar days the work
contemplated shall be completed by that date.
Contractor The person, firm or corporation with whom the

contract has been made by the employer, or to whom
the contract has been assigned.
Compaction
(a) General The process of inducing a closer packing of particles
by mechanical means.
(b) Soil The process whereby soil particles are constrained

by rolling or other mechanical means to pack more
closely together reducing air voids, and increasing
the dry density of the soil.
Crown The highest part of a curved surface such as an arch,

or a carriage way in cross section commonly at or
near the center.
Culvert A structure designed to secure passage over an

obstacle or waterway of not more than 6 meters (20
linear feet)
Department The Highway Department, Government of the

Punjab unless otherwise specified.
Detour A temporary road, adequately maintained, for the use

of the traveling public through the project area.
Drain A trench cut in the ground for the purpose of

receiving and conducting drainage water.
Dry Density The weight of material after drying it to constant

weight at 105oC (221oF) contained in a unit volume.
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Dry Density (Maximum) The dry density of soil obtained by a specified

amount of compaction at the optimum moisture
content.
Dual Carriageway A road in which there are two physically separated

carriage ways reserved for up and down traffic
separately.
Engineer Incharge The duly authorized representative of the

Government as Incharge of the work at site/acting
directly or through his designated representative who
is responsible for supervision of the work.
(where the term “ The Engineer” is used in this
document, it should be taken to mean Engineer
Incharge).
Embankment The work built above the natural ground by the

deposition of material to support pavement structure.
Equipment All machinery and equipment, together with the

necessary supplies for up keep and maintenance, and
also all tools and apparatus necessary for the proper
construction and acceptable completion of work.
Expansion Joint A space between two rigid parts of the same

structure, formed to allow small relative movements
to occur without the development of serious stresses,
with or without provision of means to preserve
functional continuity
Extra work An item of work not provided for in the contract as

awarded but found essential to the satisfactory
completion of the work within its intended scope.
Filler A finely divided mineral powder mostly passing 75-

micron sieve, added to bitumen or the like, or to a
mixture containing the same.
Final Hand Over The final acceptation of the work by the Department,
as authorized by the General conditions of the
contract.
Flexible Pavement A form of road construction, which, for the purpose

of design, is assumed to have no flexural rigidity.
Force Majeure An unexpected and disruptive event, which may

operate to excuse a party from a contract or part
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thereof.
Free Haul The maximum distance upto which excavated

material is transported without extra charge.
Gallon Unless otherwise specified, the word “gallon” used

in the specifications designates the imperial gallon
(4.546 litres) and not U.S. gallon (3.785 litres).
Graded Material Material having particle sizes within the limits

specified.
Gradient The rate of rise or fall with respect to the horizontal

plane along the centerline of a road or bridge.
Grading a) The proportions by weight, of particle sizes in a

granular material.
b) The operation of bringing the profiles to the required

grades.
Gravel Waterborne stones of irregular shape and size

occurring in natural deposits, with or without some
finer material.
Gravel Road A road constructed with layers of gravel with or

without the addition of sand or clay.
Grubbing Uprooting small trees, hedges, brushwood etc.
Guarantor A financial institution approved by the Government

which provides the guarantees called for in the
contract documents.
Haul (Lead) The total distance through which material is

transported.
Interchange A grade separated intersection with one or more

turning roadways for travel between intersecting
legs.
Intersection The general area where two or more roads join or

cross, within which are included the roadway and
roadside facilities for traffic movements in the area.
Island A central or subsidiary area in a roadway generally at

road junctions, shaped and placed so as to constrain
and control the movement of traffic.
Joint filler A strip of compressible material used to fill the space
in an expansion joint.
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Kerb (Web) A border of bricks, stone, concrete or other rigid

material formed at the edge of a roadway.
Laybys Areas for the parking of motor vehicles off the

roadway other than the shoulders.
Litre/ Liter One thousandth part of a cubic meter (1000 ml)
Loam Soil consisting of a natural mixture of clay, sand and

silt.
Macadam A layer of coarse graded, angular mineral aggregate

with a filler of fine aggregate interlocked by
compaction.
Maintenance period The period during which a contractor may be

required to maintain at his own expense the contract
works after completion.
Major road A road which has, or to which is assigned a priority

of traffic movement over that of other roads.
Minor road A road which has, or to which is assigned, lesser

priority for traffic movement than that of a major
road.
Median The portion of a divided highway or street separating

the carriageways for traffic movement in opposite
directions.
Overhaul The distance of the Haul in excess of the free Haul.
Pavement or Pavement The combination of sub-base, base and surface

structure course placed on a sub grade to support the traffic
load and distribute it over the subgrade.
Paving A wearing course laid upon a prepared foundation

consisting of units fitted closely together or of a
layer of bitumen coated macadam, concrete or the
like.
Penetration macadam A macadam constructed with application of bitumen

(Bitumen macadam) by penetration process.
Potholes Bowl shaped holes in the pavement resulting from

localized disintegration.
Prime coat An application of low viscosity bitumen to an

absorbent surface.
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Profile grade The grade intersecting the top surface of the

proposed wearing surface, usually along the
longitudinal centerline of the roadbed.
Retaining wall A wall constructed to resist lateral pressure from the

adjoining ground, or to maintain in position a mass
of material usually the road embankment.
Revetment A facing of stone or other material laid on a sloping

(Pitching) face of earth to maintain the slope in position or to
protect it from erosion.
Right of way (ROW) The land acquired or secured or reserved for

development, improvement and construction of all
structures pertaining to a road.
Road bed The graded portion of a road prepared as a

foundation for the pavement structure and shoulders.
Road Formation The width of a road on top consisting of pavement

and shoulders.
Roadway That portion of right of way which includes the road

formation, slopes of embankment and road side
ditches (infilling) or full width from back to back of
retaining or breast walls.
Safety Fence (a) A fence erected to prevent vehicles from

leaving the carriageway at a dangerous
place.
(b) A fence erected for the safety of pedestrians
(c) A fence on a highway to prevent any
specified type of traffic from leaving the part
of highway appropriate to its use.
Scarifying The systematic disruption and loosening of the top of

a road or of natural ground by mechanical or other
means.
Screening Fine material to fill voids or interstices in a layer of

macadam base course.
Seal coat A thin treatment consisting of bituminous material,

usually with coarse aggregate, applied to a surface
course to close the voids with the object of rendering
the surface water proof.
Section (Cross) A vertical section at right angles to the center line,

showing the elevation of the ground.
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Section (Longitudinal) A vertical section showing the elevation of the

ground usually along the center line.
Service road A temporary road with reasonably good riding

surface constructed parallel to main road for the
transportation of machinery and construction
material etc.
Shingle Round or water-worn stones of irregular size and

shape as occurring in natural deposits and
substantially free from sand
Shoulders The portion of the road formation adjacent to and

level with the pavement but generally of local soil or
of lighter construction, to provide an opportunity for
vehicles to leave the pavement for passing or parking
or to provide lateral support to the pavement.
Sidewalk That portion of the roadway primarily constructed

for the use of pedestrians.
Site The land and other places provided by the

Department for the execution of the work.
Site Engineer The on site representation of the contractor duly

authorized to receive and execute all instructions of
the Engineer Incharge and to supervise and direct all
of the contractors construction operations in all
phases of the work.
Soil Any naturally occurring loose or soft deposit,

forming part of the earth’s crust and resulting from
weathering or break down of rock formations.
Special specifications Additions and revisions of the General and

Supplemental Specifications covering conditions
peculiar to an individual project.
Specifications A general term applied to all directions, provisions

and requirements pertaining to the performance of
the work.
Stabilized soil Any natural material which has been modified to

improve and maintain its load carrying capacity and
resistance to weathering.
Structures Bridges, culverts, catch basins, catch pits, drop in

lets, retaining walls, cribbing manholes, end walls,
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buildings, sewers, service pipes, under drains,

foundation drains and other features which may be
encountered in the work and not otherwise classified
herein.
Sub-contractor An individual firm or corporation to whom the

contractor sublets part of the work.
Sub-grade surface The top surface of a road-bed upon which the

pavement structure and shoulders are constructed.
Subgrade surface limit The limits of the road-bed which are included in the
designation sub-grade, shall be taken as extending to
full embankment width in fills and to full formation
width in cuts to a depth of 30 cms ( 1 foot) below
sub base.
Sub-Base A layer of material provided between the subgrade

and the base, for a special purpose e.g. drainage or to
add strength to the pavement.
Substructure All of that part of the structure below the bearings of

simple and continuous spans, skewtacks of arches
and tops of footings of rigid frames, together.
Superstructure The entire structure except the substructure.
Supplemental Additions and revisions to the General specifications

specifications that are adopted subsequent to issuance of the printed
book.
Super elevation The inward tilt or transverse inclination given to the

cross section of a carriageway through out the length
of a horizontal curve to reduce the effect of
centrifugal force on a moving vehicles.
Surety The corporation, partnership or individual, other than

the Contractor, executing a Tender Guarantee
furnished by the Contractor.
Surface course One or more layers of a pavement structure designed

to accommodate the traffic load, the top layer of
which resists skidding, traffic abrasion and the
disintegrating effects of climate.
Surface dressing The surfacing process consisting of the application

of bituminous binder and cover aggregate to an
existing road surface.
Surface treatment One or more applications of bituminous binder and
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cover aggregate on a prepared base course.
Tack coat A very light application of bitumen to an existing

bituminous or Portland cement concrete surface to
provide bond to a super-imposed course.
Tender The bid or offer made by a bidder, on the prescribed

form, to perform the works and to furnish the labour
and materials at the prices quoted.
Tender documents The approved form on which the Department

requires Tenders to be prepared and submitted for the
work.
Tender guarantee The security furnished with a Tender to guarantee

that the bidder will enter into a contract if his Tender
is accepted, and includes the specified forms on
which the Contractor shall furnish required
information and to his ability to perform and finance
the work.
Ton The word “Ton” used in the specifications designates

the long ton of 2240 lbs.
Tonne (Metric ton) Equivalent to 1000 Kilograms (2204 lbs)
Traffic Lane A unit of carriage way width sufficient to

accommodate a single line of vehicular traffic with
provision for slight lateral movement.
Wall (a) Curtain: A thin wall used as a shield or
protection (as distinct from retaining wall)
(b) Head: A retaining wall formed at the
termination of a culvert or pipe.
(c) Toe: A low retaining wall formed at the
termination of a culvert or pipe.
(d) Wing: A wall in extension of an abutment, as
in a bridge or a culvert for retaining the side
slopes or earth filling.
Water Bound Macadam A form of road construction consisting of crushed

stone or crushed gravel, compacted in the presence of
water, the binding agent used being stone screenings
or approved material.
Water table The level at which ground water would finally stand
in an un-pumped borehole, well or other depression,
when equilibrium has been reached.
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Wearing course The top layer of the bituminous concrete, which

carries the traffic, resists skidding, surface abrasion
and the disintegrating effects of climate.
Weep hole A small aperture or pipe through a retaining wall or

abutment which, by using as a drain, prevents the
accumulation of water.
Work The work shall mean the furnishing of all labour,

materials, equipment and other incidentals necessary
or convenient to the successful completion of the
project and the carrying out of all the duties and
obligations imposed by the Contract.
Working day A working day shall be any day on which the

Contractor can physically and legally execute the
work.
Working drawings Stress sheets, shape drawings, execution plans, work

plans, framework plans, plans for bending of
reinforcing steel, or any other supplementary plans,
or similar data which the contractor is required to
submit to the Engineer Incharge for approval.
Zone (safety) A raised pavement or platform, or a guarded area so

sited in a carriageway as to divide the stream or
traffic and to provide a safety area for pedestrians.
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101-4 ABBREVIATIONS
AASHTO American Association of State Highway and

Transportation Officials.
ASTM American Society for Testing and Material
AWG American Wire Gauges.
AWPA American Wood Preservers Association
BS British Standard Code of Practice.
ACI American Concrete Institute.
FHWA U S Federal Highway Administration.
PCA Portland Cement Association.
Wt Weight.
Lb Pound
R.L. Reduced level.
R.O.W. Right of Way
in. Inch
ft. Foot
Yd. Yard
Ltr. Liter.
mm Millimeter
cm Centimeter
m Meter
Km Kilometer
m2 Square Meter
m3 Cubic Meter
ha Hectare (10,000 m2 )
Kg Kilogram
N Newton
o
C Degree Centigrade
o
F Degree Fahrenheit
Psi Pounds per Square inch
Kg/cm2 Kilogram per Square Centimeter
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101.5 CONVERSION FACTORS
Commonly used conversion factors and certain constants are listed in Annexure-3.
******************
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CHAPTER 200
CONSTRUCTION EQUIPMENT
AND LABORATORY
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SECTION 201
CONSTRUCTION EQUIPMENT GENERAL

REQUIREMENTS
201-1 GENERAL
The equipment to be used on the work shall be such as can give the
specified and required results conforming to specifications. Unless
restricted to a specific type or types, by the Specifications, Drawings,
special Provisions of the Engineer Incharge, the equipment combination
and number of units to be used on the work shall be such as the Contractor
selects for obtaining the specified and required results.
201-2 EQUIPMENT CONDITION AND APPROVAL
All equipment required to be used in construction of the project or in any

stipulated portions of a project, shall be on the site in first class working
condition and shall have been approved by the Engineer Incharge before
construction of any particular item of work is started. The number of units,
the sizes, etc. of all equipment shall be adequate to ensure completion of
work within the time specified in the contract. No equipment shall be
removed from the site without written approval of the Engineer Incharge.
All equipment, tools, and machinery used shall be maintained in a

satisfactory working condition throughout the required period of their use.
Any plant or equipment or portion thereof, which becomes worn or
defective shall be immediately repaired or replaced to the satisfaction of the
Engineer Incharge.
201-3 CONSTRUCTION EQUIPMENT
Various categories of construction equipment shall include but not limited

to the items listed below:
A Earth Moving Equipment
1. Scrapers
2. Bulldozers/Angle dozers
3. Tractors fitted with front blades
4. Motor graders
5. Excavator
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B Compacting Equipment
1 Tamping or sheep foot rollers.

2 Two axle/three axle Tandem steel rollers.
3 Three Wheeled steel rollers.
4 Trench rollers.
5 Self propelled pneumatic tyre rollers.
6 Pull type pneumatic tyre rollers.
7 Vibrating compactors.
C Hauling and Weighing Equipment
1. Trucks
2. Tractor trolleys.
3. Dump trucks.
4. Platform scales
5. Controlled water distribution equipment
equipped with spray bars (water lorries)
D Cement Concrete Equipment
1. Cement concrete paving equipment

2. Batching plant and equipment
3. Concrete Mixers.
4. Concrete Spreaders.
5. Finishing machine
6. Longitudinal Finisher.
7. Concrete saw
8. Joint compound hearing & placing equipment
9. Concrete vibrators.
10 Transit mixer.
E Asphaltic Construction Equipment
1. Asphalt plant
2. Equipment for heating bituminous material
3. Bitumen distributor.
4. Paving machine
5. Self propelled aggregate spreader
6. Air Compressor.
7. Mechanical Brooms
201-4 SPECIAL EQUIPMENT
Where a special type of plant or equipment is specified for a particular

operation, the Contractor may, with the written approval of the Engineer
Incharge, use alternative equipment provided that he satisfies the
Engineer Incharge at his own risk and cost that he can achieve the
required results within the time schedule. If the Contractor does not
achieve the result to the satisfaction of the Engineer Incharge, the
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Engineer Incharge will require him to revert to the originally specified

special equipment for the satisfactory completion of the work.
201-5 RECOMMENDED MAJOR EQUIPMENT
Recommended major construction equipments is given at Annexure-1

201-6 CONTRACTOR’S RESPONSIBILITY
The approval of number of units, the sizes or particular types, by the

Engineer Incharge does not absolve the Contractor of the responsibility
of timely and satisfactory completion of the work.
*******************
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SECTION 202
FIELD TEST LABORATORY FOR

QUALITY CONTROL
202-1 GENERAL
The contractors employed on the construction or improvement of roads,
bridges or other road structures shall be required to provide and maintain
during execution of work (for quality control) a field test laboratory
properly equipped with approved equipment and furniture to carry all the
tests indicated in the relevant sections of these specifications. Contractors
shall also be required to employ necessary qualified technical staff as
approved by the Engineer Incharge to carry out the specified tests and
maintain its record in a manner approved by the Engineer Incharge. The
laboratory shall be provided with equipment specified in the quality control
manual of the Punjab Highway Department for various tests. The
contractor shall also make arrangements of electric power supply, water
supply and drainage for the field test laboratory.
202-2 LOCATION
The laboratory shall be located in the project area at the site of work,
approved by the Engineer Incharge. It shall be housed in a temporary
building or a double fly tent, spacious enough to accommodate
laboratory equipment and furniture and allowing enough space for
performing tests.
202-3 COST
The cost of the provision and maintenance of field test laboratory, pay of
laboratory staff, and labour and cost of materials for testing and cost of
stationery etc., shall be borne by the contractor. The contractor shall
allow the Engineer Incharge or his staff to use the field test laboratory
for carrying out quality control tests. There will be no direct payment
for these services and the costs thereof are considered as included in
the unit rate respective items of work, unless provided otherwise.
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SECTION 211
MAINTENANCE OF TRAFFIC
211-1 DESCRIPTION
The work specified in this section consists of maintaining traffic in a
manner approved by the Engineer Incharge within the limits of the
project and for the duration of the construction period including any
temporary suspensions of the work. It shall include the construction and
maintenance of any necessary detour facilities and making of any special
arrangements for the maintenance of traffic, as shown or indicated on the
Drawings or as directed by the Engineer Incharge.
211-2 GENERAL REQUIREMENTS
The Contractor’s responsibility for maintenance of traffic shall begin on

the day he starts work on any component of the project.
All lanes that are being used for the maintenance of traffic, including
those on detours and temporary facilities, shall be adequately maintained
with a substantial surface under all weather conditions. The lanes shall
kept free of dust and, when necessary to accomplish this, they shall be
sprinkled with water or some other dust palliative.
The contractor will be required to maintain two way traffic except as

otherwise provided for in the special provisions or herein. Where one-
way traffic is permitted, traffic is to alternate in direction so that it will
not be delayed beyond a reasonable time.
The contractor shall provide competent flagmen during the day and
proper and adequate lights during the night to direct all one-way
or otherwise restricted traffic, and to direct traffic at all restricted
bridges and other hazardous location unless relieved of the
requirement in writing by the Engineer Incharge or his
authorized representative.
The contractor will not be permitted to block any road or street, which
intersects or crosses the project, unless otherwise specifically permitted.
Detours for intersecting or crossing traffic shall be provided and
maintained, in accordance with provisions of section 211-3
Where, in the opinion of the Engineer Incharge, traffic over the base or
surface course would be injurious to such work, all traffic passageways
along the project shall be outside the pavement area.
When traffic is specified to be detoured over other roads or streets, the

contractor will not be required to maintain such roads or streets, and all
posting including those at the intersections with the project, will be done
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by the Department.
The contractor will not be permitted to isolate residences or places of

business. Access shall be provided to all residences and all places of
business whenever construction interferes with the existing means of
access.
Barricaded, warning lights, warning and detour signs are to be erected by

the Contractor wherever necessary, in accordance with provisions of
section 211-4 to ensure that traffic does not deviate from the established
usable road way limit.
211-3 DETOURS OR DIVERSIONS
On all construction works where the contractor is required to maintain

traffic, he will be required to construct and maintain detour facilities
wherever it becomes necessary to divert from any existing roadway
or wherever construction operations block the flow of traffic. The
minimum lane width shall be 3.65 meters ( 12 feet)
All detours are to be planned, constructed and maintained in such a

manner that they will be capable of conveniently carrying the traffic
volume throughout all conditions of weather. It will be the contractor’s
responsibility to provide all detour facilities with adequate drainage to
meet this requirement.
The contractor will generally be required to provide all materials, labour

and equipment for the construction and maintenance of all detours.
In general, the requirements of the Standard Specifications pertaining to

construction and material details shall not apply to detour construction,
and it will be the responsibility of the contractor to select and to use
construction methods and materials that will satisfactorily provide a
stable detour facility of sufficient durability to remain in good condition
as supplemented by his maintenance for as long a period as it is
necessary to utilize the detour. Detours shall be removed by the
contractor after completion of the project.
211-4 BARRICADES, WARNING LIGHTS, WARNING AND DETOUR

SIGNS
The contractor shall furnish, erect and maintain all necessary barricades,
suitable and sufficient warning lights, danger signs and warning signs,
and flares and shall also provide sufficient number of courteous
watchmen to direct the traffic and shall take all necessary precautions for
the protection of work and safety of the public. Roads closed to traffic
shall be protected by effective barricades on which shall be placed
appropriate warning signs. The contractor shall erect and maintain the
proper warning and directional signs at all closures and intersections and
along the detour routes, directing the traffic around the closed road or
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portions of the road, and such that the temporary detour route shall be
indicated clearly throughout its entire length. All barricades and
obstructions shall be illuminated at night and all lights shall be kept
burning from sunset until sunrise.
During the entire period of construction operations at railway crossings, it

shall be the Contractor’s responsibility to erect & maintain,
during day & night and in a satisfactory and clearly legible
condition, the advance warning signs which are normally
installed by the Railway. Wherever such signs are not installed
by Railways, the Contractor shall install and properly maintain
adequate temporary advance warning signs.
211-5 WATERING
The contractor shall sprinkle the surface with adequate amount of water
where so required to keep down the dust.
211-6 MEASUREMENT
The item for maintenance of traffic at all points affected by the project
will be job item.
211-7 RATE
The unit rate shall be full compensation for all costs of complying with
the provisions of this section and includes costs of all materials, labour
and machinery etc.
211-8 PAYMENT
The Payment shall be made under

Item No. 211-8.1 Maintenance of traffic lump sum.
***************
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CHAPTER 300
SITE CLEARANCE
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SECTION 301
CLEARING AND GRUBBING
301.1 DESCRIPTION
This work shall consist of clearing, grubbing, removing and disposing

off all vegetation and debris within the limits of the road formation
including slopes both in filling and cutting, easement areas and areas
where road structures are to be constructed except such objects as are
designated by the Engineer Incharge to remain or are to be removed in
accordance with other sections of these specifications.
301.2 CONSTRUCTION REQUIREMENT
301.2.1 General.
The contractor shall demarcate limits of the road formation including

slopes and the Engineer Incharge will designate all trees, shrubs,
plants and other objects to remain and the Contractor shall preserve
all such things designated by the Engineer Incharge to remain.
301.2.2 Work Included.
Clearing and grubbing shall consist of the complete removal and

disposal as directed by the Engineer Incharge of all surface objects,
shrubs, roots and other protruding obstructions not designated to
remain.
301.2.3 Work Not Included.
Clearing and grubbing does not include removal of structures and

plugging of abandoned water wells etc. as specified in Section 311. It
does not include removal of utilities such as sewer lines, drains, water
or gas pipe lines, telephone or electric conduits, railroads, poles, walls,
posts etc (as separately provided for in Section 311).
301.3 DISPOSAL OF MATERIALS.

301.3.1 General Disposal.
All useless timber, stumps, brush, roots, rubbish and objectionable

material resulting from clearing and grubbing shall be disposed off
within the limits of the right of way as directed by the Engineer
Incharge.
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301.3.2 Blocking Waterways.
Natural waterways or irrigation channels shall not be blocked in the

disposal of debris from clearing and grubbing operations.
301.3.3 Boulders.
All loose boulders lying on the surface of the ground shall be removed
and place in neat piles along (but inside) the right of way line.
301.4 MEASUREMENTS.
Unless the Bill of Quantities includes the item of “Clearing and

Grubbing” and provides the payment for the work described under this
Section will not be paid for separately but will be considered
subsidiary work pertaining to Sections 401, 402, 403 and 411 of these
specifications.
When the bill of quantities includes the item of clearing and grubbing
and provides for payment for the work to be paid for shall be measured
in square meters of square feet and the unit of measurement shall be
100 square meter or 100 square feet. The measure shall be limited to
those locations designated on the plans or locations designated in
writing by the Engineer Incharge.
301.5 RATE.
The unit rate for clearing and grubbing shall be full compensation for
all the work specified in this section and shall include all necessary
hauling, furnishing and operation of equipment, disposal of debris, and
cost of furnishing and compaction of material required for back filling
of holes left by stumps and other obstructions removed. It shall also
include the cost for preserving all things designated to remain.
301.6 PAYMENT.
Where separately called for in the tender documents, the payment shall
be made under:
Item No.301-6.1 Clearing and Grubbing per 100 square meter

or per 100 square feet.
*************
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SECTION 302
REMOVAL OF TREES
302-1 DESCRIPTION
This work shall consist of the removal of trees and stumps along with
their roots to a depth, to ensure complete removal of roots and stumps
and their disposal as provided in Special Provision or as directed in
302-2 CONSTRUCTION REQUIREMENTS
Such individual trees as the Engineer Incharge may designate and mark
in white paint shall be left standing uninjured. All other trees to be
removed shall be counted and an inventory prepared showing girth of
the tree stem.
When necessary to prevent injury to other trees or structures or to

minimize danger to traffic, trees shall be cut in sections from top
downwards.
Hole or loose earth resulting from the removal of trees shall be filled
and re-compacted to a degree of compaction of adjoining area. Any
extra material required for such purpose shall not be measured for
payment.
Contractor shall prevent damage to all under-ground utilities, such as

pipes cables or conduits etc. For this purpose if so required, removal of
trees shall be carried out manually. Any under-ground or over-ground
property damaged by the contractor shall be immediately repaired by
the contractor at his own expense.
302-4 MEASUREMENT AND PAYMENT
302-4.1 Measurement
Engineer Incharge and Contractor shall jointly measure the girth and
number of trees to be removed under this item. Any tree having a girth
of less than 150mm (6 inch) measured six hundred (600)mm (24 inch)
above ground level shall not be measured under this item, as the same
shall be removed under item “Cleaning and Grubbing”.
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302-4.2 Payment
The quantities determined as provided above shall be paid for at the

contract unit price for the pay item mentioned below and shown in the
Bill of Quantities which price shall be deemed to include all cost of
labour equipment and incidental related to the item.
Pay Item No. Description Unit of Measurement
302-4.2.1 Removal of trees, 150-300mm

(from 6 to 12 inch) girth Each
302-4.2.2 Removal of trees, 301-600mm

(>12 upto 24 inch) girth Each
302.4.2.3 Removal of trees, 601mm or over

(> 24 inch) girth Each
*****************
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SECTION 303
STRIPPING
303-1 DESCRIPTION
This work shall consist of the removing unsuitable topsoil, transporting

and depositing in stockpiles or spreading where indicated on the
Drawings or as directed by the Engineer Incharge. Engineer Incharge
shall give instruction in writing, starting area and depth to be stripped.
303.2 CONSTRUCTION REQUIREMENTS

The areas from which stripping of topsoil is required shall be as
indicated on the Drawings or as directed by the Engineer Incharge. The
Contractor shall remove topsoil from these areas to depth as directed
by Engineer Incharge. Stripping of topsoil in any case shall be not less
than 10 cm in depth. The removed topsoil shall be transported,
deposited in stock piles at locations designated by the Engineer
Incharge and/or spread where indicated on the drawings or as directed
by the Engineer Incharge. Engineer Incharge shall, however identify
the soil as unsuitable through laboratory tests, before such a decision.
303.3 MEASUREMENT AND PAYMENT

303.3.1 Measurement
Measurement shall be made by multiplying the length, breadth and

depth of layer approved by the Engineer Incharge in cubic meter or
cubic feet of material removed and disposed as directed by the
Engineer Incharge. However space thus created shall be filled by the
material as directed by the Engineer Incharge and paid separately
under relative item.
303.3.2 Payment.
The payment under this item shall be made for at the contract unit
price per cubic meter or 100 cubic feet of stripping measured as above,
for removal of material to a depth approved by the Engineer Incharge
including its disposal at designated place and in the manner as directed
by the Engineer Incharge.
303-3.2.1 Stripping. m3 or 100 cft.
*******************
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SECTION – 311
REMOVAL OF EXISTING STRUCTURES
311.1 DESCRIPTION.
The work specified in this section consists of the removal and disposal
of the materials from existing structures. The structures to be removed
shall be: (1) those structures, or portions of structures, shown on the
plans to be removed; (2) those found within the limits of the area to be
cleared and grubbed, and directed by the Engineer Incharge to be
removed and (3) those structures or portions of structures which, in the
opinion of the Engineer Incharge are necessary to be removed in order
to construct the new structures.
311.2 REMOVAL.
The existing structures designated for removal shall be removed in

such a way as to avoid damage to the materials and to leave no
obstructions to any proposed new structures and any waterways. All
pilling shall be pulled or cut, or shall be broken off one meter (3.3 ft)
below the finished excavation surface or the original ground surface.
Structural steel members shall be marked as directed, for identification.
Where a portion of the existing structure is to remain in place,
explosives shall not be used to remove reinforced concrete.
Underground structures, abandoned wells and chambers shall be
demolished to the depth shown on the drawings and shall be properly
cleared out, closed or filled with suitable material and compacted to the
specified density as directed by the Engineer Incharge.
On concrete bridges to be partially removed and widened, concrete

shall be removed by manually or mechanically operated pavement
breakers, concrete saws or chipping hammers. Wherever concrete is to
be removed to confine required dimensions, the outlines of the work
shall first be made with small trenches or grooves about 25 mm (1
inch) deep cut in the existing concrete surface. Care shall be taken to
confine the breakage to the correct outline.
311.3 DISPOSAL.
All waste materials shall be disposed off, as directed by the Engineer

Incharge within 150 meters (500 ft) unless otherwise specified in the
Bid Schedule. All usable materials, as determined by the Engineer
Incharge shall be stacked in neat piles along (but inside) the right of
way line.
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311.4 MEASUREMENT.
The unit of measurement for removal of existing structures will be job
item, for the area of the project designated in the contract.
311.5 RATE.
The lump sum rate shall be full compensation for costs of all materials,
Labour and machinery etc.
311.6 PAYMENT.
Payment shall be made under:
311-6.1 Removal of Existing Structure Lump sum
*************
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CHAPTER 400
EARTHWORK AND RELATED

OPERATIONS
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SECTION 401
SCARIFICATION OF EXISTING ROAD /

BREAKING OF ROAD PAVEMENT STRUCTURE
401-1 DESCRIPTION
This work shall consist of scarification of existing road surface or

breaking of existing road pavement structure to ensure bondage of new
layer with the existing road pavement and to ensure drainage of water
below the surface of freshly laid base-course. The surface on which the
base materials is to be constructed, shall be approved and accepted by
the Engineer Incharge prior to placing the crushed stone base
aggregate.

The method of scarification of road surface or breaking of pavement
structure shall be proposed by the contractor and approved by the
Engineer Incharge in accordance with the requirements under site
conditions.
401-3 MEASUREMENT AND PAYMENT

401-3.1 Measurement
The quantity for road pavement structure broken and removed, to be
paid for, shall be measurement in cubic meter/cft to a depth as shown
in the drawings/cross sections or as specified by the Engineer Incharge
and in the area earmarked by the Engineer Incharge for such purpose.
The quantity for road pavement structure scarified, to be paid for shall
be measured in Sq. meter/sft as shown in the drawings/cross sections
or as specified by the Engineer Incharge and in the area earmarked by
the Engineer Incharge for such purpose.
401-3.2 Payment
The quantities as measured above shall be paid for at the contract unit
price per cubic meter/cft of breaking of road pavement structure and
per Sq. meter/sft of scarification of existing road pavement structure,
for carrying out the works mentioned above including cost of labour,
equipment, tools and incidentals necessary to complete these items.
401-3.2.1 Breaking of Existing Road Pavement CM or Cft

Structure
401-3.2.2 Scarification of Existing Road Pavement SM or Sft
***************
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SECTION 402
STRUCTURAL EXCAVATION AND BACKFILL
402.1 DESCRIPTION
The work specified in this section consists of structural excavation

which includes the removal of all material of what ever nature,
necessary for the construction of foundations of bridges, culverts,
retaining walls, head walls, wing walls, catch basins, manholes, inlets
and other structures, not otherwise provided for in these specifications
and in accordance with the Drawings or as directed by the Engineer
Incharge. It shall include the furnishing of all necessary equipment for
construction of all cribs, cofferdam, caissons, de-watering, sheeting,
shoring etc., which may be necessary for the execution of this work. It
shall also include the subsequent removal of caissons, cofferdam, and
cribs etc. and the placement of all necessary backfill as hereinafter
specified. It shall also include the disposing of excavated material,
which is not required for backfill, in a manner and at locations as
directed in writing by the Engineer Incharge.
402.2 MATERIAL REQUIREMENTS
402.2.1 Backfill.
Backfill shall consist of granular material or other common materials

as shown on the Drawings or as specified or approved by the Engineer
Incharge.
4.2.3.1 Structural Excavation
(i) General
All substructures, where practicable, shall be constructed in

open excavation and, where necessary, the excavation shall
be shored, braced, or protected by cofferdam in accordance
with approved methods.
(ii) Preservation of Channel
Unless otherwise specified, no excavation shall be made

outside of caissons, cribs, cofferdam, or sheeting. The natural
stream bed adjacent to the structure shall not be disturbed
without permissions from the Engineer Incharge. If any
excavation or dredging is made at the site of the structure
before caissons, cribs, or cofferdam are sunk in place, the
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contractor shall, without extra charge, after the foundation is

in place, backfill all such excavation to the original ground
surface or river bed with material specified by the Engineer
Incharge. Material deposited within the stream area from
foundation or other excavation or from filling of coffer-dam
etc. shall be removed and the stream bed kept free from
obstruction thereby.
(iii) Depth of Footings
The reduced level of footings, as shown on the Drawings,

shall be considered as approximate only and the Engineer
Incharge may order, in writing, such changes in dimension or
elevation of footings as may be necessary to secure a
satisfactory foundation.
(iv) Preparation of foundations for Footings
All rock or other hard foundation material shall be free from

all loose material, cleaned and cut to a firm surface, either
level, stepped, or roughened, as may be directed by the
Engineer Incharge.
Where masonry is to rest on an excavated surface other than

rock, special care shall be taken not to disturb the bottom of
the excavation, and the final removal of material at the grade
shall not been made properly until just before the masonry is
to be placed.
(v) Coffer-dam and Cribs
For substructure work, the Contractor shall submit drawings

showing his proposed method of construction of coffer-dam.
Contractor shall not work until the Engineer Incharge has
approved such drawings.
Coffer-dam and cribs shall be carried to adequate depths and

heights, and be made as watertight as is necessary for the
proper performance of the work inside them. The interior
dimensions of coffer-dam and cribs in general shall be such
as to give sufficient clearance for the construction of forms
and the inspection of their exteriors, and to permit pumping
outside the forms. Coffer-dam or cribs which are tilted or
moved laterally during the process of sinking shall be reset,
or enlarged so as to provide the necessary clearance and this
shall be solely at the expense of the Contractor.
When conciliations are encountered which, in the opinion of

the Engineer Incharge, render it impracticable to dewater the
foundation before placing masonry, he may require the
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construction of a concrete foundation seal of such dimensions

as may be necessary. The foundation shall then be pumped
out and the balance of the masonry placed in the dry. When
weighted cribs are employed and the weight is utilized to
partially overcome the hydrostatic pressure acting against the
bottom of the foundation seal, special anchorage such as
dowels or keys shall be provided to transfer the entire weight
of the crib into the foundation seal. During the placement of
foundation seal, the elevation of the water inside the
cofferdam shall be controlled to prevent any flow through the
seal, and if the coffer dam is to remain in place, it shall be
vented or ported at low water level.
Coffer-dam or cribs shall be constructed so as to protect green

concrete against damage from a sudden rising of the stream
or river and to prevent damage to the foundation by erosion.
No timber or bracing shall be left in coffer-dam or cribs in
such a way as to extend into the substructure masonry
without written permission from the Engineer Incharge.
Unless otherwise provided, coffer-dam or cribs with all

sheeting and bracing shall be removed after the completion of
the substructure, care being taken not to disturb or otherwise
injure the finished masonry.
(vi) Pumping
Pumping from the interior of any foundation enclosure shall

be done in such a manner as to preclude the possibility of the
movement of water through any fresh concrete. No pumping
will be permitted during the placing of concrete or for a
period of at least twenty four (24) hours thereafter, unless it
be done from a suitable sump separated from the concrete
work by a watertight wall or other effective means.
Pumping to unwater a sealed coffer dam shall not commence
until the seal has set sufficiently to withstand the hydrostatic
pressure.
(vii) Inspection
After each excavation is completed the Contractor shall
inform in writing to the Engineer Incharge and no masonry
shall be placed until the Engineer Incharge has approved the
depth of the excavation and the character of the foundation
material.
4.2.3.2 Backfill
a. Granular Backfill
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Granular backfill material as approved by the Engineer

Incharge shall be placed in position and to the required depth,
shown on the Drawing or where and as required in writing by
the Engineer Incharge and it shall be well compacted in
layers not exceeding thirty 30 cm (1 foot) in thickness and to
the density shown on the Drawings or as specified by the
Engineer Incharge.
b. Common Backfill
Common backfill shall consist of earth free from large lumps,

wood and other organic materials and be to a quality
acceptable to the Engineer Incharge. It shall be placed in
position and to the required depths shown on the Drawings or
where and as required in writing by the Engineer Incharge
and it shall be well compacted in layers not exceeding 20 cm
(8 inch) in depth and to the density shown on the Drawings or
as specified by the Engineer Incharge.
c. Taking Care for Settlement
All spaces excavated and not occupied by abutments, piers,

or other permanent work shall be refilled with earth or
granular fill as approved by the Engineer Incharge upto the
surface of the surrounding ground, with a sufficient
allowance for settlement. All such backfill shall be
thoroughly compacted and in general, its top surface shall be
neatly graded.
d. Backfill for Bridge Abutments and Wing Walls
The fill behind abutments and wing walls of all bridge

structures shall be deposited in horizontal layers. The
backfill in front of such units shall be placed first to prevent
the possibility of forward movements. Special precautions
shall be taken to prevent any wedging action against the
masonry, and the slope bounding the excavation for
abutments and wing walls shall be destroyed by stepping or
roughening to prevent wedge action. Jetting of the fill
behind abutments and wing walls will not permitted.
e. Backfill for Piers and Culverts
Fill placed around culverts and piers shall be deposited on

both sides to approximately the same elevation at the same
time.
f. Preventing Pore Water Pressure
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Adequate provision shall be made for the thorough drainage

of all backfill. French drains shall be placed at weep holes.
g. Setting Time Allowed for Masonry
No backfill shall be placed against any masonry abutment,

wing wall, or culvert until permission shall have been given
by the Engineer Incharge and preferably not until the
masonry has been in place for fourteen (14) days.
402.4 MEASUREMENT
402.4.1 Structural Excavation
The quantities of Structural Excavation to be paid for shall be the

number of cubic meters or Cft. material measured in its original
position computed by the average end-area method, and excavated to
the satisfaction of the Engineer Incharge.
Structural Excavation will be classified for measurement and payment

as “Structural Excavation in Common Material”, “Structural
Excavation in Rock Material” and “Structural Excavation in Rock
Material below water level” according to whether the excavation is in
earth or rock and according to whether the excavation is above or
below the water level which is the constant level to which the water
naturally rises in a foundation pit. The water level shown on the
Drawings is approximate only and any variation in such level found
during construction shall not be a ground for extra compensation.
The volume of earth or rock to be measured for Structural Excavation

shall consist of a prismoid bounded by the following planes.
The vertical limits for computing pay quantities will be vertical planes
30 centimeters (12 inch) outside of the neat lines of footings for
foundations as shown on the Drawings or as directed by the Engineer
Incharge.
The upper limit for payment of structural excavation shall be the

ground surface as it existed prior to the start of construction operations,
except where structural excavation is performed within roadway
excavation or ditch excavation areas, the upper limit shall be the planes
of the bottom and side slopes of said excavated areas.
The lower limits for computing pay quantities of structural excavation

of backfill shall be plane at the bottom of the completed footings,
foundations or structures.
Measurement for structural excavation shall not include material

removed below the footing grade and beyond specific limits to
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compensate for anticipated swell or as a result of effective swell during

pile driving, or additional material resulting from slides, slips, cave-
ins, silting or fillings, whether due to the action of the elements or to
carelessness of the contractor. The depth of the footings shown on the
Drawings is approximate only and any variation found to be necessary
during construction shall be paid for at the contract unit price.
402.4.2 Backfill
a. Granular Backfill
The quantities of granular backfill to be paid for shall be

numbers of cubic meters or Cft of material laid in place within
the limits defined in section 402.4.1, computed by the average
end-area method, compacted and accepted by the Engineer
Incharge.
b. Common Backfill
The quantities of common backfill to be paid for shall be

number of cubic meters or cft of material laid in place within
the limits defined in section 402.4.1 computed by the average
end-area method, compacted and accepted by the Engineer
Incharge.
402.5 RATE
the provisions of this section regarding structural excavation and
backfill in accordance with these Specifications, Drawings and as
directed in writing by the Engineer Incharge.
402.6 PAYMENT
The quantities determined as provided above shall be paid for at the

contract unit price respectively, for each of the particular pay item
listed below that is shown in the Bill of Quantities, which price and
payment shall be full compensation for all the costs involved in the
proper completion of the work prescribed in this item.
Pay Item No. Description. Unit of

Measurement
402.6.1 Structural Excavation in

Common Material m3 or 100 Cft

Common Material Below
Water level. m3 or 100 Cft
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Rock Material m3 or 100 Cft

Rock Material Below
Water Level. m3 or 100 Cft
402.6.5 Granular Backfill m3 or 100 Cft.
402.6.6 Common Backfill m3 or 100 Cft.
**************
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SECTION 403
ROAD WAY EXCAVATION/

BORROW EXCAVATION
403.1 DESCRIPTION
The work specified in this section consists of all excavation excluding

“Structural Excavation and includes excavation of materials of
whatever nature encountered within the limits required for proposed
work, their removal and carriage to designated sites upto a free haul
distance of 900m (3000 ft) for the construction of embankments or
disposal otherwise, as shown on the plans or as directed by the
Engineer Incharge. The work covered in this section includes:-
1. Roadway Excavation
2. Borrow Excavation
403.2 CLASSIFICATION OF EXCAVATED MATERIAL
All material excavated shall be classified as under:-
a. Common Soil
Clayey, silty and sandy soils including small quantities of stone
fragments, or gravel.
b. Gravel
Soil containing predominantly water worn stones of rounded
shape of irregular size, occurring naturally.
c. Soft Rock
Rock formation requiring pick and crow bar operation.
d. Hard Rock
All other rock formations requiring blasting.
For the purposes of making embankment, common soil and gravel are
to be considered as “COMMON MATERIALS” and soft rock and hard
rock as “ROCK MATERIALS”.
403.3 ROADWAY EXCAVATION
It shall include the excavation and disposal of material that is not

required in its original position within the limits of the roadway
including the removal of all unsuitable or suitable material lying within
such planes which is necessary to be removed in order to excavate the
unsuitable material. When such material like, clay, rock or other in the
opinion of the Engineer Incharge, is unsuitable in its original position,
the contractor shall excavate such material to the cross section shown
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on the Drawings and shall backfill with suitable material, which shall
be shaped and compacted to conform to the required cross sections.
403.4 BORROW EXCAVATION
It shall consist of material obtained from the approved borrow pits.

Borrow shall be resorted to only when sufficient quantities of suitable
material are not available from structural excavation or from roadway
excavation to properly construct the embankment, sub-grade and
shoulders and to complete the backfilling of structures. Permission to
use material from borrow shall first be obtained in writing from the
Engineer Incharge. No borrow pit shall be opened until the Engineer
Incharge has approved their location with respect to the classification
of the soil & lead involved. The approved borrow pits shall be outside
ROW limits or at least 30 meters (100 ft) from the toe of the
embankment or the top of the cut, which ever is more unless otherwise
shown on the Drawings.
The borrow pits shall be excavated neatly at the bottom and edge so
shaped that accurate measurements are taken. Where the plans show
the depth & width of excavation, such depth and width shall be
considered as approximate and approval of the Engineer Incharge for
the extent of work shall be necessary.
Where shown on the plans the ditches for drainage of the borrow pits
of roadway shall be constructed. The excavation of such drains shall be
classified as borrow & suitable material thus obtained, used where
required on the works.
All suitable material excavated within the limits and scope of the
project shall, unless provision is expressly made to the contrary in
these specifications, be used in the most effective manner for the
formation of the embankment, for widening the road formation, for
backfill, or for other work included in the contract.
Any material surplus to this requirement or any materials declared in

writing by the Engineer Incharge to be unsuitable shall be disposed off
and leveled in layers by the Contractor outside the right of way or as
directed by the Engineer Incharge.
When unsuitable material is ordered to be removed and replaced, the

soil left in place shall be compacted to a depth of 20 cm(8”) to the
density prescribed under 411-3. Payment for such compaction shall be
included in the contract prices for the excavation of unsuitable
materials.
If the unsuitable material which is removed is below standing water

level and the replacement material is gravel or a similar self draining
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material of at least 30 cm (1 ft) in depth, the compaction may be

dispensed with, if approved by the Engineer Incharge.
403.6 MEASUREMENT
Only material which is surplus to the requirements of the project or is

declared in writing by the Engineer Incharge to be unsuitable will
qualify for payments under pay items No.403-8.1, 403-8.2, 403-8.3
and 403-8.4 as the case may be.
The cost of excavation of material which is used anywhere in the

project shall be deemed to be included in the pay items relating to the
parts of the work where the materials is used.
The under mentioned pay items No.403-8.1 to 403-8.4 shall include

the cost of obtaining the consent of the owner or tenant of the land
where the disposal of surplus or unsuitable materials is made.
Unsuitable or surplus material shall be measured in its original position

and its volume shall be calculated in cubic meters or cubic feet.
403.7 RATE
The unit rate shall be full compensation for all costs or complying with
the provisions of this section regarding roadway excavation in
accordance with Drawings and as directed in writing by the Engineer
Incharge.
403.8 PAYMENT
The quantities determined as provided above shall be paid for, at the

contract unit price respectively for each particular pay items listed
below and shown in the bill of Quantities which prices and payment
shall constitute full compensation for all costs involved in the proper
completion of the work prescribed in this item.
PAY ITEM NO DESCRIPTION UNIT OF

MEASUREMENT
403-8.1 Excavate Unsuitable Common Material m3 or 100 Cft.

403-8.2 Excavate Unsuitable Rock Material m3 or 100 Cft.
403-8.3 Excavate Surplus Common Material m3 or 100 Cft.
403-8.4 Excavate Surplus Rock Material m3 or 100 Cft.
****************
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SECTION 409
SUBGRADE PREPARATION
409.1 DESCRIPTION
The sub-grade preparation shall be that part of the work which is to be

carried out by compaction of the defined thickness/depth of material to
prepare such surface on which the sub-base is placed or, in the absence
of sub-base, it acts as the base of the pavement structure. It shall
extend to the full width of the road bed including the .shoulders and
laybys as indicated on the Drawings or as specified herein.
409.2.1 Prior Work
Before commencing the work all culverts, drains, ditches including

fully compacted backfill over them outlets for drainage, head
walls/wing walls of culverts and any other minor structure below thirty
(30) Centimeters of existing sub-grade level or all structures which will
be below thirty (30) Centimeters of newly placed subgrade level, shall
be in such operative conditions as to ensure prompt and effective
drainage and to avoid damage to subgrade by surface water. No work
of subgrade preparation will be started before the prior work herein
described has been approved by the Engineer Incharge.
409.2.2 Compaction Requirement
All materials down to a depth of 30cm below the subgrade level in

earth cut or embankment shall be compacted to at least 95 percent of
the maximum dry density as determined according to AASHTO T-180
Method “D (Modified).
409-2.3 Subgrade Preparation in Earth Cut
In case bottom of subgrade level is within thirty (30)cm of the natural

ground, the surface shall be scarified, broken up, adjusted to moisture
content and compacted to minimum density of Ninety five (95) percent
of the maximum dry density as determined by AASHTO T-180
Method-D. Subsequent layer of approved material shall be
incorporated to ensure that the depth of subgrade layer is thirty (30)cm.
In case, the bottom of subgrade is below the natural ground by more
than thirty (30)cm, the material above the top of subgrade shall be
removed and subsequent layer of thirty (30)cm shall be scarified,
broken up, adjusted to moisture content and compacted to the same
degree of compaction as described above.
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Subgrade preparation process shall be carried out in two layers of

fifteen (15) cms each. To achieve required compaction standards, layer
thickness could be increased to 30 cms to prepare the subgrade in one
layer subject to the availability of adequate equipment and to the
satisfaction/instruction of the Engineer Incharge.
In case, unsuitable material is encounter at the sub-grade level within

the depth of thirty (30) cm, the same shall be removed and replaced by
the approved material. The contractor shall be paid for removal and
disposal of unsuitable material as per pay item 106.
409-2.4 Sub-grade Preparation in Rock Cut
Execution in solid rock shall extend to the subgrade level or as shown

on drawing. Rock shall be under cut nearly to required elevation and
sections shown on the plans or as directed by the Engineer Incharge.
Transverse and longitudinal profile checked by template shall be
accurate to the specification. Cuts below subgrade level shall be
backfilled with selected subbase material and compacted to at
minimum ninety eight (98) percent of the maximum dry density as
determined by AASHTO-T-180, method “D” at Contractor’s cost.
No rock shall be higher than two centimeters above the under cut
section elevation. The under cut material shall be placed in
embankment or disposed off at the direction of Engineer Incharge.
409-2.5 Sub-grade in Embankment
When the subgrade is formed in embankment, its width shall be the

full width of top of embankment and material placed in the upper part
of embankment down to a depth of thirty centimeters below subgrade
level shall meet compaction requirement of 109.2.2. soils of A-1-a, A-
1-b and A-2-4 classification having a minimum value of CBR of seven
percent and swell value of not more than 0.3 percent shall be used.
Unsuitable material if encountered within the formation layer as per
laboratory specified test, shall be removed, disposed off and replaced
by suitable one as per discretion of Engineer Incharge of which the
payment will be made under relevant items of work.
Rollers of approved size and type, accepted by the Engineer Incharge,

shall be used for compaction. Water shall be added to obtain optimum
moisture content; if necessary.
Performance of this item of work shall not be paid for under this
section but shall be covered by the contract price for pay item no 108a,
or 108b as the case may be.
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409-2.6 Sub-grade level in Existing Road
Where indicated on the Drawings or directed by the Engineer Incharge

that the existing road surface is to be used as the subgrade, the correct
elevation on which the base or subbase is to be laid shall be obtained,
where necessary, either by means of leveling course or by scarification,
the leveling course shall be constructed to the requirements of the
Engineer Incharge and paid for under the appropriate Pay item
involved. Scarification shall include disposal of any surplus material in
the adjacent embankment or elsewhere as may be ordered by the
Engineer Incharge.
When the width of the new road is greater than that of the existing
road, that part of the new road subgrade which comprises the existing
road surface shall be prepared as herein provided, and the part that falls
outside the existing road surface shall be prepared as provided in item
109.2.3,4 and 5 above, or item 109.2.7 below as the case may be.
409-2.7 Sub-grade Reinforcement
When the width of the existing pavement, either to be scarified or not,

is insufficient to contain the subbase or base to be placed upon it, the
Engineer Incharge may order to strengthen and support the subbase or
base on one or both sides of the existing pavement. This work shall
consist of the removal and disposal of any unsuitable material and its
replacement with suitable material to such width and depth as required
The excavated material shall, if declared suitable for use elsewhere in

the embankment by the Engineer Incharge be so used, and payment for
its removal shall be covered under the contract price of pay item No.
108a; if declared unsuitable it shall be disposed off and paid as
provided in item 106a. The finished compacted surface of the subgrade
shall be as specified in item 109.2.3.
409-2.8 Protection of Completed Work
Any part of the subgrade that has been completed shall be protected
and well drained. Any damage resulting from carelessness of the
Contractor shall be repaired as directed by the Engineer Incharge.
without additional payment.
The contractor shall be responsible for all the consequences of traffic
being admitted to the subgrade. He shall repair any ruts or ridges
occasioned by his own traffic or that of others by reshaping and
compacting with rollers of the size and type necessary for such repair.
He shall limit the amount of subgrade preparation to an area easily
maintained with the equipment available. Subgrade preparation and
subbase or base placing shall be arranged to follow each other closely.
The subgrade, when prepared too soon in relation to the placing of the
subbase, is liable to deteriorate, and in such case the Contractor shall,
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without additional payment, repair, reroll, or re-compact the subgrade

as may be necessary to restore it to the state specified herein.
409-2.9 Templates and Straight Edges
The Contractor shall provide for the use of the Engineer Incharge,
satisfactory templates and straightedges in sufficient numbers to check
the accuracy of the work, as provided in these specifications and no
subsequent work shall be permitted until the subgrade levels have been
checked and approved by the Engineer Incharge. For tolerances,
referred to the, “Table for Allowable Tolerances” in these
specifications.
409.3.1 Measurement
The quantity to be paid for shall be the number of square meters or

square feet of sub-grade prepared as herein before prescribed and
accepted. Subgrade in rock cuts and on embankment not consisting of
the existing road surface in fill area shall not be measured for direct
payment.
Sub-grade preparation on “Existing Surface” shall only be measured

for payment when ordered by the Engineer Incharge.
409.3.2 Payment
The quantities, determined as provided above, shall be paid for at the

contract unit price for the pay item listed below and shown in the Bill
of Quantities which prices and payment shall be full compensation for
furnishing of material, water, equipment, tools, labour, and all other
items incidental to and necessary for completion of this work.
409-3.2.1 Subgrade preparation

in Earth Cut. m2 or 100 sft.
409-3.2.2 Subgrade preparation in

Existing Road
i) Without any fill m2 or 100 sft.

ii) With fill less than
30 cms m2 or 100 sft.
****************
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SECTION 410
IMPROVED SUBGRADE
410.1 DESCRIPTION
This work shall consist of the formation of top thirty centimeters of the
roadbed, under subbase or base course as the case may be, with an
approved blend of materials, uniformly mixed, compacted, shaped and
finished to the lines, grades and typical cross-sections shown on the
Drawings.
Improved subgrade as herein referred to may be defined as material

suitable for embankment to which better quality of material is blended
in proper proportion to improve its strength properties or performance.
The major component of improved subgrade shall consist of material

conforming to item 108.2 – “Material requirements for embankment”.
The blending material shall be any soil that classifies as A-1,A-2,A-2-4

or A-3 according to AASHTO M-145.
The blended mixture when compacted to Ninety five percent of the

maximum dry density determined by AASHTO M-145.
The blended mixture when compacted to Ninety five percent of the

maximum dry density determined by AASHTO-T-180-D Method, shall
exhibit a laboratory soaked CBR (96 hours) not less than 20, or as
specified in the drawings.
410.3.1 Preparation
The surface of the roadbed on which the improved subgrade is to be

constructed shall be compacted to the density specified under item
108.3.1.
410.3.2 Proportioning of Materials
Prior to start of construction, the proportion of each material to be

incorporated for improved subgrade shall be established as approved
by the Engineer Incharge. The Engineer Incharge shall specify a single
percentage of each material to be blended and shall establish the
gradation of the resulting mixture along with the ranges of permissible
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gradation tolerances to obtain the required CBR for the improved

subgrade.
The blend proportions thus established shall apply only when each
material to be used is obtained from same source. Should a change in
source of material be made, a new proportion shall be established.
When unsatisfactory results or other conditions make it necessary, the
Engineer Incharge may require additional laboratory tests.
410.3.3 Mixing and Spreading
Improved subgrade may be constructed with any combination of

machines or equipment that will yield results meeting these
specifications.
a) Stationary Plant Method
The soil ingredients and water shall be mixed in an approved

mixing plant. The plant shall be equipped with feeding and
metering devices that will add the materials to be blended in the
specified quantities. Water shall be added during the mixing
operation in the quantity required for proper compaction which
is approximately optimum moisture content plus or minus two
percent. The mixing time shall be that which is required to
secure a uniform mixture. After mixing, the blended material
shall be transported to the job site while it contains the
sufficient moisture and shall be placed on the roadbed by
means of an approved mechanical spreader. The mixture shall
be spread at rate that will produce a uniform compacted
thickness conforming to the required grade and cross-sections.
Compaction shall start as soon as possible after spreading and
shall continue until the specified relative compaction is
achieved.
b) Traveling Plant Method
The traveling plant shall be either a flat transverse shaft type or

a windrow type pug mill. After the materials have been placed
by a mechanical spreader or windrow sizing device the
materials shall be uniformly mixed by the traveling mixing
plant. During the mixing operation, water shall be added as
necessary to bring the moisture content of the mixture to the
percentage suitable for proper compaction.
c) Road Mix Method
The materials shall be transported to the site and spread on the

roadbed in the quantities required to produce the specified
blend. After the materials for each lift have been spread, the
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materials shall be mixed by motor graders and other approved

equipment until the mixture is uniform throughout.
During mixing operation, water shall be added as necessary to

bring the moisture content to the proper percentage.
410.3.4 Compaction
Unless otherwise permitted by the Engineer Incharge based on the

performance of the compacting equipment used as determined from the
trial section, each layer of improved subgrade shall be placed in
horizontal layers of uniform loose thickness not exceeding twenty
centimeters. Each layer shall be compacted to the density conforming
to the requirements specified in item 108.3.1.
In-place density determinations of the compacted layers shall be made

in accordance with AASHTO-T-191, T-238 or other approved methods.
410.3.5 Trial Sections
Prior to the formation of the improved subgrade, the Contractor shall

construct three trial sections of 200 meter length, one for each blend of
improved material proposed to be incorporated for improved subgrade,
or as directed by the Engineer Incharge. The compacting equipment to
be used in the trial sections shall be the same equipment that the
Contractor intends to use for main work, accepted by the Engineer
Incharge.
The object of these trials is to determine the proper moisture content,

the relationship between the numbers of passes of compacting
equipment, density obtained for the blended material, and to establish
the optimum lift thickness that can be effectively compacted with the
equipment used. No separate payment will be made for this work,
which will be regarded as a subsidiary obligation of the Contractor
under pay Item No.110.
410.3.6 Protection of Completed Work
Any part of the completed improved subgrade shall be protected and

well drained and any damage shall be repaired as directed by the
Engineer Incharge without additional payment. The contractor shall be
responsible for all the consequences of traffic being admitted to the
improved subgrade. He shall repair any ruts or ridges occasioned by
his own traffic or that of others by reshaping and compacting with
rollers of the size and type necessary for such repair. He shall limit the
improved subgrade preparation to an area easily maintained with the
equipment available. Subgrade preparation and placement of
succeeding layer to follow each other closely. The improved subgrade,
when prepared too soon in relation to the placing of the layer above it,
is liable to deteriorate, and in such case the Contractor shall, without
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additional payment, repair, reroll, or re-compact the improved

subgrade as may be necessary to restore it to the state specified herein.
410.3.7 Templates and Straightedges
The contractor shall provide for the use of Engineer Incharge,

satisfactory templates and straightedges in sufficient numbers to check
the accuracy of the work, as provided in these specifications and no
subsequent work shall be permitted until the improved subgrade level
have been checked and approved by the Engineer Incharge.
410.3.8 Tolerance
The allowable tolerances for the finished improved subgrade surface

prior to placing the overlying subbase, base or asphaltic concrete
course are given in the relevant, “Table for Allowable tolerances” in
these specifications.
410.4 MEASUREMENTS & PAYMENT
410.4.1 Measurement
The quantity of improved subgrade to be paid for shall be measured in

cubic meter or cubic feet by the theoretical volume in place as shown
on the Drawings, placed and accepted in the completed improved
subgrade.
410.4.2 Payment
The accepted quantities measured as provided above shall be paid for

at the contract unit price per cubic meter or per 100 cft of improved
subgrade for the pay item listed below and shown in the Bill of
Quantities, which price and payment shall constitute full compensation
for furnishing all materials, hauling, mixing, placing in layers,
watering and compacting, labour equipment, tools and incidentals
necessary to complete the item.
410-4.2.1 Improved Subgrade m3 or 100 Cft.
*****************
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SECTION 411
MAKING EMBANKMENT
411.1 DESCRIPTION.
This work shall consist of the formation of embankment in accordance

with these specifications and in conformity with the lines, grades,
sections and dimensions shown on the Drawings or as directed by the
Engineer Incharge.
411.2 MATERIAL REQUIREMENTS.
Material for embankment such as common soil, gravel, soft or hard

rock shall consist of suitable material obtained from structural
excavation, roadway excavation or borrow excavation as approved by
the Engineer Incharge. Borrow material however, shall only be used
when there is no suitable material available from structural excavation
or roadway excavation.
411.3.1Formation of Embankment with Common Material.
Material for embankment, obtained and approved as provided above,

shall be placed in horizontal layers of uniform thickness and in
conformity with the lines, grades sections and dimensions shown on
the Drawings or as required by the Engineer Incharge. The layers of
loose material other than rock shall be not more than 20 cm (8 inch)
thick.
The material placed in all embankment layers and the material

scarified to the designated depth shall be compacted to the density
specified in table 411-3.
TABLE 411.3
SPECIFIED DENSITY FOR EMBANKMENT/SUBGRADE
Depth below sub-grade Percent of maximum dry density as applicable

level AASHTO T-180*
0 to 30 cm(0 to 1 ft) 95
30 to 75 cm (1 ft to 2.5 ft) 93
over 75 cm (over 2.5 ft) 90
NOTE:-
*Method “B” or “D” of AASHTO-T-180 whichever is applicable may be adopted. In
road sections constructed of uniformly graded sands, or gravel the compaction shall
preferably be determined by “Relative Density Method”
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In place density determinations of the compacted layers shall be made

in accordance with AASHTO T-191 (Sand Cone Method) or other
approved methods. For all soils, with the exception of rock fill
materials, containing more than 10% oversize particles (retained on
19 mm (3/4 inch sieve), the in-place density thus obtained shall be
adjusted to account for such oversize particles as directed by the
Engineer Incharge. Subsequent layers shall not be placed and
compacted unless the previous layer has been properly compacted to
desired standards and accepted by the Engineer Incharge.
Material for embankment at points inaccessible to normal compaction

equipment shall be placed in horizontal layers of loose material not
more than 20 centimeters (8”) thick and compacted to the densities
specified above by the use of mechanical tampers, or other appropriate
equipment.
The compaction of the embankment shall be carried out at the

optimum moisture content consistent with the available compacting
equipment. In forming the embankment, the Contractor shall take steps
to ensure that the work can be drained free of rain water, and he shall
make due allowance in the height and width of the work for swelling
or shrinkage.
Embankment material that does not contain sufficient moisture to

obtain the required compaction shall be given additional moisture by
means of approved sprinklers and mixing. Material containing more
than the amount of moisture necessary to obtain the required
compaction may not, without written approval of the Engineer
Incharge be incorporated in the embankment until it has been
sufficiently dried out. The drying of wet material may be expedited by
scarification and disking or other approved methods.
When materials of widely divergent characteristics, such as clay and

chalk or sand, drawn from different source are to be used in the
embankment, they shall be deposited in different layers (with
individual layer of the same material) over the full width of the
embankment to depths and sequence of material to be laid as approved
by the Engineer Incharge. Lumps of clay or other similar material shall
be broken down, and no accumulation of lumps or boulders in the
embankment will be permitted. No surplus material shall be permitted
to be left at the toe of embankment or at the top of cut sections.
Side slopes shall be neatly trimmed off to the lines and grades shown
on the Drawings or as directed by the Engineer Incharge and the
finished work shall be left in a neat and acceptable condition.
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411.3.2Formation of Embankment with Rock Material
No rock fill shall be placed until after the contractor has discussed his
plans for the work of cut and fill with the Engineer Incharge and
obtained the latter of approval in writing.
In order to provide a suitable grade level, material satisfactory for

covering the rock fill shall be reserved from the roadway excavation or
structural excavation. Should such material be available and not
reserved by the Contractor, so that Borrow Excavation has to be used
for forming the grade level, such borrow shall be supplied and placed
by the Contractor, without any extra payment.
Rock fill shall be placed in loose layers not to exceed 60 centimeters (2

ft) in thickness and compacted as herein provided and interstices
through the full depth shall be thoroughly filled with clean small
spawls, shale, gravel or similar approved material and thoroughly
compacted to the satisfaction of the Engineer Incharge. The covering
layer of approved material over this fill shall not be less than 20
centimeters (8”) thick.
Where rock to be incorporated in fill or portion of fill is composed

largely of weak or friable material, the rock shall be reduced to
maximum size not exceeding 75 percent of the thickness of the layer
being placed.
411.3.3Formation of Embankment on Steep Slopes.
Where embankments are to be constructed on steep slope, hill sides or

where new fill is to be placed and compacted against existing
pavement or where embankment is to be built along one half the width
at the time, the original slope of the hill side, of existing pavement or
adjacent to half width of embankment shall be cut in steps of twenty
(20) centimeters depth. Benching shall be of sufficient width to permit
operation of equipment possible during placing and compaction of
material.
Cut material shall be incorporated with the new embankment material

and compacted in horizontal layers. No extra payment will be allowed
for such an operation.
411.3.4Subgrade Preparation in Earth Cut
In case bottom of subgrade level is within thirty (30)cm of the natural

ground, the surface shall be scarified, broken up, adjusted to moisture
content and compacted to minimum density of Ninety five (95) percent
of the maximum dry density as determined by AASHTO T-180
Method-D. Subsequent layer of approved material shall be
incorporated to ensure that the depth of subgrade layer is thirty (30)cm.
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In case, the bottom of subgrade is below the natural ground by more

than thirty (30)cm, the material above the top of subgrade shall be
removed and subsequent layer of thirty (30)cm shall be scarified,
broken up, adjusted to moisture content and compacted to the same
degree of compaction as described above.
Sub-grade preparation process shall be carried out in two layers of

fifteen (15) cms each to achieve required compaction standards. Layer
thickness could be increased to 30 cms to prepare the subgrade in one
layer subject to the availability of adequate equipment and to the
satisfaction/instruction of the Engineer Incharge.
In case, unsuitable material is encountered at the sub-grade level

within the depth of thirty (30) cm, the same shall be removed and
replaced by the approved material. The contractor shall be paid for
removal and disposal of unsuitable material as per pay item 106.
411.3.5Sub-grade Preparation in Rock Cut
Execution in solid rock shall extend to the subgrade level or as shown

on drawing. Rock shall be under cut nearly to required elevation and
sections shown on the plans or as directed by the Engineer Incharge.
Transverse and longitudinal profile checked by template shall be
accurate to the specification. Cuts below subgrade level shall be
backfilled with selected subbase material and compacted to, at
minimum ninety eight (98) percent of the maximum dry density as
determined by AASHTO-T-180, method “D” at Contractor’s cost.
No rock shall be higher than two centimeters above the under cut
section elevation. The under cut material shall be placed in
embankment or disposed off at the direction of Engineer Incharge.
411.3.6Formation of Embankment on Existing Roads.
Before fill is placed and compacted on an existing carriageway, the

existing embankment and or pavement may be leveled by cutting,
rooting or scarifying by the approved mechanical means to a level to
be determined by the Engineer Incharge. The earth, old asphalt or other
material arising as a result of this operation will be declared by the
Engineer Incharge, either suitable or unsuitable for use in the
construction of embankment/sub base. In the first case it shall be used
in the adjacent embankment as directed by the Engineer Incharge, and
payment shall be made as per pay item No.411-6.1. In the second case
the material shall be disposed off as provided in section 403 and
payment shall be made as per pay item No.403-8.1
Scarified material removed from the existing road surface may be

placed in the embankment in thin layers in strict compliance with the
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instructions of the Engineer Incharge. No. extra compensation shall be

allowed for the storing and re-handling of such material.
411.3.7Formation of Embankment in Water Logged Areas.
Where embankments are to be placed in water logged areas and which

are inaccessible to heavy construction equipment, a special working
platform shall be first established, consisting of a blanket of fill
material placed on top of the soft layer. The material of the working
table shall consist of normal or processed granular fill, obtained from
borrow excavation. This material shall conform to the following
specifications:
Sieve Description Percentage of Weight Passing

Mesh Sieve, AASHTO-T-27
3 inch (75 mm) 100
The remaining grading shall be such as to avoid intrusion into the

working platform material of subgrade or natural ground surface
material. For this, condition to be met it will be required that the ratio.
D15 (Working Platform Material)

---------------------------------------- is less than 5.
D85 (Natural Ground Material)
D85 and D15 mean the particle diameters corresponding to 85% and
15%, respectively, passing (by weight) in a grain size analysis.
Construction of this working table shall proceed from one edge of the
soft area by using the fill as a ramp for further material transport.
The thickness of the working table as prescribed above shall be

approximately 0.5 meter unless directed otherwise by the Engineer
Incharge, and the width shall be that of the embankment. The
placement and compaction of the working table shall be carried out by
use of light equipment, as directed by the Engineer Incharge.
411.3.8PAVEMENT WIDENING
SPECIAL PROVISION FOR HANDLING TRAFFIC.
Widening operation shall be permitted on only one side of the

pavement at a time and excavation of trenches shall be permitted only
sufficiently in advance of other operations to ensure a continuity of the
operation of excavation, placing of material in widened portion and
rolling. The trench width for widening should be sufficient to allow the
rolling and compaction of the earthwork and other materials to the
required density.
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Reflectorized barricades shall be placed along open trenches through

out day and night until completion of work. Light shall be placed at
each barricade at night. Barricades and light shall be approved by the
Engineer Incharge. The barricades shall be placed at intervals not to
exceed one hundred (100) meters or as directed by the Engineer
Incharge.
The contractor shall make adequate provision to enable traffic to cross

open trenches at intersection roads, streets and private entrances.
Partial shouldering shall be performed immediately after completion of

widening portions of the work in order to eliminate the hazard.
No separate payment will be made for handling traffic, will be

considered subsidiary to the item of “Pavement Widening”.
411.3.9Trial Section.
Before starting the formation of the embankment the Contractor shall

construct a maximum of three trial sections of 200 meter (660 feet)
each for each soil type proposed to be used for compaction as directed
by the Engineer Incharge. The soil used in the trials shall be the same
as those intended to be used for the formation of embankment and the
compacting equipment shall be the same equipment that the contractor
will use for the main work and that has been accepted by the Engineer
Incharge.
The object of these trials will be to determine the optimum moisture

content and the relationship between the number of passes of
compacting equipment and density obtained for the soil types under
trial and for the verification of the soil type itself. No separate payment
will be made for this work, as it is a subsidiary obligation of the
contractor under pay item No.411-6.1, 411-6.3, or 411-6.5 as the case
may be.
411.3.10 Excavation in Embankment.
Unless otherwise specified in the Special Provisions, the Contractor

may choose with the approval of the Engineer Incharge to make
excavation for road structures, culverts, and pipe culverts after the
embankment has been constructed. Any space remaining after the
placing of such structures of culverts and deducting for specified bed
or backfill, shall be filled with material approved by the Engineer
Incharge and compacted as follows:-
Layers not more than 20 cm (8”) in loose thickness shall be placed and
compacted in succession, with mechanical tampers or tyres or tracks of
motor driven equipment operated transversely to the roadway, to the
densities specified in section 411-3. Moisture content shall be adjusted
as directed by the Engineer Incharge.
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The excavation in embankment and the placing of backfill for the

purposes described above shall not constitute any claims for payment
but shall be covered under the contract unit price paid for other works
in which the operation is involved. Granular backfill when specified by
the Engineer Incharge shall be paid under pay item 402-6.5.
411.3.11 Miscellaneous Requirements.
To avoid interference with the construction of bridge abutments and

wing walls the contractor shall, at points to be determined by the
Engineer Incharge suspend work on Embankment and/or in cuts
forming the approaches to any such structure until such time as the
construction of the latter is sufficiently advanced to permit the
completion of the approaches without the risk of interference or
damage to the bridge works. The cost of such suspension of work shall
be included in the contract unit prices for embankment. In carrying
embankments upto or over bridges, culverts or pipe drains, care shall
be taken by the Contractor to have the embankments brought to
equally on both sides and over the top of any such structure.
When as result of settlement, an embankment requires the addition of

material upto 20 cm (8”) in thickness to bring it up to the required
grade level, the top of the embankment shall be thoroughly scarified
before the additional material is placed, and no extra payment shall be
made for the scarification.
The contractor shall be responsible for the stability of all embankments

and shall replace any portions that in the opinion of the Engineer
Incharge have been damaged or displaced. Embankment material
which may be lost or displaced as a result of natural causes such as
storm, cloud-burst or as a result of unavoidable movement or
settlement of the ground or foundation upon which the embankment is
constructed shall be replaced by the contractor with acceptable
material from excavation or borrow. No additional compensation will
be allowed for the replacement.
During construction the roadway shall be kept in shape and drained at

all times. When unsuitable material has been placed in the
embankment by the contractor he shall remove it without extra
payment.
411.4 MEASUREMENT
The quantities to be paid for shall be the number of cubic meters or
thousands of cubic feet in the volume of embankment compacted to
desired densities in place, after clearing, grubbing and stripping,
accepted by the Engineer Incharge formed with material resulting
from:
1. Roadway Excavation.
2. Borrow Excavation.
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3. Structural Excavation.
Material from Roadway Excavation as defined in section 403 which is

placed in the embankment and accepted by the Engineer Incharge will
be paid for only in the embankment and such payment will be deemed
to include the cost of excavating and hauling within free haul distance
and all other costs in connection with this material in constructing the
embankment.
Material from Structural Excavation, as defined in section 402-3.1

which is placed in the embankment and accepted by the Engineer
Incharge will be paid for under pay item Nos. 411-6.5 or 411-6.6 as the
case may be, and such payments will be deemed to include all costs in
connection with this material in constructing the embankment.
411.5 RATE.
the provisions of this section regarding making of embankment, in
accordance with Drawings and as directed in writing by the Engineer
Incharge.
411.6 PAYMENT.
The quantities, determined as provided above shall be paid for at the

contract unit price, respectively, for each of the particular pay items
listed below and shown in the bill of Quantities. The price and
payment shall be full compensation for all the costs necessary for the
proper completion of the work prescribed in this item.
Pay Item Description Unit of

No. Measurement
411-6.1 Formation of Embankment from Roadway m3 or 1000 Cft.
Excavation in Common Material.
411-6.2 Formation of Embankment from Roadway m3 or 1000 Cft.
Excavation in Rock Material.
411-6.3 Formation of Embankment from Borrow m3 or 1000 Cft.
411-6.4 Formation of Embankment from Borrow m3 or 1000 Cft.
411-6.5 Formation of Embankment from Structural m3 or 1000 Cft.
411-6.6 Formation of Embankment from Structural m3 or 1000 Cft.
***************
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CHAPTER 500
SUB BASE AND BASE

CONSTRUCTION
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SECTION 501
MECHANICALLY STABILIZED SUB-BASE
1.1 DESCRIPTION
The work specified in this sectional consist of the construction of a

layer or layers of mechanically stabilized aggregates comprising of
either naturally occurring materials or blended materials consisting of
mixtures of gravel, crushed stone or crushed brick and fines whichever
is specified in the bid schedule, conforming to specify grading placed
and compacted on a prepared sub grade in accordance with these
specifications and in conformity with the lines, grades, thickness and
typical cross section shown on the plans.
1.2 MATERIALS FOR SUBBASE
501-2.1 Mixed Aggregate
The material for dense graded sub base shall comprise mixed aggregate
conforming to any of the grading requirements of table 501-1 and shall
be free from vegetable matter, and lumps of clay. Coarse and fine
material shall conform to the requirements of sections 501-2.2 and
501-2.3 other than the grading requirements in case of dense graded
sub base. The compacted sub base shall have a minimum soaked CBR
value of 30 percent.
501-2.2 Coarse Aggregate
Coarse aggregate shall consist of hard durable fragments of stone

gravel or brick (suitably crushed to give the required grading) and may
include some sand or other finely divided mineral matter. The coarse
aggregate shall have a percentage wear by the Los Angeles Abrasion
machine test of not more than 50 at 500 revolutions as determined by
AASHTO T-96. Coarse aggregate for gap graded sub base shall
conform to any of the grading requirements of table 501-2.
501-2.3 Fine Aggregate.
The fine aggregate passing 2 mm (No.10) sieve shall consist of natural

or crushed finely divided mineral matter. The fraction passing the
0.075 mm (No.200) sieve shall not be greater than two thirds of the
fraction passing the 0.42 mm( No.40) sieve. The fraction passing 0.42
mm(40) sieve shall have a liquid limit not greater than 25 and plasticity
index not greater than 6. Fine aggregate for gap graded sub base shall
conform to the grading requirements of table 501-3.
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501-2.4 Grading Requirements:- D – 1241 – ASTM
Table 501-1
GRADING REQUIREMENTS FOR DENSE GRADED MATERIALS
FOR SUB BASE
SIEVE DESIGNATION PERCENT PASSING BY WEIGHT

Standard Alternate Grading A Grading B Grading C Grading D
50 mm 2” 100 100 -
25mm 1” 60-80 75-95 100 100
9.5mm 3/8” 30-65 40-75 50-85 60-100
4.75mm No.4 25-55 30-60 35-65 50-85
2.0mm No.10 15-40 20-45 25-50 40-70
0.42mm No.40 8-20 15-30 15-30 25-45
0.075mm No.200 2-8 5-15 5-15 8-15
Table 501-2
GRADING REQUIREMENTS FOR COARSE AGGREGATE FOR GAP
GRADED MATERIALS FOR SUB BASE

Standard Alternate Grading 1 Grading 2 Grading 3
75 mm 3” - - 100
50 mm 2” 100 100 -
37.5mm 1½“ 35-70 - -
25mm 1” 0-15 35-70 -
19 mm ¾” - - -
12.5mm ½” 0-5 10-30 40-65
9.5mm 3/8” - - -
4.75mm No.4 - 0-5 0-5
Table 501-3
GRADING REQUIREMENTS FOR FINE AGGREGATE/SAND FOR GAP
GRADED MATERIALS FOR SUB BASE

Standard Alternate
2.0 mm (No.10) 100
0.42mm (No.40) 80-100
0.075mm (No.200) 0-10
501-2.5 Blending Materials
Blending of coarse and fine aggregate for gap graded sub base shall be
done in such a ratio so as to result a minimum soaked CBR value of 30
percent. If in addition to fine aggregate, filter (non plastic soil) is
necessary in order to meet the grading requirements of table 501-1 for
dense graded sub base or for satisfactory bonding of the materials, it
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shall be uniformly blended within the total mass. The material for such
purposes shall be obtained from sources approved by the Engineer
Incharge and shall be free from clay lumps.
501.3 CONSTRUCTION OF SUB BASE.
501.3.1 Preparation of Sub grade
Sub grade including shoulders shall be constructed, prepared and

finished as provided under section 411.
501-3.2 Preparation of Previously Constructed Sub grade.
All loose or foreign material shall be removed. Any loose or soft

yielding places that appear on the subgrade shall be corrected and
rolled until firm. Suitable subgrade material shall be added and
compacted to bring the surface to proper grade and cross section.
3.1.3 Placing
The sub base course shall be placed on the prepared subgrade and
compacted in layers of the thickness shown on the Drawings. The
compacted thickness of each layer shall not be more than 150mm
(6 inch) or less than 100mm (4 inch). The compacted thickness of layer
more than 150mm (6 inch) may be allowed if the Contractor can
demonstrate that he can achieve the specified density throughout the
depth of the course to the satisfaction of Engineer Incharge. When
more than one layer is required, each layer shall be shaped, compacted
and tested before the succeeding layer is placed. The operations in the
placing of upper layers shall be such as not to disturb the lower layers.
The placing of material shall begin at the point designated and in the
manner approved by the Engineer Incharge. When hauling is done over
previously placed material, hauling equipment shall be routed as
uniformly as possible over the entire area of previously constructed
layers.
501.3.4Adding Blending Material.
When additional fine aggregate or filler is required and it is to be

blended within the material on the road, the blending material shall be
uniformly placed in a manner approved by the Engineer Incharge.
501-3.5 Mixing and Spreading
After each layer of sub base course material has been placed and
blending material added, when required, it shall be thoroughly mixed
to its full depth as may be approved by the Engineer Incharge. During
the mixing, water shall be added in the amount necessary to provide
the optimum moisture content for compacting. When uniformly mixed,
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the mixture shall be spread smoothly to a uniform thickness or, in case

of the top layer, suiting to the cross section shown on the Drawings
while providing due allowance for reduction in thickness under
compaction.
501-3.6 Compaction.
Immediately following final spreading and smoothing, each layer shall

be compacted to the full width by means of smooth wheel power
rollers or pneumatic tyre rollers. Rolling shall progress gradually from
the sides to the center line of the road, and shall continue until all the
surface has been compacted to specified requirements. Any
irregularities or depressions that develop shall be corrected by
loosening the material at these places and adding or removing material
until the surface is smooth and uniform. Along curbs, and walls, and at
all places not accessible to the roller, the sub base material shall be
tamped thoroughly with mechanical tampers or with hand tampers as
approved by the Engineer Incharge, until a smooth (even) surface has
obtained conforming to lines & grade shown on the Drawings.
The amount of rolling and tamping as required above is estimated as

the minimum necessary for compaction. During the progress of the
work, density tests shall be performed in accordance with AASHTO-T-
191 (Sand Cone Method), and if the density is found to be less than
100 percent of the maximum laboratory density as determined by
AASHTO-T-180 (Modified Proctor) and adjusted in accordance with
AASHTO-T-224 for differing percentages of coarse particles larger
than 19 mm (3/4 inch) size, present in the field density tests, the
Contractor shall perform additional rolling or tamping as may be
necessary to obtain the desired compaction.
The Engineer Incharge may permit compaction with types of

equipment other than those specified above, provided the Contractor
determines and gives assurance to the Engineer Incharge that use of the
alternative equipment will consistently produce densities of not less
than 100 percent of modified AASHTO density, determined as
provided above. The permission of Engineer Incharge for use of
alternative compaction equipment shall be obtained in writing.
Provision shall be made by the Contractor for furnishing water at the

site of the work by equipment of ample capacity and of such design as
to assure uniform application.
501.4 SURFACE TOLERANCE.
The surface of the sub base shall be true to the established grade. The
surface shall not vary more than 12.5 mm (1/2 inch) from the required
levels at center and edges of pavement and shall be even within the
following tolerances:-
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Under Template ±12.5 mm (1/2 inch) across the

road
Under Straight Edge 3m (10ft) ±9.5 mm (3/8 inch) along the

road.
501-5 RECONSTRUCTION, MAINTENANCE AND

PROTECTION OF SUB BASE
501.5.1 Reconstructing Damages Sub base.
Should the sub base at any time become soft or loose, the Contractor
shall without additional compensation remove the mixture from the
affected portion, made good the deficiency in material, reshape and
compact in accordance with the foregoing requirements.
501.5.2 Maintenance and Protection of Sub Base.
The surface of the layer shall be maintained in its finished condition

until the succeeding layer of the pavement is placed. The sub base
moisture shall be particularly maintained so that the sand fines do not
dry and flow away.
501.6 MEASUREMENT
501.6.1 Thickness
The thickness of the completed sub base course shall be determined by

depth tests or cores, taken at intervals so that each test represents
500m2 (5000 Sft). When the deficiency in thickness is more than 12.5
mm (1/2 inch), the Contractor shall correct such areas by scarifying,
adding satisfactory material, rolling, sprinkling, reshaping and
finishing it in accordance with these specifications. The Contractor
shall replace at his expense the sub base material, where test pits are
made.
501.6.2 Computation of Quantities.
The quantity of sub base course to be paid for in final position shall be
measured by volume, based upon depth tests or cores taken as
specified above or as directed by the Engineer Incharge, or at the rate
of depth test for each 500m2 (5000 Sft). On individual depth
measurements thickness more than 12.5 mm (1/2 inch) in excess of
that shown on the plans shall be considered as the specified thickness
plus 12.5 mm (1/2 inch) in computing the quantities for payment. The
unit of measurement will be one cubic meter (m3) or one hundred cubic
feet, as shown in the bid Schedule.
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501.7 RATE
The unit rate for sub base course of specified material laid in specified
thickness shall be full compensation for preparing and shaping the
subgrade and replacement of the unstable subgrade, filling test holes
and furnishing all material, labour, equipment, tools and incidentals
necessary to complete the work prescribed in this section.
501.8 PAYMENT
Item 501-8.1 Gravel Sub Base Per m3 or 100 cft

Course of the
specified thickness.
Item 501-8.2. Crushed stone Per m3 or 100 cft.
aggregate Sub-base
course of the
specified thickness
Item 501-8.3 Crushed brick Sub Per m3 or 100 cft.
Base Course of the
specified thickness.
************
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(BLANK)
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SECTION 515
GEOTEXTILES
515-1 DESCRIPTION
This work covered by this section shall consist in furnishing all

material, labour, equipment and placing of Geotextiles on prepared
surfaces complete in accordance with the specifications for the work
items involved, in thicknesses and to the dimensions shown on the
typical cross-sections of applicable drawings or as directed by the
Engineer Incharge.
515-2 GEOTEXTILE FUNCTIONS
Where indicated on the drawings or directed by the Engineer Incharge,

Geotextile will be placed to perform one or more of the following
functions.
 One road foundation for the purpose of separation between road

fill material and soft underlying soils in order to eliminate the
need for removal of poor subsoil material and quick and
effective drainage of soil-fill interface.
 For subgrade stabilization and increasing soil shear strength by

providing bonding mechanism of the Geotextile – soil system.
 As a filter for all drainage systems where a danger of clogging

by fine particles of adjacent soil is possible, the geotextile will
retain the particles from passing while allowing the seepage
water to pass through.
 As a filter element for all bodies of water where the soil can be
eroded by current, wave action or changing water levels.
 For permanent protection of synthetic sealing systems

(Geomembranes) against mechanical damage during
installation and after completion of construction.
515-3 MATERIAL REQUIREMENTS

515-3.1 Composition and Environmental Behaviour
The raw material of geotextile shall be Ultra Violet stabilized

polypropylene. The fibers shall consist of continuous filaments of
approximately 40 micron diameter and mechanically bonded by
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needling. The geotextile materials shall be resistant to acid and alkaline

media in the pH range 2 to 13, resistant to lime, cement and concrete,
resistant to all naturally occurring bacteria and fungi. A prolonged out
side exposure of several months shall have no effect on the properties
of Geotextile.
515-4.2 Mechanical and Hydraulic Properties
 To ensure free drainage, the geotextile shall have high, water

permeability.
 Geotextile shall offer high retention capability for almost all types
of soils.
 The geotextile shall have optimum stress-strain behaviour even

with low unit weight for high resistance against installation
damage.
515.4.1 Preparation
The surface shall be fairly leveled before placement of Geotextile. It is

to be ensured that there are no protruding stones which may damage
the geotextile fabric.
515-4.2 Geotextile Placement
The Geotextile shall be rolled out directly on top of the prepared

surface in a manner as recommended by the manufacturer. It shall be
over lapped at the edges as shown on the drawings or as recommended
by the manufacturer.
515-4.3 Placement of fill
The first layer of fill material shall be applied by overhead placement.

Traffic on the geotextile itself shall be avoided. Necessary precautions
shall be observed to ensure that geotextile shall not be damaged during
placement.
515-4.4 Spreading
Spreading of fill material shall be done with suitable equipment and

procedure ensuring that geotextile must not be damaged by high axle
load stresses of spreading equipment traveling on sharp fill over the
geotextile.
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515-4.5 Compaction
The compacting method (Static/Dynamic) shall be suited to

subgrade/fill material.
515.4.6Jointing of Geotextile Panels
A tension joint shall be achieved by overlapping, welding or sewing as

shown on drawings or approved by the Engineer Incharge.
i) Overlapping
Overlapping width shall not be less than 30cm on even surface

and 50cm on uneven surface. In order to avoid displacing the
geotextile during backfill over end panel joints, the connecting
panel must be placed underneath and the previously rolled out
geotextile.
ii) Welding
Welding width shall not be less tan 10cm. A wide pattern gas
torch shall be used at low temperature and about 20 cm from
the geotextile. The welded geotextile section shall be
continuously pressed down by walking on it during placement.
iii) Sewing
The stitching method shall be single thread, double thread or

butterfly type suitable to geotextile thread type and strength.
The thread shall be sufficiently tightened and stitch density
shall be three to six stitches per inch.
515.5 GEOTEXTILE FUNCTION FOR REPAVING
This section deals geotextiles placed between old pavement and new
asphalt overlay, along with suitable tack coat of bitumen. Where
indicated on drawings or directed by the Engineer Incharge, geotextile
will be placed to perform one or more of the following functions.
 To ensure proper adhesion between old pavement and new asphalt

overlay & thus reducing the over all flexural tensile stresses and
increasing life of road surface.
 As a cut off layer for the prevention of propagation of cracks in the

pavement.
 As water barrier, even under high pressure to stop reflective

cracking in the pavements.
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515-5.1 Construction Requirements
 Removal of dirt, dust and vegetation from wearing surface and

cracks.
 Filling potholes and larger cracks (>5mm) with hot mix or an

adequate filler.
 Removal of sharp or craggy edges on surface.
 On badly damaged roads, a level course of approx. 1.5 cm shall be

laid to avoid the labour intensive and time consuming operation of
crack filling.
515.5.2Applying the tack coat.

Depending on the condition of the old surface, a calculated amount of
tack coat (Qef) of approx. 1.1 kg/m2 active binder is to be sprayed
evenly on the prepared surface before laying geotextile, making sure
that:-
 The bitumen is applied beyond the width of the geotextile by about

5 cm on either side.
 The spraying temperature for pure bitumen is kept between 150oC

and 170 oC to achieve a coating as even as possible.
 When using bitumen emulsion, the coating amount is adjusted to

contain the required average amount of bitumen.
 The coating is only applied to areas where the paving felt is to be

laid.
 No additional pre-spray agent is applied on top of the paving felt.
 Where only sections for the road are covered with the pavement
fells, their surfaces must be gritted.
515.5.3Laying Geotextile
Geotextile shall be laid by hand or machine taking into account that:
 When using pure bitumen as tack coat, Geotextile may be laid
immediately after coating.
 When using bitumen emulsions, Geotextile shall not be laid until

the emulsion has cured.
 Wrinkles shall be avoided.
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 Edges lengthways and across overlap by 5-10 cm, an additional

pure bitumen binder of 0.9 kg/m 2 shall be applied on the
overlapping seams.
 Transverse overlapping is to be carried out with reference to the

direction in which the asphalt finisher will proceed i.e. under the
previous one so that the felt does not shift out of place when the
asphalt concrete is applied.
 When one half of the road is made (leaving the other open to
traffic), at least 25cm of the lengthways felt edge shall remain
uncovered to allow overlapping when laying the other half of the
road.
 During short time stoppages of construction work, the road under

construction shall be opened only to slow traffic without detriment
to Geotextile.
 Rain water on the Geotextile surface shall be allowed to evaporate

before applying a top layer.
515-5.4 Applying the asphalt concrete surface
The asphalt concrete surfacing shall be applied immediately after

laying Geotextile preferably by crawler type finisher, taking the
following points into consideration.
 The material mix shall have a temperature between 145 oC and

165 oC
 To avoid types of the finisher or truck sticking to the felt (which

can happen in hot climates or where too much tack coat has been
applied), some of the mix can be spread manually in the pathway
of the vehicles.
515.6 GEOTEXTILE TESTING
Geotextiles testing, shall be in accordance with following standard test

methods.
 Weight ASTM D-3776

 Thickness ISO 9863
 CBR Puncture Resistance Test BS 6906/4
 Strip Tensile Test ASTM D-4595
 Grab Tensile Test ASTM D-1682
 Teat Strength Test ASTM D-1117
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 Penetration Resistance Test (Drop Test) NT Build -243

 Vertical Permeability. BS 6906/3
 Pore Size E DIN 60500/6
Based on the required functions and the type of stresses, the contractor
shall propose the type of Geotextiles. The contractor shall furnish
technical literature and manufacture’s Certificate of Guarantee for the
type of geotextile material approval of Engineer Incharge prior to
delivering the material to the site. The certificate shall note compliance
to the specifications and shall state the results of the tests performed on
the material, as required by the specifications. The contractor shall,
when directed by the Engineer Incharge, have the Geotextile material
tested for conformance to the applicable specifications at an approved
testing laboratory. All costs connected with certificate of Guarantee
and any subsequent quality testing shall be at the contractor’s expense.
515.7.1Measurement
The quantity of Geotextile measured to be paid shall be the number of

square meters/Sq. feet of work completed in accordance with
requirement of this item and the limiting dimensions shall not exceed
than those shown on the drawings or fixed by the Engineer Incharge.
Measurement shall only be made of area covered without considering
any overlap.
515.7.2Payment
The accepted quantity measured as provided above shall be paid at the

contract unit price per square meter/per Sft of Geotextile laid for the
pay item as listed below in the BOQ which price and payment shall
constitute full compensation for furnishing all materials, labour,
equipment and placing of geotextile.
515-7.2.1 Providing and Placing m2 or Sft

of Geotextile, type......
***************
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SECTION 521
SUB BASE COURSE BRICK PAVEMENTS
521-1 DESCRIPTION.
The work specified in this section shall consist of providing on a

prepared subgrade one or more layers of brick on edge or flat, as called
for in the Bid Schedule or shown on the Drawings laid over sand
cushion according to specified bond with joints duly filled with sand.
521-2 MATERIALS
521-2.1 Bricks
The bricks shall conform to specification contained in Section-1041
521-2.2 Sand
The sand on which the bricks are bedded and for filling the joints shall
be free flowing and shall conform to gradation and plasticity
requirements as given in Table 501-3 and Section 501-2.3
521-3.1 Preparation of Subgrade.
The subgrade shall be prepared and finished in accordance with

Section 411.
521-3.2 Stacking of Bricks.
The bricks shall be delivered at site in stacks ten courses high and two
bricks thick for the convenience of proper inspection.
521-3.3 Placing of Bricks.
The prepared subgrade shall be covered with 25 mm (1 inch) of sand

cushion over which the bricks shall be laid closely packed in parallel
rows transverse to the center line or in an approved pattern with string
courses 10 m (30 ft) apart along the length and on each side or as may
be directed by the Engineer Incharge at site. The brick shall be laid on
edge or flat, in one or two courses as called for in the Bid Schedule or
shown on the Drawings. If more than one course is to be laid the joints
in the successive courses will be staggered. Each course shall be
properly rolled and joints filled with sand before laying the next
course. Any unevenness over the first course shall be made good with
sand before laying the second course. As provided in section 411-3,
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suitable material shall then be placed on the shoulders and the

shoulders compacted at the same time as the brick pavement is rolled.
521-4 MEASUREMENT
Brick sub base course or brick pavement when laid and finished to the
required thickness and grade and accepted in place shall be measured
by volume. The quantity shall be worked by superficial area multiplied
by the nominal thickness of brick layer/layers. The unit of
measurement shall be one cubic meter or 100 cft.
521.5 RATE
The unit rate for brick sub base course or brick pavement of specified
thickness shall be full compensation for preparing and finishing the sub
grade, replacement of unstable subgrade, provision and laying of the
approved sand, provision and laying of the bricks, filling the joints
with sand and rolling the whole width for proper compaction and
includes material, labour, equipment, tools and incidentals necessary to
complete the work prescribed in this Section.
521.6 PAYMENT
Payment shall be made under-

Item 521-6.1 Brick Sub Base course of the
specified thickness per m3 or per 100 cft
Item 521-6.2 Brick pavement of the specified

thickness per m3 or per 100 cft
*******************
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SECTION 541
DRAINAGE LAYER UNDER SHOULDERS
541.1 DESCRIPTION
The work specified in this section shall consist of providing a layer of

crushed bricks crushed stone aggregate or gravel or coarse sand of
specified gradation over a prepared and well compacted subgrade
under the whole shoulder width so as to provide a free drainage layer
where the sub base does not cover the full width of the subgrade. The
drainage layer of specified thickness shall be provided only if shown
on the Plans.
541.2 MATERIALS
Drainage material shall consist of either slightly over burnt crushed

bricks or crushed stone aggregate or gravel or coarse sand. The
gradation of drainage material shall conform to that given in table
541-1
Table 541-1
GRADING REQUIREMENTS FOR DRAINAGE MATERIAL

Standard Alternate
25 mm 1” 100
19 mm ¾” 70-100
0.15mm No.100 0-10
541.3 CONSTRUCTION
A layer of drainage material of specified thickness shall be laid over

the well prepared and compacted subgrade outside the sub base to the
width shown on the plans adjoining the sub base on either side with a
four percent cross slope and rolled dry with two coverages of an 8-10
ton smooth wheel roller. Over this layer the required material for the
shoulders should be spread and compacted in layers to desired degree
of compaction and conforming to remaining thickness of the sub base
and base course.
The final surface shall be finished to the corrected levels and cross fall
and shall be within the following tolerances:-
Under template ±12.5 mm (1/2 inch) across the

road
Under 3 meter (10’) straight edge ±9.5 mm (3/8 inch) along the
road
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541.4 MEASUREMENT
The item of drainage layer under shoulders when completed to the

specified thickness and to the clear lines shown on the Plans for width
and length shall be measured by volume. The unit of measurement
shall be one cubic meter or 100 Cft of the completed work.
541.5 RATE
The unit shall be full compensation for furnishing and placing all
materials, including all labour, equipment, tools and incidentals
541.6 PAYMENT
Payment shall be made under :-
Item 541-6.1 Crushed brick drainage layer per m3 or per 100 cft
of the Specified thickness
Item 541-6.2 Crushed stone aggregate per m3 or per 100 cft

drainage layer of the
Specified thickness
Item 541-6.3 Gravel drainage layer of the per m3 or per 100 cft
Specified thickness
Item 541-6.4 Coarse sand drainage layer per m3 or per 100 cft
of the Specified thickness
*****************
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SECTION 551-A
WATER BOUND MACADAM BASE COURSE.

551-A-1 DESCRIPTION
The work specified in this section consists of constructing a base

course composed of crushed stone aggregate, and stone screening
placed and compacted with moisture control on a prepared subgrade or
sub base course in accordance with these specifications and in
conformity with the lines, grade, thickness and cross section shown on
the Drawings
551-A-2 MATERIALS FOR WATER BOUND MACADAM BASE

COURSE
551-A-2.1 Coarse Aggregate.
Coarse aggregate shall consist of hard; durable fragments of stone/rock

suitably crushed to give the required grading, shall be of reasonable
uniform quality throughout and shall be clean and free from excessive
dust and vegetable matter. The flakiness or elongation index of the
material shall not exceed 35% when tested in accordance with
B.S-812; coarse aggregate shall have a percentage of wear by the Los
Angeles test (AASHTO-T.96) not more than 40. The sulphate
soundness loss shall not be more than 12% when using sodium
sulphate and not more than 18% when using magnesium sulphate in
accordance with AASHTO-T.104. Gradation of coarse aggregate shall
conform to either grading A or B as given in Table-551-1.
Table 551-A-1
GRADING REQUIREMENTS FOR COARSE AGGREGATE
ASTM D-448
SIEVE PERCENT PASSING BY WEIGHT
DESIGNATION
Standard Alternate Grading A Grading B Grading C
Size Size Size
(25 mm to 50 mm) (37.5mm to 63mm) (37.5 mm to 90mm)
or (1” to 2”) or (1½” to 2½”) or (1½” to 3½”)
100 mm 4” - - 100
90 mm 3½” - - 90-100
75 mm 3” - 100 -
63 mm 2½” 100 90-100 25-60
50 mm 2” 90-100 35-70 -
37.5 mm 1½” 35-70 0-15 0-15
25 mm 1” 0-15 - -
19 mm ¾” - 0-5 0-5
12.5 mm ½” 0-5 - -
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551-A-2.2 Screenings
The Screenings shall be a product of stone crushing and shall be of
suitable binding quality, well graded from coarse to fine, and free from
dirt and other foreign materials, having plasticity index less than 3, and
shall conform to the gradation given in table 551-2.
Table 551-A-2
GRADING REQUIREMENTS FOR FINE SCREENINGS
SIEVE DESIGNATION PERCENT PASSING

BY WEIGHT
Standard Alternate
9.5 mm 3/8” 100
4.7 mm No.4 85-100
0.15mm No.100 10-30
551-A-2.3 Quantities
Suitable ratio of coarse aggregate and screenings as directed by the

Engineer Incharge shall be used to make a compact dense mass of the
required thickness as indicated on the Drawings.
551-A-3 CONSTRUCTION
551-A-3.1 Preparation of Previously Constructed Subgrade or Sub base

yielding places that appear on the sub grade or sub base course shall be
corrected and rolled until firm. Necessary sub-grade or sub base course
material shall be added or removed and compacted to conform to
proper grade and cross section.
551-A-3.2 Thickness of Layers
The base course shall be constructed in completed layers of not less

than 100 mm (4 inch) or more than 150 mm (6 inch) compacted
thickness. The compacted thickness of layer more than 150 mm (6
inch) may be allowed if the Contractor can demonstrate that he can
achieve the specified density throughout the depth of the course to the
satisfaction of Engineer Incharge by using special rolling equipment.
Each layer of base course shall be constructed as described ahead.
551-A-3.3 Spreading Coarse Aggregate
Sufficient coarse aggregate shall be uniformly spread to give the

required thickness for each layer when compacted; Oversize aggregate
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and all patches or areas of fine or undersize aggregate shall be removed

and replaced with suitable aggregate. The thickness of each layer shall
be set by the use of depth blocks or templates.
Coarse aggregate shall not be spread more than 200 meter (660 feet) in
advance of rolling and application of screenings.
551-A-3.4 Compaction
Immediately after the spreading of the coarse aggregate, it shall be

compacted to the full width by rolling with a power roller. The entire
area of the course should be rolled by the rear wheels. Rolling shall be
continued until the aggregate is well keyed and does not creep ahead of
the roller and until the surface is firm, even and true to geometric line,
grade and crown or camber. Places inaccessible to roller shall be
compacted by mechanically operated or hand tampers or as directed by
the Engineer Incharge.
551-A-3.5 Applying Screenings
Immediately after the compaction of the coarse aggregate, sufficient

clean, dry screenings shall be uniformly applied, to fill all voids. Dry
rolling shall be continued while screenings are being applied. Hand
brooms shall be used if the roller is not equipped with a broom.
Screenings shall be spread in thin layers at a uniform and slow rate to
ensure filling of voids.
Spreading screenings, brooming and rolling shall be continued until the

voids are completely filled.
551-A-3.6 Sprinkling
Immediately after the voids of a layer have been filled with screenings,
the macadam shall be sprinkled with water, the sprinkler being
followed by the roller. All excess screenings forming in piles or cakes
on the surface shall be scattered by light sweeping, the sprinkling and
rolling shall continue, and additional screenings shall be applied where
necessary, until all voids are completely filled and the coarse stone
firmly set and bonded. The quantity of screenings and water shall be
sufficient to completely fill and bond the entire depth of the coarse
aggregate and to produce a granular surface.
Provision shall be made by the Contractor for furnishing water at the

site of the work by equipment of ample capacity and of such design as
to assure uniform application.
551-A-3.7 Density Requirements
As soon as proper conditions of moisture are attained, the density test

shall be performed in accordance with AASHTO-T-191 (Sand Cone
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Method). If the density is found to be less than 100 percent of the

maximum density determined by AASHTO-T-180, adjusted for
differing percentages of coarse particles in the field density test in
accordance with AASHTO-T-224, the Contractor shall perform
additional rolling to obtain the required density.
551-A-3.8 Surface Tolerance
The surface of the base shall be true to the established grade. The
surface shall not vary more than 6 mm (1/4”) from the required levels
at centre and edges of pavement and shall be even with the following
tolerances.
Under template 6 mm (1/4 inch) across the road

Under 3 m (10ft) straight edge 9.5mm(3/8 inch) along the road.
551-A-3.9 Reconstructing Damaged Base Course.
Should the subgrade or sub-base at any time become soft or churned up

with base course material the Contractor shall without additional
compensation remove the mixture from the affected portion, reshape
and compact the subgrade or sub base and replace the removed section
in accordance with the foregoing requirements.
551-A-3.10 Maintenance and Protection of Base Course
The surface of each layer shall be maintained in its finished condition

until the succeeding layer of pavement is placed.
551-A-4 MEASUREMENT
551-A-4.1 Thickness
The thickness of the completed base course shall be determined by

depth tests or cores, taken at intervals so that each test shall represent
500 m2 (5000 Sft). When the deficiency in thickness is more than
12.5 mm (1/2 inch) the Contractor shall correct such areas by
scarifying, adding satisfactory material, rolling, sprinkling, reshaping
and finishing it in accordance with these specifications. The Contractor
shall replace at his expense the base course material, where test pits are
made.
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551-A-4.2 Computation of Quantities.
The quantity of base course to be paid for in final position shall be

measured by volume based upon depth tests or cores taken as directed
by the Engineer Incharge, or at the rate of I depth test for each 500 m 2
(5000 Sft). On individual depth measurements thickness more than
12.5 mm (1/2 inch) in excess of that shown on the plans shall be
considered as the specified thickness plus 12.5 mm (1/2 inch) in
computing the quantities for payment. The unit of measurement will be
one cubic meter (m3) or one hundred cubic feet, as shown in the Bid
Schedule.
551-A-5 RATE
The unit rate of water bound macadam base course of specified

thickness shall be full compensation for preparing and shaping the
subgrade or sub base course over which it is being laid, replacement of
unstable subgrade or sub base course, filling & re-compacting test
holes, furnishing all materials, labour, equipment, tools and incidentals
551-A-6 PAYMENT
Payment shall be made under:-
Pay Item Crushed stone water bound Per cubic meter or

551-A-6.1 macadam base course of the per 100 Cft
specified thickness
******************
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SECTION 551-B
AGGREGATE BASE COURSE
551-B-1 DESCRIPTION
This item shall consist of furnishing, spreading and compacting one (1)
or more layers of aggregate base on a prepared sub-grade, sub-base, or
existing road surface, in accordance with the specifications and the
drawings and /or as directed by the Engineer Incharge.
551-B-2 MATERIAL REQUIREMENTS;
Material for aggregate base course shall consist of crushed hard

durable gravel, rock or stone fragments. It shall be clean and free from
organic matters, lumps of clay and other deleterious substances. The
material shall be of such a nature that it can be compacted readily
under watering and rolling to form a firm, stable base for both flexible
and rigid pavements.
The aggregate base shall comply with the following grading and
quality requirements.
(a) The gradation curve of the material shall be smooth and within
the envelope limits for Grading A or B given below. However
preference will be given to gradation ‘A’
Table 551-B-1
GRADATION REQUIREMENTS FOR AGGREGATE BASE MATERIAL

AASHTO M-147-65(1996)
SIEVE DESIGNATION MASS PERCENT PASSING
Standard Alternate Grading -A Grading –B

50.0 mm 2” 100 100
25.0 mm 1” - 75-95
9.5 mm 3/8” 30-65 40-75
4.75 mm No.4 25-55 30-60
2.00 mm No.10 15-40 20-45
0.425 mm No.40 8-20 15-30
0.075 mm No.200 2-8 5-20
The material shall be well graded such that the coefficient of

uniformity D60/D10 shall be greater than four (4) and the coefficient
of curvature i.e. (D30)2 /D10 X D60 shall be between 1 and 3.
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(b) Crushed Aggregate (material retained on sieve No.4) shall consist of

material of which at least ninety (90) percent by weight shall be
crushed particles, having a minimum of two (2) fractured faces.
(c) The Coarse aggregate shall have a percent of wear by the Loss Angeles
Abrasion Test (AASHTO-T-96 ) of not more than forty (40).
(d) The material shall have a loss of less than twelve (12) percent when
subjected to five cycles of the Sodium Sulphate Soundness or less than
18% when using Magnesium sulphate Soundness test, according to
AASHTO-T-104.
(e) The sand equivalent determined according to AASHTO-T-176 shall not

be less than 50 % or the material shall have a Liquid Limit of not more
than twenty five (25) a plasticity index of not more than 6 as
determined by AASHTO-T-89 and T-90 and a linear shrinkage of not
more than three (3) when tested in accordance with AASHTO-M-145-
93.
(f) The material passing the 19mm sieve shall have a CBR value of a
minimum eighty (80) percent, tested according to the AASHTO-T-193.
The CBR value shall be obtained at the maximum dry density
determined according to AASHTO-T-180 Method D.
(g) The flakiness index of the base material shall not exceed thirty five
(35) percent when tested in accordance with BS-812 Part 105(1085).
551-B-3 CONSTRUCTION
551-B-3.1 Preparation of Previously Constructed Sub-grade or Sub-base.

yielding places that appear on the sub-grade or sub base course shall be
corrected and rolled until firm. Necessary sub-grade or sub-base course
material shall be added or removed and compacted to conform to
proper grade and cross section.
551-B-3.2 Thickness of layers.
Aggregate base shall be deposited on the sub-grade or sub-base in a

quantity which, will provide the required compacted thickness without
resorting to spotting, picking up or otherwise shifting the sub-base
material.
551-B-3.3 Spreading
Aggregate base shall be spread on approved sub-grade or Sub-base

layer as a uniform mixture, Segregation shall be avoided during
spreading and the final compacted layer shall be free from
concentration of coarse or fine materials.
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Aggregate base shall be deposited on the sub-base in a quality, which

will provide the required compacted thickness without resorting to
spotting, picking up or otherwise shifting the sub-base material.
When the required thickness is fifteen (15) cm or less, the aggregates

may be spread and compacted as one layer, but in no case shall a layer
be less than seven and a half (7.5) centimeters thick. Where the
required thickness is more that 15 cm, the aggregates shall be spread
and compacted in 2 or more layers of approximately equal thickness,
but in any case the maximum compacted thickness of one layer shall
not exceed 15 cm. All subsequent layers shall be spread and compacted
in a similar manner.
Aggregate base shall be spread with equipment that will provide a

uniform layer conforming to the specified item both transversely and
longitudinally within the tolerances as specified in these specifications.
No hauling or placement of material will be permitted when, in the
judgment of the Engineer Incharge, the weather or road conditions are
not favourable.
551-B-3.4 Compaction Requirement.
The relative compaction of each layer of the compacted base shall not
be less than 100 percent to the maximum dry density determined
according to AASHTO-T-180, Method D (Modified). The field density
shall be determined according to AASHTO-T-191 or other approved
method. For all materials, the field density thus obtained shall be
adjusted to account for oversize particles (retained on 19 mm sieve) as
directed by the Engineer. Also for adjustment of any material retained
on 4.75 mm sieve, AASHTO method T-224 shall be used.
Moisture content for calculation of field density shall be observed on

material passing 4.75 mm sieve.
Completed based course shall be maintained in acceptable conditions

at all times until prime coat is applied. When base course is to carry
traffic for an indefinite length of time before receiving surfacing, the
contractor shall maintain the surface until final acceptance and shall
prevent reveling by wetting, balding, rolling and addition of material as
may be required to keep the base lightly bound and leave slight excess
of material over the entire surface which must be removed and the
surface finish restored before application of prime coat.
551-B-3.5 Trial Section.
Prior to commencement of aggregate base course operations, a trial

section of two hundred (200) meters minimum, but not to exceed five
hundred (500) meters shall be prepared by the contractor using same
material and equipment as will be used at site to determine the
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adequacy of equipment, loss depth measurement necessary to result in

the specified compacted layer depths, field moisture content, and
relationship between the number of compaction passes and the
resulting density of material.
551-B-3.6 Tolerance.
The completed base course shall be tested for required thickness and
smoothness before acceptance. Any or having waves, irregularities in
excess of half (0.5) cm in three (3) M or one (1) cm in fifteen (15) M
shall be corrected by scarifying the surface, adding approved material,
reshaping, re-compacting and finishing as specified. Skin patching of
an area without scarifying the surface to permit proper bonding of
added material shall not be permitted.
551-B-4 MEASUREMENT AND PAYMENT
551-B-4.1 Thickness
The quantity of aggregate base to be paid for, shall be measured by the

theoretical volume in place as shown on the drawings or as directed
and approved for construction by the Engineer Incharge, placed and
accepted in the completed crushed aggregate base course. No
allowance will be given for materials placed outside the theoretical
limits shown on the cross sections.
551-B-4.2 Computation of Quantities.
The quantity of base course to be paid for in final position shall be

measured by volume based upon depth tests or cores taken as directed
by the Engineer Incharge, or at the rate of 1 depth test for each 500 m
(5000 Sft). On individual depth measurements thickness more than
12.5 mm(1/2 inch) in excess of that shown on the plans shall be
considered as the specified thickness plus 12.5 mm (1/2 inch) in
computing the quantities for payment. The unit of measurement will be
one cubic meter (m3) or one hundred cubic feet, as shown in the Bid
Schedule.
551-B-5 RATE
The unit rate of aggregate base course of specified thickness shall be

full compensation for preparing and shaping the sub-grade or sub-base
course over which, it is being laid, replacement of unstable sub-grade
or sub-base course, filling & re-compacting test holes, furnishing all
materials, labour, equipment, tools and incidentals necessary to
complete the work prescribed in this section.
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551-B-6 PAYMENT
The accepted quantities measured as above shall be paid for at the

contract unit price per cubic meter or 100 Cft, of aggregate base, for
the item listed below and shown in the Bill of Quantities, which price
and payment shall constitute full compensation for furnishing all
materials, hauling, placing, watering, rolling, labour, equipment, tools
and incidentals necessary to complete this item.
Pay Item Aggregate Base Course of Per cubic meter or

551-B-6.1 the specified thickness per 100 cft
**************
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SECTION 552
BRICK EDGING
552.1 DESCRIPTION
This item where shown on the plans shall consist of providing brick
edging 75 mm (3 inches) wide on end and 225 mm (9 inches) deep,
contiguous to the pavement edge and in line with the finished profile of
the road crust. The bricks shall be laid with close joints, on a prepared
sub-grade, covered with a layer of sand 25 mm (1 inch) thick.
552-2 MATERIAL
552.2.1 Bricks
The bricks shall conform to the specifications as laid down in section

1041
552.2.2 Sand
The sand on which the bricks are bedded and for filling the joints shall
be free flowing and shall conform to the specification given in table
501-3
552.3 CONSTRUCTION REQUIREMENTS.
Before laying the top most layer of the road crust, brick edging 75 mm
(3 inches) wide brick on end layer shall be laid with close joints. The
top of these bricks after rolling shall be in line with the finished profile
of the road crust. The brick layer shall be rolled simultaneously with
the final layer of base course if the road surface is to be given triple
surface treatment and with the final layer of asphalt concrete, if the
road surface is to be carpeted.
552.4 MEASUREMENT.
Brick edging when laid and finished in accordance with the provisions
of this section shall be measured in linear units. The unit of
measurement shall be one meter or 100 linear feet of the brick edging,
completed and accepted.
552.5 RATE
The unit rate of providing brick edging shall be full compensation for
provision of materials and completion of the work as specified in this
section.
552.6 PAYMENT
Item 552-6.1 Brick Edging per linear meter or
per 100 linear feet.
***************
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CHAPTER 600
BITUMINOUS BASE AND

SURFACING
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SECTION 601
BITUMINOUS PRIME COAT
601.1 DESCRIPTION.
This work shall consist of furnishing and applying bituminous material

to a newly constructed absorbent sub base or base course in accordance
with these specifications and to the width shown on the typical cross
section on the drawing.
601-2 MATERIALS
601.2.1 Bituminous Materials
Bituminous materials shall be of the type and grade called for in the
bid schedule and shall conform to the requirements of section 1011-1.
Medium curing (MC) grades are most widely used which best serve
the purpose.
601.2.2 Rate of Application
MC-70 Grade is generally suited for priming non-bituminous

aggregate base and rate of application shall be 0.65 litre to 1.75
litres/m2 (13 Lbs to 35 Lbs/100 sft). A quantity of 1 litre/m 2 (20
Lbs/100 sft) is usually recommended.
The ideal rate of application of a primer is the maximum that will

under favourable weather conditions be completely absorbed by the
base course aggregate particles within 24 to 48 hours from the time of
application.
601.2.3 Blotter Materials
Generally a prime coat should be touch dry within 2 to 4 hours and

completely dry in 24 to 48 hours. If it is necessary to use blotter
materials because the section has to be opened to traffic or for other
reasons, the blotter material shall be clean and dry sand passing 4.75
mm (No.4) sieve.
601.3 CONSTRUCTION
601.3.1 Weather Limitations.
Prime coat shall be applied only when the surface to be treated is dry
or slightly damp and drying when the atmospheric temperature in the
shade is above 13°C (55°F) and rising or above 16°C ( 60°F) if falling,
and it shall not be applied in rain or a dust storm. The temperature
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requirements may be waived, but only when so directed by the

Engineer Incharge.
601.3.2 Preparing Surface

Immediately before applying the bituminous material, all loose dirt and
other objectionable material shall be removed from the surface with the
broom and /or blower if required. If the Engineer Incharge so requires
the surface shall be slightly bladed and rolled immediately prior to the
application of bituminous materials, in which case brooming or
blowing will not be required. A light application of water shall be made
just before the application of the bituminous material, if directed by the
Engineer Incharge.
601.3.3 Application of Bituminous Material
Bituminous material shall be applied by means of a Distributor at the

rate or rates directed by the Engineer Incharge at a temperature within
the range for the type and grade of bitumen and the type of distributor.
Successive spray widths shall be over-lapped sufficiently to give an
even distribution across the joints.
The surface of structures and trees adjacent to the areas being treated
shall be protected in such a manner as to prevent their being spattered
or marred. No bituminous materials shall be discharged into a borrow
pit or gutter
601.4 MAINTENANCE AND OPENING TO TRAFFIC
Traffic shall not be permitted on the primed surface until the

bituminous material has penetrated and dried, and in the opinion of
Engineer Incharge will not pick up under traffic. This period shall be
determined by the Engineer Incharge.
The Contractor shall maintain the primed surface until the subsequent
course is laid.
601.5 MEASUREMENT
The bituminous prime coat at specified rate shall be measured by the

superficial area. The unit of measurement shall be one Sq. meter or
100 Sq. ft
.
601.6 RATE
The unit rate shall be full compensation for furnishing and placing the
materials including all labour, equipment, tools and incidentals
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601.7 PAYMENT
Payment shall be made as under:
Item 601-7.1 Bituminous Prime Coats at

Specified rate of Application per sq. meter (m2) or
per 100 sft.
***************
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SECTION 611
BITUMINOUS TACK COAT
611.1 DESCRIPTION
This work shall consist of furnishing and giving a very light

application of bitumen to an existing bituminous surface to provide a
bond to superimposed course.
611.2 MATERIALS
Bituminous material shall be of the type and grade called for in the bid
schedule and shall conform to the requirements of Section 1011-1.
However, materials commonly used for tack coats include the bitumen
of 80/100, or lighter grades, or emulsified asphalt of SS-1 or SS-1h
grades.
611.3 CONSTRUCTION
611-3.1 Weather Limitations.
Tack coat shall be applied only when the surface to be treated is dry. It
shall be carried out when the atmospheric temperature in the shade is
above 10°C (50°F) and rising or above 16°C (60°F) if falling and it
shall not be carried out in rain or dust storm. The temperature
requirement can be waived, but only when so directed by the Engineer
Incharge.
611-3.2 Equipment.
The equipment used by the Contractor shall include power broom

(hand brooms may be used if sufficient labour is available) and /or
power blower, a binder-distributor, and equipment for heating
bituminous materials.
611-3.3 Cleaning Surface
When necessary in the opinion of the Engineer Incharge the full width
of surface to be treated shall be cleaned with a broom or power blower
to remove loose dirt and other objectionable material. The surface to be
treated shall be dry.
611.3.4 Application of Bituminous Material
Immediately after cleaning the surface, bituminous material shall be

applied at the rate directed by the Engineer Incharge. When straight-
run bitumen 80/100 or lighter grades are used for tack coat, it shall be
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applied as a “spatter” coat of not more than 0.25 litre/ m 2 (5 Lbs/100

sft)
The actual rate of application of tack coat shall be decided by the

Engineer Incharge.
The tack coat shall be applied on cleaned surface and only when it is
dry.
When emulsified asphalt is used, it shall be diluted with an equal
amount of water and applied at the rate of 0.25 to 0.70 litre/ m 2 or 5 lbs
to 14 lbs/100 sft, of the diluted asphalt emulsion.
The surface of structures and trees adjacent to the areas being treated
shall be protected in such manner as to prevent their being spattered or
marred. No bituminous material shall be discharged into a borrow pit
or gutter.
The surface shall be allowed to dry until it is in a proper condition of

tackiness to receive the surface course. Tack coat shall be applied only
so far in a advance of surface course placement as is necessary to
obtain this proper condition of tackiness. Until the surface course is
placed the Contractor shall protect the treated area from damage.
611.4 MEASUREMENT.
The bituminous Tack Coat at specified rate shall be measured by

superficial area. The unit of measurement shall be one square meter or
100 sft.
611.5 RATE
The unit rate shall be full compensation for furnishing and placing the
materials including all labour, equipment tools and incidentals
611.6 PAYMENT.
Payment shall be made as under:
Item 611-6.1 Bituminous Tack Coat at

specified rate of Application per sq.meter (m2) or
per 100 sq.ft.
*************
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SECTION 621
PLANT MIX BITUMINOUS BASE COURSE
621.1 DESCRIPTION
The work specified in this section consists of constructing a base

course composed of crushed stone aggregate, crust stone dust mineral
filler if required and bituminous binder mixed in a central, plant, laid
on a prepared sub base in accordance with these specifications and in
conformity with the lines, grades, and typical cross section shown on
the drawings.
621-2 MATERIALS FOR PLANT MIX BITUMINOUS BASE COURSE
621.2.1 Coarse Aggregate
Coarse aggregate shall consist of crushed rock or crushed gravel,

composed of clean, hard, tough, durable and sound particles, free from
shale, clay lumps and other deleterious substances. The amount of flat
or elongated pieces in the combined aggregate shall not exceed 35
percent when tested in accordance withBS-12. It shall have a
percentage of wear by Los Angeles Abrasion test AASHTO-T-96
not more than 40 percent and shall qualify a stripping test as given in
AASHTO-T-182. The weighted average loss in sodium sulphate
soundness test of AASHTO-T-104, shall not exceed 12 percent. Water
absorption when tested in accordance with AASHTO-T-85 shall not
exceed 2%. Friable Particles when tested in accordance with
AASHTO-T-112 shall not exceed 0.25%.
Coarse aggregate shall conform to any one of the gradation given in

Table 621-1 and shall be well graded between these limits.
621.2.2 Fine Aggregate.
Fine aggregate shall be obtained by crushing gravel or rock. If a

combination of crushed stone sand or crushed gravel sand and natural
sand is used, at least 25 percent of it shall be a produce of crushing
rock or gravel. Water absorption when tested in accordance with
AASHTO-T-84 shall not exceed 2%. Friable particles when tested in
accordance with AASHTO T-112 shall not exceed 0.25%. The fineness
modulus shall not vary more than 0.25 from the base fineness modulus.
Fine aggregate shall conform to any one of the gradations given in
Table 621-2.
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TABLE NO.621-1
GRADING REQUIREMENTS FOR COARSE AGGREGATE FOR PLANT
MIX BITUMINOUS BASE COURSE.
RECOMMENDED 100 mm 75mm 50 mm

COMPACTED DEPTH (4”) (3”) (2”)
OF LAYER
SIEVE SIZE PERCENT PASSING Y WEIGHT
Standard Alternate 1 2 3 4 5 6
50.00 mm (2”) 100 100 - - - -
37.50 mm (1 ½”) 90-100 95-100 100 100 - -
25.00 mm (1”) 20-55 - 90-100 95-100 100 100
19.00 mm ¾” 0-15 35-70 40-85 - 90-100 90-100
12.50 mm ½” - - 10-40 25-60 - -
9.50 mm 3/8” 0-5 10-30 0-15 0-15 20-55 30-65
4.75 mm No.4 0-5 0-5 0-5 0-10 0-10 5-25
2.38 mm No.8 - - - 0-5 0-5 0-10
1.19 mm No.16 - - - - - 0-5
ASTM D 448-98
ASPHALT INSTITUTE –SS-1
The nominal size of coarse aggregate shall not exceed half the compacted thickness of
the layer.
TABEL-621-2
GRADING REQUIREMENTS FOR FINE AGGREGATE FRO PLANT MIX
BITUMINOUS BASE COURSE
SIEVE SIZE PERCENT PASSING BY WEIGHT

Standard Alternate Grading – i Grading – ii Grading iii
9.55 mm 3/8” 100 100 100
4.75 mm No.4 100 80-100 80-100
2.38 mm No.8 95-100 65-100 65-100
1.19 mm No.16 85-100 40-80 40-80
0.60 mm No.30 65-90 20-65 20-65
0.30 mm No.50 30-60 7-40 7-46
0.15 mm No.100 5-25 2-20 2-30
0.075 mm No.200 0-5 0-10 -
Ref: ASTM D-1073
621.2.3 Mineral Filler

Mineral filler, if required shall be composed of finely divided mineral
matter such as rock dust, hydrated lime or any other approved material
and shall conform to the gradation given in Table 621-3
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TABLE 621-3
MINERAL FILLER
SIEVE SIZE PERCENT PASSING

BY WEIGHT
STANDARD ALTERNATE
0.60 mm No.30 100
0.3 mm No.50 95-100
0.075 mm No.200 70-100
ASTM-D 242
621.2.4 Composite Aggregate
The gradation of the composite aggregate including the filler, if

required shall conform to those given in Table 621-4. The combined
aggregate shall have a P.I of not more than 3/4 and a sand equivalent of
not less than 45.
TABLE NO.621-4
GRADING REQUIREMENTS FOR COMPOSITE MATERIAL FOR PLANT
MIX BITUMINOUS BASE COURSE.
ASTM - D – 3515
RECOMMENDED 100 75mm 50 37.5mm JOB MIX

COMPACTED DEPTH mm (3”) mm (1 ½”) TOLERANCE
OF LAYER (4”) (2”)
Sieve size Percent passing by weight
Standard Alternate 1 2 3 4
50.00 mm (2”) 100 - - 8
37.50 mm (1 ½”) 90-100 100 7
25.00 mm (1”) - 90-100 100 - 7
19.00 mm ¾” 56-80 - 90-100 100 7
12.50 mm ½” - 56-80 - 90-100 7
9.50 mm 3/8” - - 60-80 - 7
4.75 mm No.4 23-53 29-5 35-65 45-70 7
2.38 mm No.8 15-41 23-53 20-50 25-55 6
1.19 mm No.50 4-16 15-41 3-20 5-20 6
0.075 mm No.200 0-6 1-7 2-8 2-9 2
PERCENT BITUMEN BY 3.0-7.0 3.0-7.0 3.5-7.5 3.5-8.0 3
WEIGHT OF MIX
621.2.5 Bituminous Material

The bituminous material shall be a straight run bitumen of the type and
grade specified by the Engineer Incharge under the special provisions
of the contract and shall comply with the requirements of Section
1011.
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621.3 BITUMINOUS MIX DESIGN

Marshall’s Method of mix design shall be used for designing the
bituminous mix for base course unless otherwise specified. The mix
formula shall take into consideration the absorption of asphalt into the
aggregate.
621.3.1 Bitumen content

The percentage of bitumen by weight of total mix will usually be in the
range given in Table 621-4. The exact percentage to be used shall be
specified by the Engineer Incharge on the basis of laboratory tests on
the mix.
621.3.2 Mix Characteristics
When tested according to Marshall’s Method, the bituminous mix shall

conform to the following requirements:-
No of Blows 75
Marshall’s Stability 900 Kg (2000lbs) min
Flow 2.0-3.56 mm(0.08-0.0.14 inch)
Marshall Quotient 2.5-3.5 KEN/mm
Voids in Mineral aggregate
(VMA) As per MS-2 edition (latest available)
Voids in total mix (VIM) 3-5 %
Voids filled with Asphalt 65-75 %
Loss in Stability of mix 25% max.
621.4 CONSTRUCTION
621.4.1 Weather Limitations

Plant mix base course shall only be constructed when the surface is
dry, when the atmospheric temperature in the shade is above 10 0C (50
0
F) and rising or above 16oC (60o F), if falling, and when there is no
rain or dust storm.
621.4.2 Prime Coat

A prime coat, if required shall be in accordance with Section 601.
621.4.3 Tack Coat
A tack coat, if required shall be in accordance with Section-611 by the

Engineer Incharge.
621.4.4 Bituminous Mixing Plant
The bituminous mixing plant shall be in accordance with ASTM

Designation D 995, or as may be specified and accepted by the
Engineer Incharge.
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621.4.5 Transportation and Delivery of Mixture
The mixture shall be transported from the mixing plant to the point of
use in pneumatic tyre vehicles having tight bodies and previously
cleaned of all foreign materials. To prevent sticking, the inside of the
body may be lightly dusted with approved material, or wiped over with
diesel, ensuring that there is no surplus to contaminate the mixture.
When directed by the Engineer Incharge each load shall be covered
with suitable tarpaulins of sufficient size and thickness to protect it
from the weather.
The mixing temperature shall be adjusted within the allowable

tolerance to ensure that the material arrives on site at a temperature
suitable for spreading, compacting and finishing, generally in the range
of 1300C -1700C (2650F-3350F) when 60-70 grade bitumen is used.
However, over heating beyond temperatures specified for the grade of
bitumen to avoid burning shall not be allowed.
621.4.6 Spreading, laying compacting and Finishing
Immediately before spreading the bituminous mixture, the existing

surface shall be cleaned of loose or deleterious material by sweeping
with a power broom, supplemented by hand broom if necessary and
primed when required.
The placing and compacting of bituminous material shall progress in

sections of not more than 1600 meter (5000 ft) in length. The
bituminous mixture shall be spread, and finished with a mechanical
paver approved by the Engineer Incharge. It shall then be properly
compacted by rolling, after rolling the surface can be allowed to be
used for hauling material for subsequent reach.
All transverse joints where spreading is stopped for more than two
hours in the base course shall be tapered down and compacted. Before
spreading is recommenced, the material shall be cut back square to a
point where the layer has its full thickness and painted with hot
bitumen. Longitudinal joints if not covered within four hours shall
either be preheated so that compaction can be made to properly bond
the material over the joint or the joint shall be painted with hot
bitumen. The Paver screed should be set to overlap the first mat by
25-50 mm joints in successive layers shall be staggered by at least 300
mm(12 inches).
The speed of the laying machine shall be adjusted in relation to the

supply of the material and ensuring the break down temperature to give
the minimum number of stoppages.
Compaction shall take place as close behind the spreading, as it is

practicable. When the rolling does not, in the opinion of the Engineer
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Incharge cause undue displacement, cracking or shoving, it shall be

carried out using smooth wheel roller (3 wheel or 2 or 3 axle tandem)
or pneumatic tyre roller to give a density equal to or greater than 97
percent of the Marshall’s Density of each days production. The exact
combination of roller and sequence of rolling operations may be
worked out on the job in agreement with the Engineer Incharge.
Bitumen mix shall be spread in a placement thickness so that after

rolling the nominal thickness will not exceed 10 cm (4 inches) unless
otherwise specified by the Engineer Incharge.
621.4.7 Thickness Requirements
For determination of thickness, one (1) core for each hundred (100)
linear meter of each lane shall be taken. Unless otherwise permitted,
cores extracted for thickness measurement shall not be used for density
determination and density cores shall not be used for thickness
measurements.
When layer thickness of Asphaltic base course is deficient by more

than five (5) mm from that specified in the Drawings, the deficiency
shall be removed with satisfactory base course material and/or made up
by additional asphalt concrete wearing course thickness without extra
cost to the Employer. If such remedial action is authorized, revised
thickness determinations shall be made by measurements of new cores
taken after placing of “Asphaltic Wearing Course” material or as
directed by the Engineer Incharge. If base course deficiencies are
corrected in this manner, full payment for the “Asphaltic Base Course”
will be made to the Contractor, but no additional payment will be made
for the increase in thickness of the “Asphaltic Wearing Course”.
621.4.8 Surface Requirements
When tested by template conforming to the typical cross section on the

drawings and a 3m (10 ft) straight edge applied at right angle and
parallel, respectively, to the center line of the road, the variation of the
surface from each testing edge between any two contacts with the
surface shall at no point exceed 6 mm(1/4”) for base course.
Any irregularities that exceed the specified tolerances or that retain

water on the surface shall be corrected by removing the defective area
and replacing with new Asphaltic base course without additional cost
to the Employer.
621.4.9 Shaping Edges
All edges shall be trimmed by the Contractor to neat lines in

accordance with the drawings and chamber if there is no lateral
confinement.
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621.4.10 Weather Limitations
Hot Asphaltic mixtures shall be placed only when the air temperature
is four (4) degrees centigrade or above and no asphalt shall be laid
under foggy or rainy weather or over moisture surface.
621.4.11 Trial Section
Contractor shall prepare a trial section before the start of work in light
of procedure given in the standards.
621.5 MEASUREMENT
The quantity of bituminous mix for base course shall be measured

either by volume or by superficial area of specified thickness
compacted, placed and accepted. When measured by volume the unit
of measurement shall be one cubic meter or 100 cft. When measured
by superficial area, the unit of measurement shall be one square meter
or 100 sft
621.6 RATE
The unit rate shall be full compensation for furnishing, hauling and
placing all materials, including all labour, equipment, tools and
incidentals necessary to complete work prescribed in this Section.
621.7 PAYMENT
Payment shall be made as under:-
Item 621-7.1 Plant mixed bituminous

base course of specified
requirement per cubic meter (m3) or
per 100 cft
Item 621-7.2 Plant mixed bituminous

base course of specified
thickness. per sq. meter (m2) or
per 100 sft
***************
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SECTION 631
BITUMINOUS SURFACE TREATMENT AND SURFACE

DRESSING
631-1 DESCRIPTION
The work specified in this section shall consist of furnishing and
applying bituminous material of the type and grade specified and the
cover material of specified size (s) as detailed in these specifications.
631-2 MATERIALS
631-2.1 BITUMINOUS BINDERS
Bituminous binders will be of the type and grade as specified taking

into consideration climatic conditions and the intensity of traffic, and
will be in accordance with the requirements of section 1011. The
quantities of bituminous binders recommended in Table 631-1(A) and
631-1 (B) are for penetration grade asphalts. The quantities of cutbacks
and emulsified asphalts shall be based on the amount of asphalt residue
or as directed by the Engineer Incharge.
631-2.2 AGGREGATE
The aggregate shall be of the specified nominal size in conformity with

the grading and shape given in table 631-2. Crushed gravel or crushed
stone shall consist of clean, tough, durable fragments, free from dirt or
other deleterious substances and shall not have a percentage of Los
Angles wear greater than 35% at 500 revolutions as determined by
AASHTO T-96. The quantities of aggregates recommended in Table
631-1 (A) and 631-1(B) are for Triple Surface Treatment and Surface
Dressing/resurfacing respectively.
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TABLE 631-1(A)
QUANTITIES OF MATERIAL (BINDER AND AGGREGATE) FOR
SURFACE TREATMENT
RATE OF RATE OF
SURFACE NOMINAL SIZE SPREADING OF APPLICATION OF
TREATMENT AGGREGATE BITUMEN
Type Applicat Standard Alternate Cubic Cubic feet Kilogram Pounds

ion meter /100 per /100 (kg)/100 sq (lbs)/ 100
sq meter sq. ft meter sq. Feet
TRIPLE Ist COAT 25.00 mm 1” 1.68 5.50 1.95 40
(Heavy)
HEAVY 2nd 12.50 mm ½” 0.84 2.75 122 25
(Listed) COAT
3rd COAT 06.30 mm ¼” 0.46 1.50 68 14
TOTAL FOR THREE COATS. 2.98 9.75 385 79

TRIPLE 1st COAT 19.00 mm ¾” 1.22 4.00 171 35
LIGHT 2nd 09.5 mm 3/8” 0.61 2.00 88 18
COAT
3rd COAT 06.30 mm ¼” 0.46 1.50 68 14
TOTAL FOR THREE COATS 2.29 7.50 327 67
TABLE 631-1(B)
QUANTITIES OF MATERIAL (BINDER AND AGGREGATE) FOR
SURFACE TREATMENT
Surface treatment Nominal size Rate of spreading Rate of application of

of Aggregate Bitumen
Type Applicati Standard Alternate Cubic Cubic Kilogram Pounds (lbs)/

on meter / feet per (kg)/100 sq 100 sq. Feet
100 sq /100 sq meter
meter FT.
RESURFA SINGLE 19.00 mm ¾” 1.06 3.5 107 22

CING COAT
(HEAVY)
RESURFA SINGLE 12.50 mm ½” 0.67 2.50 98 20

CING COAT
(LIGHT)
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TABLE 631-2
GRADING SPECIFICATIONS FOR SINGLE SIZE CHIPPING.
Nominal Specified size Over size Under size Maximum

Nominal Passing Retained Minimum All to Max of Passing Max of Passing Maximum Permissible
size Sieve sieved proportion of pass sieve nominal size sieve nominal sieve Fins Flakiness
specified retaining on size Percent Index
size percent sieve percent retaining on (Bs-812)
sieve
percent
25.0 mm 25.0 mm 19.0mm 60 37.5 mm 15 12.5mm 7 02.38 2 35
(1”) (1”) (3/4”) (1-½”) (1/2”) mm(No.8)
19.0 mm 19.0 mm 12.5 mm 65 25.0mm 15 09.5mm 7 02.38 2 35
(3/4”) (3/4”) (1/2”) (1’) (3/8”) mm(No.8)
12.5mm 12.5mm 09.5mm 55 19.0mm 15 06.3mm 7 02.38 2 35
(1/2”) (1/2”) (3/8”) (3/4”) (1/4”) mm(No.8)
09.5mm 09.5mm 06.3 mm 60 12.5mm 15 02.75 10 02.38 2 35
(3/8”) (3/8”) (1/4”) (1/2”) (No.4) mm(No.8)
06.3 mm 06.3 mm 03.3mm 70 09.5mm 15 02.38 10 00.60 2 35
(1/4”) (1/4”) (1/8”) (3/8”) mm mm(No.8)
(No.8)
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ALTERNATE GRADING (SINGLE SIZE CHIPPING)
Nominal size Sieve Size

37.5 25 19 12.5 mm 9.5 mm 6.3mm 4.75 mm 2.38 mm 0.075 Maximum
mm 1- mm mm ½” 3/8” ¼” No.4 No.8 mm permissible
½” 1” ½” No.200 flakiness index
(bs-812)
Percentage Passing By Weight
25 mm (1”) 100 85-100 0-40 0-7 - - 0-1 - 0-0.5 35

19 mm (3/4”) - 100 95-100 0-20 0-5 - - - 0-05 35
12.5mm (1/2”) - - 100 95-100 0-30 0-5 - - 0-0.5 35
9.5 mm (3/8”) - - - 100 95-100 0-40 0-5 - 0-0.5 35
6.3 mm (1/4”) - - - - 100 85-100 0-30 0-10 0-0.5 35
4.75mm (No.4) - - - - - 100 95-100 0-40 0-0.5 35
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631.3 CONSTRUCTION
631.3.1 Temperature and Weather Limitations
Bituminous material shall be applied only when the atmospheric

temperature in the shade is above 10 0C(50 0F) and rising or above of
16 0C (60 0F) if falling and it shall not be carried out in rain or dust
storm.
631.3.2 Preparation of the Surface for Treatment
The surface of the base course to be treated will be cleaned of all loose
dust and deleterious materials using mechanical broom and /or
mechanical blower. Hand brooms may be approved by the Engineer
Incharge if sufficient labour is available. All necessary patching on old
black top surface shall be carried out in a way as to bring the surface of
the patch to match the texture of the remaining road as closely as
possible, at least ten days ahead of surface treatment. The surface of
the old black top road shall also be cleaned before application of
bituminous materials. The non-bituminous base shall be primed if so
required. However priming of WBM can be invariably avoided if it is
properly water bound and cleaned to create mosaic stony surface, to
the satisfaction of the Engineer Incharge.
631.3.3 Application of Bituminous Binder
The bituminous material shall be applied when the surface to be treated

is dry through a distributor at the rate of spread in general conformity
with Table 631-1(A or B) or as may be specified by the Engineer
Incharge and at the appropriate temperature range for the particular
bituminous binder. Successive widths of spray shall overlap by an
appropriate amount to give a clean start and stop, blotting paper will be
spread across the road and the spray started and stopped on this. The
paper will be disposed off as directed by the Engineer Incharge. If the
spray bar is not protected by hood to prevent the binder being blown
out care shall be taken to protect such objects.
631.3.4 Spreading the Cover Aggregate
The cover aggregate for each layer of bitumen will be spread within 2
minutes of the application of bitumen, the rate of spread will be
sufficient to give complete shoulder to shoulder coverage of chipping
and in general conformity with Table 631-2. Any bare spots will be
covered up by hand or brushing. The aggregate shall be
cleaned/screened to the satisfaction of Engineer Incharge so as to
conform to required specification before application.
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631.3.5 Rolling
Rolling may be done by a self-propelled pneumatic tyred roller (Min.

weight ¾ ton per wheel with 40 psi tyre pressure or 6-8 ton three wheel
rollers. The first rolling of the cover aggregate shall be completed
within 15 minutes after it has been spread. Rolling should not be
continued when the chippings show sign of crushing. After 24 hours,
or longer period, the surplus aggregate shall be removed by brushing
and the subsequent layers be applied in the same manner, as specified
above.
631.3.6 Opening of Traffic and Traffic Control
During the execution of work of surface treatment or surface dressing,

diversion shall be provided and sufficient control exercised to prevent
traffic coming on the treated road till the bituminous material has
dried, and in the opinion of the Engineer Incharge will not picked up
under traffic.
631.4 STOCKPILING (STACKING)
When indicated on the drawings and called for in the Bid Schedule,
cover aggregate shall be furnished and stockpiled (stacked) in the
required quantity and at the locations, as approved by the Engineer
Incharge and in accordance with Section 1031.
631.5 MEASUREMENT
Surface treatment or surface dressing of a specified type shall be

measured by superficial area. The unit of measurement shall be one
square meter or per 100 Sq. ft.
When indicated on the drawings and called for in the bid schedule
cover aggregate of the specified size (s) shall be stock piled (Stacked0
in the required quantity and at the locations approved by the Engineer
Incharge. The unit of measurement shall be one cubic meter or one
hundred cubic feet.
631.6 RATE
The unit rate shall be full compensation for furnishing and applying
bituminous material and aggregate in the specified quantities including
all labour, materials, equipment, tools and incidentals to complete the
work prescribed in this section.
When called for in the bid schedule, the unit rate for stockpiling of
aggregate of the specified size (s) shall be full compensation for
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procurement, supply and stacking of specified quantity of aggregate.

Separate rates shall be quoted by the Contractor for aggregates
required for each coat of surface treatment and surface dressing.
631.7 PAYMENT
Item 631-7.1 Triple Surface Treatment

using the specified quantities
of Bitumen and Aggregate. Per sq.m or per 100 sft
Item 631-7.2 Surface Dressing (Re-surfacing)

using the specified quantities
of Bitumen and Aggregate. Per sq.m or per 100 sft
Item 631-7.3 Supplying aggregate of specified

Sizes for triple surface
treatment. Per cubic meter (m3) or
per 100 cubic feet (ft3)
Item 631-7.4 Supplying aggregate of specified
Sizes for resurfacing Per cubic meter (m3) or
per 100 cubic feet (ft3)
*****************
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SECTION 651
BITUMINOUS PLANT MIX SURFACE
COURSE/BINDER COURSE/WEARING COURSE.
651-1 DESCRIPTION
The work specified in this section shall consist of constructing a

surface course/binder course/wearing course composed of crushed
stone aggregate, sand, mineral filler if required and bituminous binder
mixed in a central plant, laid on a prepared base course, in accordance
with these specifications and in conformity with the line, grade and
typical cross sections shown on the drawings.
651-2 MATERIALS FOR PLANT MIX SURFACE COURSE.
651.2.1 Coarse Aggregate

Coarse aggregate shall consist of crushed rock or crushed gravel,
composed of clean, hard, tough, durable and sound particles, free from
shale, clay lumps and other deleterious substances. The amount of flat
or elongated pieces in the aggregate shall not exceed 30% when tested
in accordance with B.S.812. It shall have a percentage of wear by Los
Angeles Abrasion test not more than 30 percent and shall qualify a
stripping test as given in AASHTO T-182. The weighted average loss
in sodium sulphate soundness test of AASHTO T-104, shall not exceed
12 percent. Water absorption when tested in accordance with
AASHTO-T-85 shall not exceed 2%. Friable particles when tested in
accordance with AASHTO T-112 shall not exceed 0.25%. Coarse
aggregate shall conform to any one of the gradations given in table
651-1 and shall be well graded between these limits. The maximum
size of coarse aggregate shall not exceed half the compacted thickness
of the layer.
TABLE NO.651-1
GRADATION REQUIREMENTS FOR COARSE AGGREGATE
FOR PLANT MIX BITUMINOUS SURFACE COURSE/BINDER-
COURSE/WEARING COURSE.
RECOMMENDED 75 mm 50 mm 37.5 mm 25mm

COMPACTED DEPTH OF (3”) (2”) (1 ½”) (1”)
LAYER
Standard Alternate
37.50 mm 1 ½” 100 - - -
25.00 mm 1” 95-100 100 -
19.00 mm ¾” - 90-100 100 -
12.50 mm ½” 25-60 - 90-100 100
9.5 mm 3/8” - 20-55 40-75 85-100
4.75 mm No.4 0-10 0-10 5-25 10-30
2.38 mm No8 0-5 0-5 0-10 0-10
1.19 mm No16 - - 0-5 0-5
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651.2.2 Fine Aggregate
Fine aggregate shall be obtained by crushing gravel or rock. If a

combination of crushed stone sand or crushed gravel sand and natural
sand is used, at least 75 percent of it shall be a produce of crushed rock
or gravel. Water absorption when tested in accordance with AASHTO-
T-84 shall not exceed 2%. Friable particles when tested in accordance
with AASHTO-T-112 shall not exceed 0.25%. Fine aggregate shall
conform to any one of the gradations given in Table 621-2.
651-2.3 Mineral Filler
Mineral Filler, if required shall be composed of finely divided mineral

matter such as rock dust, hydrate lime or any other approved material
and shall conform to the gradation requirements given in table 621-3.
651.2.4Composite Aggregate
The gradation of the composite aggregate including the filler, if

required, shall conform to those given in Table 651-2
The combined aggregate shall have a P.I of not more than 3% and a
sand equivalent of not less than 50.
TABLE NO.651-2
GRADATION REQUIREMENTS FOR COMPOSITE MATERIAL
FOR PLANT MIX BITUMINOUS SURFACE COURSE/BINDER-
COURSE/WEARING COURSE.
(ASTM – D – 3515)
RECOMMENDED 75 mm 50 mm 37.5 mm 25mm

COMPACTED DEPTH OF (3”) (2”) (1 ½”) (1”) Job Mix
LAYER Tolerance
Standard Alternate
37.50 mm 1 ½” 100 - - - +8
25.00 mm 1” 95-100 100 - - +7
19.00 mm ¾” - 90-100 100 - +7
12.50 mm ½” 60-80 - 90-100 100 +7
9.50 mm 3/8” - 60-85 - 90-100 +7
4.75 mm No.4 25-60 35-65 45-70 60-80 +7
2.38 mm No8 15-45 20-50 25-55 30-65 +6
0.30 mm No50 3-18 3-20 5-20 5-25 +5
0.075 mm No.200 1-7 2-8 2-9 2-10 +2
% BITUMEN BY WEIGHT 3.5-7.5 3.5-7.5 3.5-8.0 4.0-8.5
OF MIX
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651.2.5Bituminous Material
The bituminous material shall be straight run bitumen of the type and
grade specified by the Engineer Incharge under the special provisions
of the contract and shall comply with the requirement of Section 1011.
651.3 BITUMINOUS MIX DESIGN
Marshall’s Methods of mix design shall be used for designing the

bituminous mix for surface course, binder course or wearing course
unless otherwise specified. The mix formula shall take into
consideration the absorption of asphalt into the aggregate.
Bituminous plant mix surface course, when to be placed in a

compacted thickness of more than 8 cm (3”) should preferably be split
up in two layers consisting of a binder course and a wearing course, the
mix being separately designed if the thickness is different for the two
layers. However, when the ambient temperature is in vicinity of
freezing, the layer can be as thick as 4 inches to avoid temperature
losses and to keep the mix compatible.
651-3.1 Bitumen Content.
The percentage of bitumen by weight of total mix will usually be in the
range given in Table 651-2. The exact percentage to be used shall be
specified by the Engineer Incharge on the basis of laboratory tests on
the mix.
651-3.2 Mix Characteristics
When tested according to Marshall’s Method, the bituminous mix shall
Conform to the following requirements.
No. of Blows 75
Marshall’s Stability 1000 Kg (2000) lbs minimum
Flow 2.0 – 3.56 mm (0.80 – 0.14 in)
Marshall Quotient 2.5 – 3.5 KN/mm
Voids in mix (V.I.M.) 3.0 – 5.0%
Voids in mineral aggregates As per Ms-2- (Latest Addition.)
(VMA) edition
Voids filled with Asphalt (V.F.A) 65-75%
Loss in Marshall stability by
Immersion of specimen in
Water at 60°C (140°F) for
24 hours as compared with its
stability measured after immersion
in water at 60°C(140°F) for 30-40
minutes 25% Max.
Filler/Bitumen ratio 1-1.5 (applicable of hot climate
temperature greater than 40oC
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651.4 CONSTRUCTION
651-4.1 Weather Limitations
Plant mix surface course shall only be constructed when the surface is
dry, when the atmospheric temperature in the shades is above
10°C(50°F), if falling, and when there is no rain or dust storm.
651-4.2 Prime Coat
A prime coat, if required shall be in accordance with Section 601.
651-4.3 Tack Coat
A tack coat, if required shall be in accordance with Section 611.
651-4.4 Bituminous Mixing Plant shall be in accordance with ASTM

Designation D 995 or as may be specified and accepted by the
Engineer Incharge.
651-4.5 Transportation and Delivery of Mixture.
The mixture shall be transported from the mixing plant to the point of
use in pneumatic tyred vehicles having tight bodies and previously
clean of all foreign materials. To prevent sticking, the inside of the
body may be lightly dusted with approved material, or wiped over with
diesel, ensuring that there is no surplus to contaminate the mixture.
When directed by the Engineer Incharge each load shall be covered
with suitable tarpaulins of sufficient size and thickness to protect it
from the weather.
The mixing temperature shall be adjusted within the allowable

tolerance to ensure that the material arrives on site at a temperature
suitable for spreading, compacting and finishing, generally in the range
of 130°C-170°C (265°F-340°F) when 60-70 grade bitumen is used.
However over heating beyond temperatures specified for the grade of
bitumen to avoid burning shall not be allowed.
651-4.6 Spreading, Laying, Compacting and Finishing
Immediately before spreading the bituminous mixture the existing

surface shall be cleaned of loose or deleterious material by sweeping
with a power broom, supplemented by hand broom if necessary and
primed when required. The placing and compacting of bituminous mix
shall progress in sections of not more than 1600 meter (5000 ft) in
length. The bituminous mixture shall be spread, and finished with a
mechanical paver approved by the Engineer Incharge. It shall then be
properly compacted by rolling. After rolling the surface can be allowed
to be used for hauling material for subsequent reach.
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All transverse joints where spreading is stopped for more than two
hours in the surface course shall be tapered down and compacted.
Before spreading is recommended, the material shall be cut square to a
point where the layer has its full thickness and painted with hot
bitumen. Longitudinal joints if not covered within four hours shall
either be preheated so that compaction can be made to properly bond
the material over the joint, or the joint shall be painted with hot
bitumen. The paver screed should be set to overlap the first mat by
25-50 mms. Joints in successive layers shall be staggered by at least 30
cms (12 inches).
The speed of the paving machine shall be adjusted in relation to the
supply of the material and ensuring the break down temperature to give
the minimum number of stoppages.
Compaction shall take place as close behind the spreading as it is

practicable. When the rolling does not, in the opinion of the Engineer
Incharge cause undue displacement, cracking or shoving, it shall be
carried out using smooth wheel roller (3 wheel or 2 or 3 axle tandem)
or pneumatic tyred roller to give a density equal to or greater than 97
percent of the Marshall’s Density of each days production. The exact
combination of roller and sequence of rolling operations may be
worked out on the job in agreement with the Engineer Incharge.
Bituminous mix shall be spread in a placement thickness so that after

rolling the nominal thickness will not exceed 8 cm (3 inches) unless
651-4.7 Surface Treatment (Seal Coat)
If show on the drawings and called for in the bid schedule, a surface
treatment (seal coat) of the type called for shall be applied to finished
plant mix surface.
651-4.8 Thickness Requirements

Thickness requirements, including test measurement and corrective
measures shall be in accordance with the following:-
Thickness Not more than + 3 mm of the specified thickness. If a

preceding layer is out of specification regarding
thickness tolerances, the contractor may select to
provide, at his own cost, a layer of additional material
required to ensure that the deficiency in thickness is
made good to conform to the requirements.
651-4.9 Surface Requirements.
When tested by a template conforming to the typical cross section on

the drawings and a 3 m (10 ft) straight edge applied at right angle and
parallel, respectively, to the centerlines of the road, the variation of the
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surface from each testing edge between and two contacts with the
surface shall at no point exceed 3 mm (1/8”) for surface course.
651-4.10 Shaping Edges
All edge shall be trimmed by the contractor to neat lines in accordance

with the drawings and chamber if there is no lateral confinement.
651-5 MEASUREMENT
The quantity of bituminous mix for the surface course shall be

measured as given is Section 621-5.
651-6 RATE
The unit rate shall be full compensation for furnishing, hauling and
placing all material, including all labour, equipment, tools and
incidentals necessary to complete the work prescribed in this section.
651-7 PAYMENT
(1) The quantity determined as provide above shall be paid for at

the contract unit price respectively for each of the particular
pay items listed below and shown in the Bill of Quantities
which prices and payment shall constitute full compensation for
all the costs necessary for the proper completion of the work
prescribed in this item. Asphalt additive or anti-stripping agent,
if allowed and used to meet with JMF requirement shall not be
paid directly, payment shall be deemed to be included in the
respective pay items of Asphaltic wearing course.
(2) Price adjustment.
If the thickness determined as per clause 305.3.2 of this

specification is deficient by more than three (3) mm but not
more than ten (10) mm payment will be made at an adjusted
price as specified in table-1 below:-
Table – 1
Deficiency in thickness as Proportional Rate of Contract

determined by cores Price allowed.
0.0 mm to 3.0 mm 100%
3.1 mm to 5.0 mm 90%
5.1 mm to 10.0 mm 80%
When wearing course is more than ten (10) mm deficient in thickness, the
contractor shall remove such deficient areas and replace them with wearing
course of an approved quality and thickness or the contractor may opt to place
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an additional layer of wearing course asphalt, grading with a minimum

thickness of 35mm. The contractor will receive no compensation for the above
additional work.
Alternately, the Contractor may choose to overlay the area in a thickness of 30

mm (min) with smooth transition as approved by the Engineer Incharge on
either side with no extra compensation.
The payment shall be made as under:-

Item 651-7.1 Plant mixed bituminous surface
Course of specified requirements per cubic meter
(m3)
or per 100 cft
Item 651-7.2 Plant mixed bituminous surface
Course of specified thickness per sq. meter (m2)
or per 100 sft
**************
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SECTION 652
HOT RECYCLING OF ASPHALT CONCRETE
652-1 DESCRIPTION
This section shall consist of heating and removal of the existing

asphalt concrete layer to a designated depth, adding a calculated
quantity of asphalt binder, adding of freshly prepared asphalt concrete
of specified quality, mixing, laying and compaction of properly mixed
asphalt concrete in thickness and width as per drawings or as directed
Material specifications for coarse and fine aggregates and asphalt

binder shall correspond to the specification requirements elaborated
under items 203,300 and 305 respectively.
652.3.1 Heating the Existing Pavement
Asphalt pavement shall be heated and softened by pre-heaters or in

built infrared gas fired heaters, to temperatures between 140-170
degrees C.
652.3.2 Scarifying Asphalt Course
Rotating shaft scarifies fitted with carbide bits shall remove asphaltic
course to a depth as specified in drawings or as directed by the
Engineer Incharge. Scarifies shall be controlled by electronic devices
to ensure removal of materials to a specified depth and grade.
652.3.3 Mixing of Reclaimed Material
Formula for the admixture will be based on material analysis of

existing pavement by bitumen extraction and sieve analysis. Material
to be added may be asphalt binder or aggregate, which will be
calculated to ensure preparation of proper final mix.
652.3.4 Addition of Fresh Asphalt Concrete
Fresh asphalt concrete of specified design prepared as per Section 621

or 651 shall be added in proportion to be established as per
requirement of line and grades or as directed by the Engineer Incharge.
This shall be done in conventional way through dumper-hopper
arrangement. Fresh material shall be carried by drag-slat conveyor into
a second mixer. Exact mixing ratio will be achieved by calibrating the
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speed of the electronically adjustable drag-slat conveyor to the forward

advance speed of the remixer. A second mixer shall ensure
homogeneity of reclaimed and fresh asphalt. Engineer Incharge shall
establish the ratio of fresh and existing asphalt premix to be relayed,
before starting this operation. This ratio shall depend upon the quality
of existing asphaltic concrete.
652.3.5 Laying and Compaction
Laying and preliminary compaction of mixed asphalt shall be effected

by tamping and vibrating screeds of the recycling equipment. Screeds
shall be able to lay the mix true to the levels and grades required by the
drawings or as directed by the Engineer Incharge. Compaction shall be
carried out by conventional equipment to achieve ninety seven (976)
percent compaction with respect to the laboratory compaction achieved
by the mixed asphalt as per Marshall method.
652.4 GENERAL REQUIREMENTS
Any other physical property essential for workmanship or quality

control shall be fixed by the Engineer Incharge and contractor jointly.
Physical properties of the fresh material shall correspond to the
applicable requirements of such ingredients in this specifications.
652.5.1 Measurement
The quantity of recycled asphalt shall be measured in cubic meters or

cubic feet of asphalt concrete removed and relayed after mixing of
other ingredients such as asphaltic binder or fresh wearing course
asphalt.
Measurement and payment of fresh wearing course asphalt or asphaltic

binder shall be made in tons and paid under applicable item of work
separately.
652.5.2 Payment
The quantity measured as provided above shall be paid at the contract

unit price per cubic meter or 100 cubic feet as shown in B.O.Q.,
acceptably laid and compacted in place, which payment shall be
deemed to include full compensation for furnishing all materials,
Labour, equipments, tools and incidentals necessary to complete the
item.
Payment for asphaltic binder or fresh asphalt wearing course shall be

made separately under relative item of work as given below:
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Pay Item No. Description Unit of

Measurement
652-5.2.1 Recycling of Asphalt Concrete

(0-60 mm thick) Per m3 or
per 100 cft.
652-5.2.2 Bitumen Binder Grade
(40-50, 60-70, 80-100) Ton
652-5.2.3 Wearing Course Asphalt Ton
****************
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CHAPTER 700
CEMENT CONCRETE
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SECTION 701
CEMENT CONCRETE
701-1 DESCRIPTION
This work consists of furnishing, placing, forming, curing and

finishing, including transport, of cement concrete made from approved
type of cement, water, fine aggregate and coarse aggregate, together
with admixtures for air entraining, densifying, accelerating, or
retarding where specified or allowed by the specifications, all in
accordance with the requirements given in these specifications and in a
manner shown on the drawings called for in the Provisions and to the
approval of the Engineer Incharge.
701-2 MATERIALS
701-2.1 Portland Cement
The Portland cement shall conform to the specifications as contained in

Section 1001.
701-2.2 Fine Aggregate
Fine aggregate shall conform to the specifications as contained in

Section 1032.
701-2.3 Coarse Aggregate
Coarse Aggregate shall conform to the specifications as contained in

Section 1031.
701-2.4 Water
Water used in the concrete shall conform to the specifications as

contained in Section 1051.
701-2.5 Admixtures
Admixtures, when desired to be used in the concrete, shall conform to

the specifications as contained in Section 1052
3-3 PLANT AND EQUIPMENT
701-3.1 Mixers
All mixers shall be of an approved type and shall be so designed as to

ensure a uniform distribution of the materials throughout the mass. No.
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mixer shall be used which has rated capacity of less than one bag
batch. The mixer shall preferably be equipped with a batch meter or
other device for accurately recording the number of revolutions for
each batch, and an attachment for automatically locking the charging
device so as to prevent the emptying of the mixer until the materials
have been mixed in the minimum specified time.
701.3.2Measuring Devices
Scales for weighing cement and concrete aggregates shall be of the

beam or spring less dial type and as approved by the Engineer
Incharge. All cement handling, weighing and batching apparatus shall
be protected from the weather.
Ten standard test weights of 20 kg each shall be provided at each batch

plant for calibrating weighing equipment.
The water measuring equipment shall be capable of accurate

measurement, by volume or by weight and shall be capable of being
set to deliver the required quantity accurately within one percent of the
quantity of water required for the batch.
701.3.3Vibrators
The type and the number of vibrators proposed to be used shall be

subject to approval by the Engineer Incharge. Vibrators shall be
capable of producing vibrations at a frequency of not less than 3000
cycles per minute. Vibrators shall be placed at such places so as to
ensure thorough vibration of the concrete at all parts. Vibrators shall
not be given to the steel reinforcement. At least one stand-by vibrator
shall be kept ready for immediate use in the event of breakdown.
701.4 PROPORTIONS OF INGREDIENTS.
701-4.1 Mix
The concrete mix shall be designed by the minimum 28 days cube or

cylinder strength as specified. For approximate conversion purposes
cylinder strength shall be assumed to be 80 percent of the cube
strength.
In all cases preliminary tests shall be made in accordance with the

instructions of the Engineer Incharge and no mix shall be used until it
is approved.
The proportions of coarse and fine aggregate given in the Table 701-1
are intended as a guide. In actual practice the proportions in which the
various ingredients shall be used in the concrete mix for different parts
of the work, shall be designed in accordance with strength specified,
subject to variation ordered by the Engineer Incharge which be adopted
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without extra cost if tests show such variations to be necessary to

produce a dense concrete of the specified strength and work-ability.
The mix proportions shall be determined on the basis of producing
concrete having workability, density, impermeability, durability and the
required strength without the use of an excess amount of cement.
701.4.2 Water Cement Ratio
The total concrete per batch shall be regulated to conform with the
ratio, by weight of free water to cement required for the particular mix
as determined from the preliminary tests.
The total water content shall be taken to include water absorbed in the
aggregates, and free water added at the mixes.
The quantity of water introduced into the mixes shall be regulated and
arranged so as to ensure that the water-cement ratio shall be the
minimum required to produce the quality of concrete specified.
701.4.3 CLASSES OF CONCRETE.
The classes of concrete recognized in these specifications shall be

designated: A1,A2,A3,B,C,D1,D2, D3, Y and Lean Concrete. The class of
concrete to be used shall be as called for on the Drawings or as
directed by the Engineer Incharge or specified in the Special
Provisions. The following requirements shall govern unless otherwise
shown on the Drawings.
Class A1 Concrete shall be used everywhere, for non-reinforced and

reinforced concrete structures, except as noted below or directed by the
Engineer Incharge. Concrete placed under water shall be Class A 2 with
a minimum cement content of three hundred fifty (350) kg per cubic
meter of concrete with a slump between ten (10) and fifteen (15) cm.
Concrete placed for piles shall be class A 3 with a minimum cement
content of four hundred (400) kg. Per cubic meter.
Class B Concrete shall be used only where specified.
Class C Concrete shall be used for cribbing, or as otherwise directed
by the Engineer Incharge or specified in the Special Provisions or on
the Drawings.
Class D1, D2 or D3, concrete shall be used for pre-stressed and post-
tensioned elements, as indicated on drawings.
Class Y concrete shall be used as filler in steel grid bridge floors, in
thin reinforced sections, or as otherwise specified in the Special
Provisions.
Lean concrete shall be used in thin layers underneath footings and
when called for on the Drawings or directed by the Engineer Incharge.
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The concrete of the various classes shall satisfy the requirements

shown in Table 401-1
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TABLE 701-1
Portland Cement Concrete Requirements
Class of Min. Max. 28 days Consistency Maximum

Concrete Cement Size of Compressive (Range in Slump) Permissible
Kg/Cubic Coarse Strength Vibrated (mm) Water-Cement
Meter Aggregate (Min) (Cylinder) Ratio
(mm) (Kg/Sq. cm)
A1 300 20 210 25-75 0.58
A2 350 25 245 100-150 0.58
A3 400 38 280 100-150 0.58
B 250 51 170 25-75 0.65
C 275 38 210 25-75 0.58
D1 450 25 350 50-100 0.40
D2 500 25 425 50-100 0.40
D3 550 25 500 50-100 0.40
Y 400 13 210 25-75 0.58
Lean 175 51 100 - -
Concrete
701.4.4 TYPES OF CONCRETE WORKS
Under Ground Concrete
Concrete poured below Natural Surface Level with or without

shuttering and shoring.
On Ground Concrete
Concrete poured by erecting formwork with necessary bracings on

ground.
Elevated Concrete
Concrete poured by erecting props, bracing and towers to support the

formwork at higher levels.
701.5 MEASUREMENT OF MATERIALS
701.5.1Quantities
Materials shall be measured by weighing, except as otherwise specified

or where other methods are specifically authorized. The apparatus
provided for weighing the aggregates and cement shall be suitably
designed and constructed for this purpose. Each size of aggregate and
the cement shall be weighed separately. The accuracy of all weighing
devices shall be such that successive quantities can be measured to
within 1% of the desired amount. Cement in standard packages (sack)
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need not be weighed, but bulk cement shall be weighed. The mixing
water shall be measured by volume or by weight. The accuracy of
measuring the water shall be within a range of error of not over 1%.
All measuring devices shall be subject to approval and shall be tested,
at the Contractor’s expense, when deemed necessary by the Engineer
Incharge.
When volumetric measurements are authorized for projects, the weight

proportions shall be converted to equivalent volumetric proportions. In
such cases, suitable allowance shall be made for variations in the
moisture condition of the aggregates, including the bulking effect in
the fine aggregate.
When sacked cement is used, the quantities of aggregates for each

batch shall be exactly sufficient for one or more full sacks of cement
and no batch requiring fractional sacks of cement will be permitted.
701.5.2Admixtures.
The Contractor shall follow an approved procedure for adding the

specified amount of admixture to each batch and will be responsible
for its uniform operation during the progress of the work.
701.6 MIXING CONCRETE
701.6.1General Requirement
No concrete shall be mixed when the air temperature in the shade and
away from artificial heat is as low as 4.5°C(40.0°F) and falling or
35.0°C (95°F) and rising unless special temperature control
arrangements are made. No materials containing frost shall be used.
The concrete shall be mixed only in such quantity as is required for
immediate use and any concrete which has developed initial set shall
not be used. No re-tempering of concrete shall be done. Concrete not in
place within 30 minutes after the introduction of the mixing water to
the cement, shall not be used.
701.6.2Machine Mixing at the Site
Concrete shall be mixed for a period not less than 1-1/2 minutes after
all the materials are in drum. During the period of mixing, the drum
shall operate at the speed for which it has been designed, or not less
than 14, nor more than 20 revolutions per minute.
No mixer shall be operated above its rated capacity. The entire contents
of the mixer shall be removed from the drum before the materials for
the succeeding batch are placed therein. The skip and the throat of the
drum shall be kept free of accumulations.
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Each batch shall be so charged into the drum that some water will enter
in advance of the cement and aggregate, and water shall continue to
flow into the drum for at least five seconds after all the cement and
aggregates are in the drum.
Upon the cessation of mixing the mixer shall be thoroughly cleaned by

flushing with water.
701.6.3Plant Mixing
At central mixing plant, batches shall be discharged from the weighing

hopper into the mixer either directly by gravity or by an elevating
container large enough to contain the batch. The plant shall be
arranged to ensure that there is no loss of cement during transfer from
weighing hopper to mixer drum. The mixing time shall neither be less
than fifty (50) second, nor more than ninety (90) seconds.
The plasticizer, accelerator or retarder or water reducing admixture, if

required, shall be fed separately at the rate recommended by the
manufacture, or as established by laboratory trials.
701.6.4Transit Mixing
Truck mixers, unless otherwise authorized by the Engineer Incharge,

shall be of the revolving drum type, watertight, and so constructed that
the concrete can be mixed to ensure a uniform distribution of materials
throughout the mass. All solid materials for the concrete shall be
accurately measured and charged into the drum at the proportioning
plant. The truck mixer shall be equipped with a device by which the
quantity of water added can be readily verified. The mixing water may
be added directly to the batch, in case the concrete batch is poured
within twenty five (25) minutes of adding water.
The maximum size of batch in truck mixers shall not exceed the
maximum rated capacity of the mixer as stated by the manufacturer,
and stamped in metal on the mixer. Truck mixing shall be continued
for not less than fifty (50) revolutions after all ingredients, including
water, are in the drum. The mixing speed shall not be less than six (6)
rpm, nor more than ten (10) rpm.
Mixing shall being within thirty (30) minutes after the cement has been
added either to the water or aggregate, but when cement is charged into
a mixer drum containing water or surface-wet aggregate and when the
temperature is above thirty two (32) degree C, this limit shall be
reduced to fifteen (15) minutes. The limitation in time between the
introduction of the cement to the aggregate and the beginning of the
mixing may be waived when, in the judgment of the Engineer
Incharge, the aggregate is sufficiently free from moisture, so that there
will be no harmful effects on the cement.
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701.6.5Partial Mixing at the Central Plant.
When a truck mixer, or an agitator provided with adequate mixing

blades, is used for transportation, the mixing time at the stationary
plant mixer may be reduced to thirty (30) seconds and the mixing is
completed in a truck mixer/agitator. The mixing time in the truck mixer
or agitator equipped with adequate mixing blades shall be as specified
for truck mixing.
701.6.6Stiff Concrete Mix.
For mixing concrete of zero slump to be laid by pavers, gravity mixer

shall not be used. Only force mixer of moving blades shall be allowed
to ensure homogenous mix.
Concrete shall be mixed for a period not less than 1-1/2 minutes after
all the materials are in drum. During the period of mixing , the drum
shall operate at the speed for which it has been designed, or not less
than 14, nor more than 20 revolutions per minute.
No mixer shall be operated above its rated capacity. The entire contents
of the mixer shall be removed from the drum before the materials for
the succeeding batch are placed therein. The skip and the throat of the
drum shall be kept free of accumulations.
Each batch shall be so charged into the drum that some water will enter
in advance of the cement and aggregate, and water shall continue to
flow into the drum for at least five seconds after all the cement and
aggregates are in the drum.
Upon the cessation of mixing the mixer shall be thoroughly cleaned by

flushing with water.
701.6.7Hand Mixing
Hand mixing shall not be done except in case of emergency or under

written approval of the Engineer Incharge. It shall be done only on
water tight platforms. The aggregates and cement shall be thoroughly
mixed while dry by means of shovels until the mixture is of uniform
colour, after which it shall be formed into a crater and water added in
the amount necessary to produce concrete of the proper consistency.
The material in the outer portion of the crater ring shall then be
thoroughly wetted and added to the mix and the entire mass turned and
returned at least six times and until all the stone particles, are
thoroughly covered with mortar and the mixture is of uniform colour
and appearance. Hand mix batches shall not exceed the volume as
prescribed by the Engineer Incharge. Hand mixing shall not be done
for concrete to be placed under water and in members to be pre-
stressed.
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701.7 TESTING CONCRETE
Following tests shall be made in respect of each mix intended to be

used and shall be repeated as and when required by the Engineer
Incharge.
a. Slump Test
b. Cube Strength Test or Cylinder Strength Test
c. Modulus of Rupture Test (when specified).
701.7.1Slump Test
Concrete shall have slump such that it shall be workable in the required
position. It shall be of such a consistency that it will flow around
reinforcing steel but individual particles of coarse aggregate when
isolated shall show a coating of mortar containing its proportionate
amount of sand. The quantity of mixing water shall be determined as
specified above and shall not be varied without the consent of the
Engineer Incharge.
The slump of the concrete placed by the vibration method shall not
exceed the following: (the slump being determined in accordance with
the “Method of Test for Slump of Portland Cement Concrete”
AASHTO Design T-119, latest issue)
(a) For mass concrete and reinforced concrete sections, easily

accessible for rodding and working due to amount of spacing of
steel or other reasons, not over 8 cm (3 inches)
(b) For reinforced concrete sections, not easily accessible for

rodding and working due to amount of spacing of steel or other
reasons, not over 10 cm (4 inches)
701.7.2Cube Strength Test
The Contractor shall make built in provision in his tender for making
test cubes 150 mm (6”) or cylinders 150 mm x 300 mm (6” x 12”) of
the concrete being used at various times and for testing the same as
specified in B.S.1881 and AASHTO-T-22 respectively.
Generally six cubes or cylinders shall be taken from the first batch of
concrete used for every separate portion of the work and subsequently
whenever a change is made whether in the cement or aggregates or in
the consistency of the concrete. The Engineer Incharge may direct for
additional test cubes or cylinder if so required.
The test cubes or cylinders shall be stored at a place free from

vibration and covered with wet Hessian, burlap of cotton mats for one
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day. The cubes or cylinders shall then be removed from the moulds and
stored in water until dispatched for testing.
701.7.3Modulus of Rupture Test.
The modulus of rupture of the concrete test beams shall be determined

when required, according to the current “Method of Test for Flexural
Strength of Concrete (Using simple beam with centre-point loading)”
ASTM Designation C-203 or BS 1881 or AASHTO-T-177.
701-8 FORM WORK
701-8.1 Description
The work shall consist of providing, erecting and removing concrete

forms of sufficient strength with all necessary bracings, fasteners, etc.
and in conformity with the requirements hereinafter specified.
701-8.2 Material Requirements
Forms shall be of wood, metal or other approved materials and shall be

built mortar tight and of sufficient rigidity to prevent distortion due to
the pressure of the concrete and other loads incident to the construction
operations.
701-8.3 Construction Requirements
701-8.3.1 Formwork Design and Drawings
The contractor shall prepare working drawings, backup calculations

and material data for the form work and shutters to be submitted to the
Engineer Incharge for approval unless otherwise directed.
The requirements for design of formwork are the same as described

under Falsework Design and Drawings.
701.8.3.2Formwork Construction
Concrete form shall be constructed and maintained so as to prevent

warping and the opening of joints due to the shrinkage of the lumber
and shall be true to the dimensions, lines and grades of the structure
and with the sufficient strength, rigidity, shape and surface smoothness
as to leave the finished works true to the dimensions shown on
drawings or required by the Engineer Incharge and with the surface
finish as specified.
Forms for exposed surfaces shall preferably be lined with metal,

plywood, or other approved material, or may with the Engineer
Incharge permission, be made of dressed lumber of uniform thickness.
Forms shall be filled at all sharp corners (Minimum two (2) cms
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triangular fillets) and shall be given a level or draft in the case of all
projections, such as girders and copings, to ensure easy removal.
Form fasteners consisting of form bolts, clamps or other devices shall

be used as necessary to prevent spreading of the forms during concrete
placement. The use of ties consisting of twisted wire loops to hold
forms in position will not be permitted. Metal ties or anchorage within
the forms shall be so constructed as to permit their removal to a depth
of a least five (5) cms from the face without injury to the concrete.
Fitting for metal ties shall be of such design that, upon their removal,
the cavities that are left will be of the smallest possible size. The
cavities shall be filled with cement mortar and the surface left sound,
smooth, even, and uniform in colour. Anchor devices may be cast into
the concrete for later use in supporting forms or for lifting pre-cast
members. The use of driven types of anchorages for fastening forms or
form supports to concrete will not be permitted.
The inside surfaces of forms shall be cleaned of all dirt, mortar and
foreign material. Forms, which will later be removed, shall be
thoroughly coated with form oil prior to use. The form oil shall be
commercial quality form oil or other approved coating which will
permit the ready release of the forms and will not discolour the
concrete. All exposed surfaces of similar portions of a concrete
structure shall be formed with the same forming materials or with
materials which produce similar concrete surface textures, colour and
appearance.
Concrete shall not be deposited in the forms until all work in

connection with constructing the forms has been completed, all
materials required to be embedded in the concrete have been placed for
the unit to be poured, and the Engineer Incharge has inspected and
approved said forms and materials.
The rate of depositing concrete in forms shall be such as to prevent

deflections of the forms or form panels in excess of the deflections
permitted by these specifications. Maximum deflection allowed due to
prop settlement is 5 mm and due to bending of shutters is 3mm, when
measured with 3 meter straight edge.
Forms for concrete surfaces, which will not be completely enclosed or

hidden below the permanent ground surface, shall conform to the
requirements herein for forms for exposed surfaces. Interior surfaces of
underground drainage structures shall be considered to be completely
enclosed surfaces.
Formwork for concrete placed under water shall be watertight. When

lumber is used, this shall be planed and tongued and grooved.
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Forms for exposed concrete surfaces shall be designed and constructed

so that the formed surface of the concrete does not undulate
excessively in any direction between studs, joists, form stiffeners, form
fasteners, or wales. Undulations exceeding either two (2) mm or 1/270
of the center to center distance between studs, joists, form stiffeners,
form fasteners, or wales will be considered to be excessive. Should any
form or forming system, even though previously approved for use,
produce a concrete surface with excessive undulations, its use shall be
discontinued until modifications, satisfactory to the Engineer Incharge
have been made. Portions of concrete structures with surface
undulations in excess of the limits herein may be rejected by the
Engineer Incharge.
Forms shall be set and maintained true to the line designated until the
concrete is sufficiently hardened. Forms shall remain in place for
periods, which shall be determined, as herein specified. When forms
appear to be unsatisfactory in any way, either before or during the
placing of concrete, the Engineer Incharge will order the work stopped
until the defects have been corrected.
The shape, strength, rigidity, water-tightness, and surface smoothness

of reused forms shall be maintained at all times, Any warped or bulged
lumber must be resized before being reused. Forms that are
unsatisfactory in any respect shall not be reused.
For narrow walls and columns, where the bottom of the form is
inaccessible, the lower form boards shall be adjustable so that they
may be removed for cleaning out extraneous material immediately
before placing the concrete.
701.8.3.3Removal of Formwork
In the determination of the time for the removal of falsework and

forms, consideration shall be given to the location and character of the
structure, the weather, and other conditions influencing the setting of
the concrete, and the materials used in the mix.
If field operations are not controlled by beam or cylinder tests, the
following periods, exclusive of days when the temperature is below
five (5) degree C, for removal of forms and supports shall be used as a
minimum subject to the approval of the Engineer Incharge and to the
requirements of removing falsework.
Arch Center 14 Days

Centering Under Beams 14 Days
Supports under Flat Slabs 14 Days
Floor Slabs 14 Days
Vertical Wall Surfaces 24 Hours
Columns 24 hours
Side of Beams 12 Hours
Top Slabs R.C. Box Culverts 14 days
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Side forms for cast-in-place beams, girders, columns, or other

members where the forms do not resist dead load, bending shall remain
in place for at least forty (40) hours after placing concrete for the
members. Side forms for precast members may be removed the next
day after placing concrete therein.
If high early strength cement is used or by the used of additional

cement, these periods may be reduced as directed.
When field operations are controlled by cube cylinder tests, the

removal of forms, supports and housing, and the discontinuance of
heating and curing (where applicable) may begin when the concrete is
found to have the required compressive strength, provided in no case
shall supports be removed in less than seven (7) days after placing the
concrete. All forms shall be removed, except when no permanent
access is available to the cells, the forms supporting the deck of box
girders and the forms in hollow abutments or piers may remain in place
Prior to completion of forming for the deck forms, the inside of box
girders shall be cleared of all loose material and swept clean.
Methods of form removal likely to cause overstressing of the concrete

shall not be used. In general, the forms shall be removed from the
bottom upwards. Forms and their supports shall not be removed
without approval. Supports shall be removed in such a manner as to
permit the concrete to uniformly and gradually take the stresses due to
its own weight.
In general, arch centering or falsework shall be struck and the arch

made self-supporting before the railing or coping is placed. This
precaution is essential in order to avoid jamming of the expansion
joints and variations in alignment. For filled spandrel arches, such
portions of the spandrel walls shall be left for construction subsequent
to the striking of centers, as may be necessary to avoid jamming of the
expansion joints.
Centers shall be gradually and uniformly lowered in such a manner as

to avoid injurious stresses in any part of the structure. In arch
structures of two or more spans, the sequence of striking centers shall
be approved by the Engineer Incharge.
701.8.4 Measurement and Payment
For all concrete structures, prestressed concrete structures, precast

concrete elements or portions thereof, no separate measurement or
payment shall be made for formwork supporting such structures. All
formwork costs shall be considered as included in the contract prices
paid (cost per m3 or per 100 cft or LM/ft of structural members or
lump-sum) for the various items of concrete work and no additional
compensation will be allowed thereof.
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701-9 HANDLING AND PLACING CONCRETE
701-9.1 Protection of Concrete from Environmental Conditions
General
Precautions shall be taken as needed to protect concrete from damage

due to weather or other environmental conditions during placing and
curing operations.
Any concrete placed during hot weather or during cold weather shall
be at the contractor’s risk and any damaged concrete shall be removed
and replaced at the Contractor’s expense.
701-9.2 Rain Protection
Under conditions of rain, the placing of concrete shall not commence

or shall be stopped unless adequate protection is provided to prevent
damage to the surface mortar or damaging flow or wash of the concrete
surface.
701.9.3Work in Hot Weather
The temperature of concrete shall not exceed thirty two (32) degree C
at the time of laying, unless the Contractor incorporates in the mix a
plasticizer, of a make and in proportion which he has shown by
laboratory tests and full scale trial to be satisfactory to eliminate
detrimental effects of high temperature without introducing any other
detrimental effect on quality.
The following may be used to keep the temperature of concrete below

the above limitations:
(i) Chilling of concrete water by heat exchange coils or by

addition of broken ice, provided that the water shall be free
from ice at the time of entry into the mixer.
(ii) Cooling of coarse aggregate by watering provided that the

water content of the aggregate so cooled shall be uniform.
(iii) Reclaiming of aggregate from stock piles by the tunnel method

to avoid using the surface layer of the stockpile with shade and
wind protection of conveyor elevating to batching plant.
(iv) Night work provided that (i), (ii) and (iii) are proved inadequate
or unsatisfactory in their results and providing also that the
Engineer Incharge has no other reason for refusing permission
for night work.
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The Engineer Incharge shall have power to order the suspension of

concrete production in case of not taking precautionary measures by
the Contractor as mentioned above. Under no circumstances will the
Contractor be entitled to receive any additional payment for complying
with the requirements of this clause.
701.9.4Work in Cold Weather
Except by written approval of the Engineer Incharge, concreting

operations shall not be continued when a descending air temperature in
the shade and away from artificial heat falls below five (5) degree C,
nor resumed until an ascending air temperature in the shade and away
from artificial heat reaches two (2) degree C. In such cases, the mixing
water and/or aggregates shall be heated to not less than twenty one (21)
degree C nor more than sixty six (66) degree C prior to being placed in
the mixer by an approved type of heating device so that the
temperature of the concrete shall not be less than ten (10) degree C, nor
more than twenty seven (27) degree C at the time of placing. No
materials containing frost shall be used. Cement or fine aggregates
containing lumps or crusts of hardened materials shall not be used.
701-9.5 Inspection Before Placing Concrete
No concrete shall be placed until the depth and character of the

foundation and the adequacy of the forms and false work had been
approved by the Engineer Incharge. No concrete shall be deposited
until all the reinforcement is in place and has been inspected and
approved by the Engineer Incharge.
701-9.6 Depositing Concrete
The arrangements for placing concrete are to be such that in all cases
the material may be conveniently handled and place in the required
position without re-handling or segregation. Wherever possible the
concrete is to be deposited from bottom opening skips and in all cases
shall be deposited in layers of such depth that each layer can be easily
incorporated with the layer below with the use of internal vibrators or
by spading, slicing and ramming. In no case any layer is to slope
except where specified and all temporary joints are to be formed
square to the work. Concrete shall not be delivered by chute or
dropped from barrow or otherwise through a height greater than 1.5
meters (5 feet except with the approval of the Engineer Incharge who
may order the concrete to be dropped on to a bunker and it shall be
turned over by hand before being placed. The height of any lift shall
not exceed 1.5 meters (5 feet) unless otherwise permitted by the
Engineer Incharge.
The area on which any concrete is to be deposited must be made and

maintained free from standing water during concreting operations
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unless otherwise approved. Running water crossing or entering such

areas must be brought under control before concreting proceeds.
Before depositing any concrete resting or abutting on work previously

executed, the surface and ends are to be thoroughly roughened with a
chisel pointed pick to such an extent that no smooth skin of concrete
that may be left from the previous work is visible. These roughened
surfaces must be thoroughly cleaned by compressed air and water jets
or other approved means, brushed and watered immediately before
depositing concrete and if so instructed by the Engineer Incharge are to
be covered with cement mortar 12.5 mm (1/2”) thick immediately
before proceeding with the next layer of concrete.
When new concrete is to be deposited on or against rock of old

concrete, the surface of the old work must be toothed to from an
adequate bond, roughened if necessary, cleaned washed and all loose
material removed from it. The faces shall then be mortared as specified
for joints in new concrete work.
Concrete in reinforced concrete work shall be deposited in small

quantities in a plastic state with a water cement ratio such as to give it
the specified strength. The depositing of concrete in individual
members shall be continued with out stoppage up to an approved per-
arranged construction joint or until the member is completed and shall
be finished off in such a manner that the junction of members shall be
monolithic unless otherwise specified.
Mass concreting shall be carried out in sections previously ordered or

approved by the Engineer Incharge and shall proceed continuously in
each section until completed and no interval shall be allowed to lapse
while the work is in hand.
701.9.7 Concreting Under Water
Concrete deposited in water shall have the minimum cement content

for the class of concrete increased by 10%.
The concrete shall be carefully placed in a compact mass, by means of

a tremie, bottom-dumping bucket or other approved method that does
not permit the concrete to free-fall through the water. The concrete
shall not be disturbed after being deposited. No concrete shall be
placed in running water, and forms which are not watertight, shall not
be used for holding concrete deposited under water.
Pumping of water from the inside of the foundation forms while

concrete is being placed will not be permitted.
If necessary a seal of concrete shall first be placed through a closed

chute or tremie and allowed to set for at least 7 days.
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701.9.8 Vibration of concrete.
Except where otherwise permitted by the Engineer Incharge concrete

shall, during placing be compacted by approved pattern of vibrators.
The vibrators shall operate at a frequency of not less than 3000 cycles
per minute. The vibrators shall be designed for continuous operation.
The vibrators shall be disposed in such a manner that the whole of the
mass under treatment shall be adequately compacted at a speed
commensurate with the supply of concrete from the mixers. Vibration
shall continue until the concrete being placed shall be judged to be
compacted by the appearance of a glistering and even surface except
for slight irregularities where the coarse aggregate breaks through. All
air shall be this time has been expelled in accordance with
arrangements dully approved by the Engineer Incharge.
Vibration is not to be applied directly or through the reinforcement to

sections or masses of concrete which have hardened or after the initial
set has taken place. Vibration must not be used to make the concrete
flow in the form work so as to cause segregation.
701-9.9 Re-tampering
After placing and vibration of concrete, re-tampering that is re-mixing

with or without additional materials or water, will not be permitted.
701.10 JOINTS
701.10.1 Construction joints.
701-10.1.1 General
Construction joints shall be made only where located on plans, or

shown in the pouring schedule, unless otherwise approved. All planned
reinforcing steel shall extend uninterrupted through joints. In the case
of emergency, construction joints shall be placed as directed by the
Engineer Incharge and, if directed, additional reinforcing steel dowels
shall be placed across the joint. Such additional steel shall be furnished
and placed at the Contractor’s expense.
701.10.1.2Bonding
Unless otherwise shown on the plans, horizontal joints may be made

without keys and vertical joints shall be constructed with shear keys.
Surfaces of fresh concrete at horizontal construction joints shall be
rough floated sufficiently to thoroughly consolidate the surface and
intentionally left in a roughened condition. Shear keys shall consist of
formed depressions in the surface covering approximately one-third of
the contact surface. The forms for keys shall be beveled so that
removal will not damage the concrete.
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All construction joints shall be cleaned of surface laitance, curing

compound and other foreign materials before fresh concrete is placed
against the surface of the joint. Abrasive blast or other approved
methods shall be used to clean horizontal construction joints to the
extent that clean aggregate is exposed. All construction joints shall be
flushed with water and allowed to dry to a surface dry condition
immediately prior to placing concrete.
701.10.1.3Bonding and Doweling to Existing Structures
When new concrete is shown on the plans to be bonded to existing

concrete structures, the existing concrete shall be cleaned and flushed
as specified above,. When the plans show reinforcing dowels grouted
into holes drilled in the existing concrete at such construction joints,
the holes shall be drilled by methods that will not shatter or damage the
concrete adjacent to the holes. The diameters of the drilled holes shall
be ¼ inch larger than the nominal diameter of the dowels unless
shown, otherwise on the plans. The grout shall be a neat cement paste
of Portland cement and water. The water content shall be not more than
4 gallons per 94 pounds of cement. Re-tempering of gout will not be
permitted. Immediately prior to placing the dowels, the holes shall be
cleaned of dust and other deleterious materials, shall be thoroughly
saturated with water, have all free water removed and the holes shall be
dried to a saturated surface dry condition. Sufficient grout shall be
placed in the holes so that no voids remain after the dowels are
inserted. Grout shall be cured for a period of at least 3 days or until
dowels are encased in concrete.
When specified or approved by the Engineer Incharge, epoxy may be

used in lieu of Portland cement grout for the bonding of dowels in
existing concrete. When used, epoxy shall be mixed and placed in
accordance with the manufacturer’s recommendations.
701.10.1.4Forms at Construction Joints
When forms at construction joints overlap previously placed concrete,

they shall be retightened before depositing new concrete. The face
edges of all joints that are exposed to view shall be neatly formed with
straight bulk heads or grade strips, or otherwise carefully finished true-
to-line and elevation.
701.10.2 Expansion and Construction Joints
701-10.2.1 General
Expansion and contraction joints shall be constructed at the locations

and in accordance with the details shown on the plans. Such joints
include open joints, filled joints, joints sealed with sealants or
waterstops, joints reinforced with steel armor plates or shapes and
joints with combinations of these features.
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When preformed elastomeric compression joint seals or bridge deck

joint seal assemblies are required, they shall conform to the
requirements of Section 19, “Bridge Deck Joint Seals”.
701.10.2.2Materials
701.10.2.2.1 Premolded Expansion Joint Fillers
Premolded fillers shall conform to one of the following specifications:
Specification for Preformed Expansion Joint Fillers for Concrete

Paving and Structural Construction.
AASHTO M 213 (ASTM 1751)
Specification for Preformed Sponge Rubber and Cork Expansion Joint
Fillers for Concrete Paving and Structural Construction, AASHTO M
153 (ASTM D 1752). Type II (cork) shall not be used when resiliency
is required.
Specification for Preformed Expansion Joint Filler for Concrete,
AASHTO M 33 (ASTM D 994).
701.10.2.2.2 Polystyrene Board Fillers
Board fillers shall be expanded polystyrene with a minimum flexural

strength of 35 pounds per square inch, as determined by ASTM C 203,
and a compressive yield strength of between 16 and 40 pounds per
square inch at 5% compression. When shown on the plans, or required
to prevent damage during concrete placement, the surface of
polystyrene board shall be faced with 1/8 inch thick hard board
conforming to Federal Specification LLL-B-810.
701.10.2.2.3 Contraction Joint Material
Material placed in contraction joints shall consist of asphalt saturated

felt paper or other approved bond-breaking material.
701.10.2.2.4 Pourable joint Sealants
Pourable sealants for placement along the top edges of contraction or

filled expansion joints shall conform to the following:
Hot-poured sealants shall conform to ASTM D 3406, except that when

the sealant will be in contact with asphaltic material, it shall conform
to ASTM D3405.
Cold poured sealant shall be silicone type conforming to Federal

Specification TT-S-1543, Class A. The sealant shall be a one-part, low
modulus silicone rubber type with an ultimate elongation of 1,200%.
Polyethylene foam strip, for use when shown on the plans, shall be of
commercial quality with a continuous impervious glazed top surface,
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suitable for retaining the liquid sealant at the proper elevation in the
joint while hardening.
701.10.2.2.5 Metal Armor
Expansion joint armor assemblies shall be fabricated from steel in

conformance with the requirements of section 23, “Miscellaneous
Metal”. Assemblies shall be accurately fabricated and straightened at
the shop after fabrication and galvanizing, as necessary to conform to
the concrete section.
701.10.2.2.6 Waterstops
Waterstops shall be of the type, size, and shape shown on the plans.
They shall be dense, homogeneous, and on the plans. They shall be
dense, homogeneous, and without holes or other defects.
701-10.2.2.6.1 Rubber Waterstops
Rubber waterstops shall be formed from synthetic rubber made

exclusively from neoprene, reinforcing carbon black, zinc oxide,
polymerization agents, and softeners. This compound shall contain not
less than 70% by volume of neoprene. The tensile strength shall not be
less than 2,750 pounds per square inch with an elongation at breaking
of 600%. The Shore Durometer indication (hardness) shall be between
50 and 60. After seven days in air at temperature of 158 o (+) oF or after
4 days in oxygen at 158o (+2) oF and 300 pounds per square inch
pressure, the tensile strength shall not be less 65% of the original.
Rubber waterstops shall be formed with an integral cross section in

suitable molds, so as to produce a uniform section with a permissible
variation in dimension of 1/32 inch plus or minus. No splices will be
permitted in straight strips. Strips and special connection pieces shall
be sell cured in a manner such that any cross section shall be dense,
homogeneous, and free from all porosity. Junctions in the special
connection pieces shall be full molded. During the vulcanizing period,
the joints shall be securely held by suitable clamps. The material at the
splices shall be dense and homogeneous throughout the cross section.
701-10.2.2.6.2 Polyvinylchloride Waterstops
Polyvinylchloride waterstops shall be manufactured by the extrusion

process from an elastomeric plastic compound, the basic resin or which
shall be polyvinylchloride (PVC). The compound shall contain any
additional resins, plasticizers, stabilizers, or other materials needed to
ensure that, when the material is compounded, it will meet the
performance requirements given in this Specification. No reclaimed
PVC or other material shall be used.
The material shall comply with the following physical requirements
when tested under the indicated ASTM test method:
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Specific Gravity ASTM D 792 1.35 Max.
Durometer Hardness ASTM D 2240 75 + 5

Tensile Strength ASTM D 412 1,800 psi Min
Elongation ASTM D 412 350%
Cold Brittleness ASTM D 2240 -35 F
Stiffness in Flexure ASTM D 2240 350 psi Min
701-10.2.2.6.3 Copper Waterstops
Sheet copper shall conform to the Specifications for Copper Sheet,

Strip, Plate, and Rolled Bar, AASHTO M 138 (ASTM B 152) and shall
meet the Embrittlement Test of Section 10 of AASHTO M 138.
701-10.2.2.6.4 Testing of Waterstop Material
The manufacturer shall be responsible for the testing, either in his own
or in a recognized commercial laboratory, of all waterstop materials,
and shall submit three certified copies of test results to the Engineer
Incharge.
701-10.2.3 Installation
701-10.2.3.1 Open joints
Open joints shall be constructed by the insertion and subsequent

removal of a wood strip, metal plate, or other approved material. The
insertion and removal of the template shall be accomplished without
chipping or breaking the corners of the concrete. When not protected
by metal armor, open joints in decks and side walks shall be finished
with an edging tool. Upon completion of concrete finishing work, all
mortar and other debris shall be removed from open joints.
701-10.2.3.2 Filled joints
When filled joints are shown on the plans, premolded type fillers shall
be used unless polystyrene board is specifically called for. Filler for
each joint shall consist of as few pieces of material as possible.
Abutting edges of filler material shall be accurately held in alignment
with each other and tightly fit or taped as necessary to prevent the
intrusion of grout, Joint filler material shall be anchored to one side of
the joint by water proof adhesive or other methods so as to prevent it
from working out of the joint but not interfere with the compression of
the material.
701-10.2.3.3 Sealed Joint
Prior to installation of pourable joint sealants, all foreign material shall

be removed from the filler material shall be cut back to the depth down
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or approved and the surface of the concrete which will be in contact

with the sealant cleaned by light sand blasting. When required, a
polyethylene foam strip and shall be placed in the joint to retain the
sealant and isolate it from a filler material. The sealant material shall
then be mixed and installed in accordance with manufactures
directions. Any material that fails to bond to the sites of the joints
within 24 hours after placement shall be removed and replaced.
701-10.2.3.4 Waterstops
Adequate waterstops of metal, rubber, or plastic shall be placed as

shown on the plans. Where movements at the joints is provided for, the
waterstops shall be of a type permitting such movement without injury.
They shall be spliced , welded, or soldered, to form continuous
watertight joints.
Precautions shall be taken so that the waterstops shall be neither

displaced nor damaged by construction operations or other means. All
surfaces of the waterstops hall be kept free from oil, grease, dried
mortar, or any other foreign matter while the waterstop is being
embedded in concrete. Means shall be used to insure that all portions
of the waterstop designed fro embedded shall be tightly enclosed by
dense concrete.
701-10.2.3.5 Expansion Joint Armor Assemblies
Armor assemblies shall be installed so that their top surface matches

the plane of the adjacent finished concrete surface throughout the
length of the assembly. Positive methods shall be employed in placing
the assemblies to keep them in correct position during the placing of
the concrete. The opening at expansion joints shall be that designated
on the plans at normal temperature or as directed by the Engineer
Incharge for other temperatures, and care shall be taken to avoid
impairment of the clearance in any manner.
701-11 CURING
701-11.1 Water Curing.
All surfaces not covered by forms shall be protected with wet burlap or
wet jute, as soon after placing the concrete as it can be done without
marring the surface and kept wet by the continuous application of
water by means of suitable sprinkling device for a period of not less
than 14 days. Wood forms without lines, if left in place longer than 2
days after the placing of concrete, shall be thoroughly wet down at
least twice each day for the remainder of the curing period. Portions of
the covering material may be removed temporarily and continuous
sprinkling stopped as and when necessitated by any required finishing
operation.
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701-11.2 Water Proof Membrane Curing.
Immediately after the free water has disappeared on surface not

protected by from and immediately after the removal of forms and
surface finishing, or if forms and removed before the end of the 14
days water curing period, the concrete shall be sealed by spraying as a
fine mist, a uniform application of an approved curing material, in such
manner as to provide a continuous, uniform impermeable film without
marring the surface of the concrete.
The membrane curing shall be applied in one or more separate coats as

per instructions of the manufacturer. Membrane curing compound shall
not be applied to surfaces of concrete members to which other concrete
is to be bonded.
Unless adequate precautions are taken to protect the surface of the

membrane, workmen, materials and equipment shall be kept off the
membrane for the duration of curing period.
701.12 REPAIRING CONCRETE SURFACE
If on the stripping of forms, concrete is found to be not formed as

shown on the drawings, or is out of alignment or level, or shows a
defective surface, it shall be considered not conforming to the intent of
these specifications and shall be removed and replaced by the
contractor at his expense unless the Engineer Incharge grants
permission to repair the defective area, in which case patching shall be
performed as described in the following paragraphs.
Defects that require replacement or repair are honeycombed surfaces

resulting from the stripping of forms, loose pieces of concrete, bolt
holes, the rod holes, ridges at form joints and bulges caused by the
movement of the forms. Ridges and bulges shall be removed by
chipping or tolling followed by rubbing with a grinding stone.
Honeycomb and other defective concrete shall be chipped out, and the
chipped openings shall be sharp edged and shaped so that the filling
shall be keyed in place. All holes shall be thoroughly moistened before
the filling is placed. The surface of the filling shall be finished flush
with the surrounding wall, and shall have the same texture. All patches
shall be cured.
Imperfections bolt and tie rod holes, shall be filled with dry patching
mortar composed of one part of Portland cement, tow parts of regular
concrete sand and just enough water so that ingredients are thoroughly
mixed and mortar sticks together on being moulded into a ball by a
light pressure of the hands which does not extrude free water. Mortar
repairs shall be placed in thin layers and thoroughly compacted by
suitable tools. Care shall be taken infilling rod, bolt and pipe holes so
that the entire depth of the holes is complete filled with compacted
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mortar. Where concrete is exposed to view mortar shall be made to

match the colour of the concrete by substituting white cement in the
required amount of a portion of the regular cement.
701.13 FINISHING
Unless otherwise specified the tip face of the slabs shall be finished to
a level surface suitable for receiving screeds.
Immediately after the removal of form work all surfaces to be left

exposed shall be rubbed down with the carborundum blocks to remove
roughness if so directed by the Engineer Incharge. This rubbing down
shall be done with the addition of water only, but subsequently when
so directed by the Engineer Incharge the contractor shall, at no extra
cost fill, and make good with an approved mortar any exposed holes or
sunken places.
All external exposed surfaces shall be brushed down with a wire brush
to remove laitance and exposed aggregate.
The class of finish for formed surfaces shall be as follows:-
a. Formed surfaces of well curb or well transom slabs or
b. surfaces against which backfill is to be placed will required

no treatment after from removal, except for removal and
repair of the defective concrete and for the work specified.
c. Submerged and belowground-formed surfaces, which are

not exposed to the action of flowing water and are not
prominently exposed to public view, shall need no sack
rubbing except that needed for surface imperfections.
d. In the case of formed surface above ground, there shall be

no visible offsets. Surface irregularities measured for abrupt
irregularities shall not exceed 3 mm (1/8) inch and for
gradual irregularities 6 mm (1/4 inch)
e. The surface of all waterways including the interior surface

of culverts etc. Shall not have surface irregularities
exceeding 3 mm (1/8 inch) for abrupt irregularities and 6
mm (1/4inch) gradual irregularities.
f. Unformed surface that will be covered by backfill or

concrete shall be finished by sufficient leveling to produce
an even uniform surface.
g. A hard steel trowel finish shall be applied to unformed

surfaces that shall be exposed to view or that shall be
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subject to action of flowing water. Floating and traveling

shall be started as soon as the screeded surface has stiffened
sufficiently, and shall be the minimum necessary to produce
a surface free from screed marks and uniform in texture.
Joints and edges shall be tooled.
701-14 PROTECTION OF CONCRETE
Unless otherwise directed by the Engineer Incharge, concrete bridge

floors and culverts shall be closed to all types of loads for a period of
at least 14 days after placing for normal strength concrete or for such
time as may be deemed advisable.
701-15 CONCRETE STRUCTURES
701-15.1 Columns
Concrete in columns shall be placed in one continuous operation,

unless otherwise directed by the Engineer Incharge. The columns shall
be allowed to set at least 12 hours before the caps are placed. No
concrete shall be placed in the superstructure until the columns have
been stripped sufficiently to determine the character of the concrete in
the columns.
701-15.2 Slabs.
Before any slab concrete is placed an approved template and finish tool
shall be on hand for striking off the surface of the slab to the required
crown as shown on the drawings.
701.15.3Deck Girders.
The slabs and beams in T-beam or deck girder construction shall be

placed in one continuous operation except that where special shear
anchorage of keys are provided, as shown on the drawings or approved
by the Engineer Incharge, the beams and slabs may be constructed in
successive pours.
701-16 MEASUREMENT
For any item of work constructed under this Section measurement shall
be made by volume. The unit of measurement shall be one cubic meter
or one cubic feet. In computing the concrete quantity the dimensions
used shall be the plan dimensions of the concrete with the neat lines
shown on the drawings except that no deduction will be made for weep
holes and floor drains and no account shall be taken of chamfers,
scorings, fillets of 37.5 mm (1.5 inches) or less in cross section area.
The quantity to be paid for shall be the original drawings quantity, and
any variations approved by the Engineer Incharge.
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No measurements for other allowances will be made for work or

material for forms, false work, pumping, bracing, expansion joint
material and testing of concrete etc. The volume of all materials
embedded in the concrete such as structural steel, pile heads, etc.
except reinforcing steel, shall be deducted in computing the volume of
concrete to be paid for.
In computing the volume of concrete in deck girders and beam spans

the thickness of the floor shall be taken, as the nominal thickness
shown on the drawings and the width shall be the horizontal distance
measured across the roadway. The volume of lugs over beams shall be
included in the volume to be paid for.
701-17 RATE
The unit rates for various types of Portland cement concrete listed in
Table 701-1 shall be full compensation for all the work specified in this
section including testing of concrete and shall also include all forms,
false work, weep holes, drain, setting anchor bolts and dowels, surface
finish and cleaning up as shown on the drawings or ordered by the
Engineer Incharge.
701-18 PAYMENT
Item 701-18.1 Cement Concrete Class “A1” per Cubic meter (m3) or per cft
Item 701-18.4 Cement Concrete Class “B” per Cubic meter (m3) or per cft
Item 701-18.5Cement Concrete Class “C” per Cubic meter (m3) or per cft
Item 701-18.6 Cement Concrete Class “D1” per Cubic meter (m3) or per cft
Item 701-18.9 Cement Concrete Class “Y” per Cubic meter (m3) or per cft
Item 701-18.10 Cement Concrete Class “Lean Concrete” per Cubic meter
(m3) or per cft
*****************
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SECTION 711
CEMENT CONCRETE PAVEMENT
711-1 DESCRIPTION
The work specified in this section consists of construction of Cement

Concrete Pavement, constructed in one course on a prepared sub-grade
and under course in accordance with these specifications and in
conformity with the lines and cross sections shown on the drawings.
The concrete for pavement construction shall be of specified quality
and shall be reinforced with steel bars, or steel mesh, where called for
in contract and in accordance with the details shown on the drawings.
711-2 MATERIALS
Materials needed to make the cement concrete of the specified type for
pavement construction shall conform to specifications as contained in
section 701-2.
Reinforcing steel bars shall conform to specifications as contained in

section 821.
Materials for filling of joints shall be as specified on drawings and

711.2.1 Joint Filler
Joint filler shall consist of cane or other suitable long fibers of a

cellular nature uniformly impregnated with asphalt. The asphalt
content of the joint material shall be between thirty and fifty percent.
The joint material will not deteriorate under any weather conditions
and is to be of such a character as not to be permanently deformed or
broken by moderate twisting, bending or other ordinary handling.
Strips of the joint filler which do not conform to the specified
dimensions within the tolerance + two (2) mm for thickness and +
twelve (12) mm for depth are to be rejected. All damaged strips are to
be rejected too.
711.2.2 Joint Sealing Compound
Joint sealing compound is to be as BS 2499 (1973) type A1 or A2, or

as approved by the Engineer Incharge.
The compound is to be impermeable, is to withstand all weather

conditions and is to be capable of adhering to the concrete without
cracking, spalling or disintegrating and will not require an
impracticable condition of dryness or cleanliness of the concrete slabs.
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Where recommended by the manufacturer of the sealing compound, a

primer supplied by him is to be used to improve adhesion.
711.2.3 Dowel Bars
Dowel bars shall be cut from mild steel bars and will be approved by
the Engineer Incharge. The Contractor’s attention is directed to the
requirement that one end of each dowel bar in all joints, except bonded
construction joints, shall be sawn and not sheared so that no
irregularities likely to interfere with its sliding action in the concrete
shall occur. The minimum length of the dowel bars spaced at one meter
centre to centre or as shown on the drawings, shall be thirty five (35)
times the diameter of the bar used unless otherwise specified or as
711-2.4 Expansion Caps
Expansion caps for dowel bars in expansion joints shall consists of

pressed metal sleeves plugged at one end by punching the specified
joint filler board of a wad of cotton waste of similar compressibility
and sealed at the end against entry of mortar. The tube shall have an
internal diameter permitting sliding on the dowel bar but close enough
to prevent entry of mortar.
711-2.5 Darkening Agent
Darkening agent for the top course of concrete pavements if ordered

and specified shall be a carbon black; either as an aqueous dispersion
containing at least 25% of solids, to be added to the mixing water, or as
a self-dispersing power to be added to the mixing water, or as a self
dispersing power to be added to aggregate and cement. It shall be
approved by the Engineer Incharge as non-deleterious and as giving a
grey colour and shall be added at the rate of 0.1% by weight of the
mixed concrete if it is aqueous dispersion. The minimum quantity of
self dispersing power shall be 0.025% by weight of the concrete
aggregate.
The darkening agent shall be free from sulphur trioxide and from any
other matter deleterious to concrete.
711-2.6 Crack Inducing Battens
Crack inducing battens shall be of wood or of any other suitable

material proposed by the contractor at the time of tendering and
approved of at the award of the contract or approved by the Engineer
Incharge at his discretion after the award of the Contract. Battens of
highly absorbent wood or other material shall be of cross-sectional
dimensions shown on the Drawings, and treated to prevent adhesion
between them and the concrete.
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711.3 PLANT AND EQUIPMENT
Plant and equipment needed for making the required concrete shall be
in accordance with section 701-3.
711-4 CONSTRUCTION DETAILS
711-4.1 Proportions of Ingredients.
This shall conform to specifications contained in section 701-4,

provided that the mix shall be designed on minimum fourteen (14)
days flexural strength which shall not be less than 3.5 N/mm 2 (500 Psi)
and having 28 days compressive strength not less than 31.3 N/mm 2
(4500 Psi)
711-4.2 Mixing and Testing Concrete
The concrete shall be mixed in accordance with specifications under

section 701-6 and tested according to specifications under section
701-7.
711-4.3 Pavement Subgrade (Embankment)
The subgrade (embankment) for the concrete pavement where required

shall be constructed in accordance with section 411.
711.4.4 Pavement under Course.
A granular under course shall invariably be provided under the

concrete pavement in a compacted thickness of minimum of 8 cm (3”)
in or as per design and drawings and as per specifications laid down in
section 501. The Soaked CBR of such under course shall not be less
than 30. The under course shall extend 30-60 cm (1-2 ft) outside the
pavement to provide edge support and shall be smooth, compacted to
the grades and cross sections shown on the drawings so maintained
throughout the period of placing concrete pavement. The under course
shall be moistened immediately prior to placing concrete.
To ensure proper depth and section of the concrete pavement a

template true to depth and section and resting on accurately set side
forms, shall be moved over the under course before placing concrete,
and any irregularities shall be immediately corrected. High spots shall
be planed down, an the contractor shall have the option of either filling
low spots to the proper elevation with approved material which shall
be watered, compacted and struck off to the required grade or of
placing additional concrete. No measurement or payment shall be
made for such additional concrete.
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711-4.5 Forms
Unless as may otherwise be directed by the Engineer Incharge, the

forms shall be made of steel, of an approved section with a base width
of at least 200 mm (8 inches), and the depth shall be equal to the
thickness of the pavement at the edge. Each section of forms shall be
straight and free from bends and warps at all times. No section shall
show a variation greater than 3 mm in 3 meters (1/8 inch in 10 feet)
from a true plane surface on top of the form, and the inside face shall
not vary more than 6 mm (1/4 inch) from a plane surface.
Before placing forms, the underlying materials shall be excavated to

the required grade if necessary and shall be firm and compact. The
forms shall have full bearing upon the foundation throughout their
length and shall be placed with exactness to the required grade and
alignment of the edge of the finished pavement. They shall be so
supported during the entire operation of placing, tamping and finishing
the pavement that they will not deviate vertically at any time more than
3 mm (1/8 inch) from the proper elevation.
Forms shall be set to the required lines and grades well ahead of
placing concrete preferably not less than 150 m (500 ft).
Forms shall not be removed for at least 12 hours after the concrete has
been placed. Forms shall be carefully removed in a manner to avoid
damage to the pavement. Under no circumstances will the use of pry
bars between the forms and the pavement be permitted.
Forms shall be thoroughly cleaned and oiled each time they are used.
711-4.6 Consistency
The slump of the pavement concrete shall be from 25 mm to 75 mm

(1 to 3 inches) or as directed by the Engineer Incharge. The slump shall
not vary more than 25 mm (One inch) from batch to batch.
711-4.7 Placing Concrete
Concrete shall be placed on the prepared and moistened under-course

in such a manner as will require as little re-handling as possible to
avoid segregation of materials and in accordance with specifications
under section 701.9.
If required by the Engineer Incharge the forms shall be wetted

immediately prior to the placing of concrete.
711-4.8 Re-tempering
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After placing and vibration of concrete, re-tempering that is remixing

with or without additional material or water will not be permitted.
711-5 JOINTS
711-5.1 General Requirements.
Joints shall be constructed exactly in accordance with the details

shown on the drawings and the specifications and with the best of
workmanship. Failure to construct the joints as called for and in the
best possible manner, as determined by the Engineer Incharge will be
cause for suspension of work until the cause of the defective work is
remedied.
If removal of existing pavement of any types is required to connect

with the new pavement, and the termination of the removal is not at an
existing joint, the new joint shall be made by sawing the existing
pavement not less than 50 mm (2 inch) deep before removal.
711.5.2 Expansion Joints
The subgrade at expansion joints shall be accurately trimmed to the

required cross section and to the proper depth of the pavement.
A string line shall be stretched between the pavement forms along the
centerline of the joint.
One half of the length of each dowel bar shall be painted in accordance
with the directions shown on the drawings, and then thoroughly coated
with hard grease, or lubricant as approved by the Engineer Incharge to
prevent the concrete from bonding to that portion of the dowel.
The entire joint assembly shall be of a type designated on the

drawings and shall be installed in such a position that the centerline of
the joint assembly is perpendicular to the centerline of the pavement
slab and the dowels lie parallel to the centerline of the slab. Finished
joints shall not deviate more than 6 mm (1/4 inch) in the horizontal
alignment from a straight line. No plugs of concrete shall be permitted
any where within the expansion space.
A PVC slip sleeve of the dimensions shown on the drawings shall be

placed on the greased end of each dowel. The greased ends shall be
free to slide in the dowel holder and shall extend in the direction as
indicated on the drawings. Any excess grease on the dowel holder shall
be removed.
The joints shall be securely staked or fastened in place prior to placing

the concrete and in a manner to ensure that the joint and the dowel bars
will remain in their proper position after the concreting and finishing
operations are completed.
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Joints for pavement designed for two (2) or less lanes of traffic shall be
assembled and installed in one (1) continuous piece or the connections
between sections shall be made rigid and tight to prevent offsets in
section of the joints. The length of individual pieces of the expansion
joint filler shall be not less than the width of one (1) traffic lane of the
pavement.
The finishing machine shall be operated in a manner that will prevent

displacement of the joint. If for any reason it is necessary to straighten
a joint, any depressions caused by this operation shall immediately be
filled with fresh concrete, responded and brought to the original crown
in advance of the longitudinal finishers. Any fluid laitance or mortar
caused by this operation shall be removed and replaced with fresh
concrete.
As the finishing machine approaches the joint on the first trip, the
excess concrete shall be shoveled ahead of the tamper and each screed,
in turn; the screed may be operated over the joint.
711-5.3 Contraction Joints.
Contraction joint shall be of the type and dimensions and at the spacing
shown on the drawings.
Sawed contraction joint shall be cut by means of an approved concrete

saw. The joints shall not be sawed until the concrete has hardened.
All joints shall be sawed during the initial curing period and the sawing
shall begin before the pavement starts shrinking and before
uncontrolled cracking takes place.
Any procedure which results in premature and uncontrolled cracking

shall be revised immediately by adjusting the sequence of cutting the
joints or the time interval involved between the placing of the concrete
or the removal of the curing media and the cutting of the joints. In no
case shall the pavement be left overnight without having the joints
sawed.
The joints shall be sawed at the depth, spacing, and lines shown on the
drawings. Guidelines or devices approved by the Engineer Incharge
shall be provided to insure cutting the joint in a straight line and
perpendicular to the centerline of the pavement.
The dust resulting from sawing shall be completely removed from the
joint and adjacent areas by means of an air jet or combination of air
and water applied under pressure immediately after the joint has been
cut, and before filling with joint compound.
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When the drawings specify that dowels be installed through

contraction joints the under course at the contraction joints shall be
accurately trimmed to the required cross section and to the proper
depth of the pavement.
A string line shall be stretched between the pavement forms along the
centerline of the joint.
Each dowel shall be painted and thoroughly coated with hard grease, or
lubricant, in accordance with the directions given on the drawings or as
approved by the Engineer Incharge, to prevent the concrete from
bonding to that portion of the dowel.
The entire joint assembly shall be of the type designated on the

drawings and shall be installed in such a position that the centerline of
the joint assembly is perpendicular to the centerline of the slab and the
dowels lie parallel to the slab surface and parallel to the centerline of
the slab.
The greased ends of the dowels shall be placed in the direction as

indicated on the drawings and shall be free to slide in the dowel holder.
Any excess hard grease on the dowel holder shall be removed.
711-5.4 Longitudinal Joints
Longitudinal joints shall be constructed in conformance with the

details shown on the drawings. When the fabricated steel strip is
specified, it shall be held rigidly in place with an adequate number of
pins driven into the sub grade to insure that it will remain true to line
and grade during concreting and finishing operations. On multiple lane
pavements where longitudinal joints are constructed at the form line,
and approved recessed form and tie bars will be required. The full
depth fabricated steel strip designated for other longitudinal joints will
not be permitted. When sawed joints are specified or used, suitable
guidelines or devices shall be furnished to insure cutting the
longitudinal joint on the true line as shown on the drawings. The
sawing of longitudinal joints shall be performed at a time that will
preclude erratic or uncontrolled cracking. Sawed joints shall be filled
with the type of joint compound indicated on the drawings. The dust
resulting from sawing shall be completely removed from the joint and
adjacent areas by means of an air jet or a combination or air and water
applied under pressure immediately after the joint has been cut and
before filling with joint compound.
711-5.5 Construction Joints.
A butt construction joint shall be made perpendicular to the centerline

of the pavement at the close of each day’s work and also when the
process of depositing concrete is stopped for a length of time such that,
in the opinion of the Engineer Incharge, the concrete will have taken
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its initial set. This joint shall be formed by using a clean plank header
having a nominal thickness of 50 mm (2 inch), a width of not less than
the thickness of the pavement and a length of not less than the width of
the pavement and shall be accurately set and held in place in a plane at
right angles to centerline and perpendicular to the surface of the
pavement.
The top surface of the header shall be protected with steel as approved
by the Engineer Incharge. On the face along the centre of the header
there shall be fastened a trapezoidal piece of metal or wood for the full
length of the header 50 mm (2 inch) wide and at least twenty five (25)
mm (one inch) depth to for a grooved joint. The header shall have
drilled holes to accommodate the dowel or tie bars herein after
specified. Upon resumption of work any surplus concrete remaining
upon the subgrade shall be removed. The header shall then be carefully
removed and fresh concrete deposited against the old in such a manner
as to avoid injury to the edge of the old concrete. The fresh concrete
shall be vibrated into the groove in a manner to insure an interlocking
joint.
Dowel bars or load transfer devices shall be used in all construction

joints in accordance with the details shown on the drawings. Tie bars
as provided for the longitudinal joint, and spaced at forty five (45)
centimeter (18 inch), shall be placed across the joint in a plane parallel
to the surface of the pavement approximately midway between the top
and bottom surface of the pavement. The edges of the joint shall be
grooved, edges, and sealed with the material used for sealing
expansion and contraction joints.
No construction joint shall be placed within three (3) meters (10 feet)
of an expansion, contraction, or other construction joint.
711.5.6 Permanent Header Board
Immediately after the forms are removed from the ends of concrete
pavement that will be exposed to other than permanent type surfacing
and temporary and permanent traffic, a header board having dimension
of not less than eight (8) centimeter (3 inch) (nominal) by twenty (20)
centimeter (8 inch) shall be bolted securely to the end of the pavement
in a manner to protect the edge of the pavement from damage. The
header board shall extend the full roadway width, but may be in two
(2) sections. At the time of placing the concrete, six (6) (three for each
lane), thirteen (13) mm (1/2 inch) by twenty (20) centimeter (8 inch)
bolts shall be embedded in the end of the pavement in a manner that
will hold the header board securely. The header board shall be shaped
to conform to the crown of the pavement and shall be installed flush
with the concrete pavement surface. The header board will not be
required on concrete base course work.
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711-6 SPREADING FINISHING AND FLOATING
711-6.1 General Requirements.
Except as otherwise specified, the striking off, compacting and floating

of concrete shall be done by mechanical methods, where the Engineer
Incharge determines that it is impracticable to use mechanical methods,
manual methods of spreading, finishing and floating may be used on
pavement lanes of widths less than 3 meters (10 feet).
711.6.2 Mechanical Methods
711-6.2.1 Spreading and Finishing.
The concrete shall be spread uniformly between the forms,

immediately after it is placed, by means of an approved spreading
machine. The spreader shall be followed by an approved finishing
machine. The spreading machine or the finishing machine shall be
equipped with vibrating equipment that will vibrate the concrete for the
full paving width. Internal vibrators shall be used adjacent to the
longitudinal edge of the pavement. The rate of vibration shall be not
less than 3000 vibrations per minute.
The concrete shall be spread in full width before being struck off by
the finishing machine. The concrete shall be struck off and compacted
so that the surface will conform to the finished grade and cross section
shown on the drawings and at the same time leave sufficient material
for the floating operation. The spreading or finishing machine shall
move over the pavement as many times and at such intervals as may be
required by the Engineer Incharge to ensure thorough compaction.
711.6.2.2 Floating
Except as otherwise specified, after the pavement has been struck off
and compacted, it shall be finished with an approved longitudinal float.
The contractor may use a longitudinal float composed of one or more
cutting and smoothing floats, suspended from and guided by a rigid
frame of a longitudinal float which works with a swing motion, while
held in a floating position parallel to the road centerline and passing
gradually from one side of the pavement to the other.
If any spreading, finishing and floating equipment is not maintained in

full working order of if the equipment as used by the contractor proves
inadequate to obtain the results prescribed, such equipment shall be
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improved or satisfactory equipment substituted or added at the

direction of the Engineer Incharge.
711-6.3 Manual methods
711-6.3.1 Striking off and Compaction
When striking off and compacting by manual methods are permitted,

the concrete shall be approximately leveled and then struck off to such
an elevation that when properly compacted, the surface will conform to
the required grade and cross section. The strike board shall be moved
forward with a combined longitudinal and transverse motion, the
manipulation being such that neither end is raised from the side forms
during the process. While striking off, a slight excess of concrete shall
be kept in front of the cutting edge at all times.
711.6.3.2 Straight-edge Testing.
After striking off and compaction and longitudinal floating has been
completed and the excess water removed, but while the concrete is still
plastic, the surface of concrete shall be tested for trueness with a 3 m
(10 ft) straight-edge. The straight-edge shall be held in contact with the
surface in successive position, parallel to the road centerline and the
whole area gone over from one side of the pavement to the other.
Advancing along the road shall be in successive stages of not more
than one-half the length of the straight-edge. Any depressions found
shall be filled immediately with fresh mixed concrete, and any high
areas shall be cut down. The surface shall be struck-off, consolidated
and refinished. Special attention shall be given to ensure that the
surface across the joints fully meets the requirements for smoothness.
The straight-edge testing and refloating shall continue until the entire
surface is found to be free from observable departures from the
straight-edge and the pavement has the required grade and crown.
711-6.3.3 Grooving
It shall be provided in the finished concrete surface by mechanical

means as may be approved by the Engineer Incharge and as shown on
the drawings.
711.6.3.4 Surface Test
As soon as the concrete has hardened sufficiently, the pavement

surface shall be tested with a 3 meter (10 feet) straight-edge. Areas
showing high spots of more than 3 mm (1/8”) but not exceeding 12.5
mm in 3 meter (1/2” in 10ft) between any two contact points shall be
marked and immediately ground down with not show surface
deviations in excess of 3 mm (1/8”) when tested with a 3 meter (10
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feet) straight-edge. Where the departure from correct cross section

exceeds 12.5 mm (1/2”), the pavement shall be removed and replaced
by and at the expense of the contractor. Any area or section so removed
shall be not less than 3 meter (10 feet) in length nor less than the full
width of the lane involved. When it is necessary to remove and replace
a section of pavement, any remaining portion of the slab adjacent to
the joint that is less than 3 meter (10 feet) in length, shall also be
removed and replaced at the Contractor’s expense.
711-7 CURING CONCRETE
In all cases in which curing requires the use of water the curing shall
have prior right to all water supply. As no time shall more concrete be
laid than can be immediately and properly covered, nor when that
already laid is not being properly cured.
An soon as the concrete has hardened sufficiently to permit walking,

the entire surface of the concrete shall be covered with burlap and shall
be kept soaked with water for at least 72 hours unless otherwise
directed by the Engineer Incharge. Thereafter, the burlap may be
removed and the concrete kept moist by frequent sprinkling of water
for a total period of at least eleven days after the concrete is laid.
711-8 OPENING PAVEMENT TO TRAFFIC
Pavement shall remain closed to traffic until tests show the concrete to
have a minimum modulus of rupture, when tested in accordance with
AASHTO T-177 of not less than 3.5 N/mm 2 (500 pounds per square
inch) but in no case shall the pavement be opened to traffic in less than
21 days after concrete is placed.
711-9 CONCRETE LUG ANCHORS
“Concrete Lug Anchors” shall be constructed in accordance with the

dimensions and notes and at the locations shown on the plans. Unless
otherwise indicated on the plans, the class, composition, consistency,
proportioning, batching, mixing and curing of the concrete used in
concrete lug anchors shall conform to the same requirements as the
concrete pavement. Reinforcing steel, concrete and excavation for lug
anchors shall be subsidiary to the Bill of Quantities item “Concrete
Lug Anchors”.
711-10 MEASUREMENT.
Cement concrete pavement shall be measured by the volume of cement

concrete laid on the pavement according to the thickness and cross
section shown on the drawings. The length shall be measured along the
actual surface at the pavement and width from outside of completed
pavement. The unit of measurement shall be one cubic meter (m 3) or
one cubic feet (cft).
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711-11 RATE
The unit rate for cement concrete laid for concrete pavement shall be
full compensation for the work specified in this section completed,
cured with water, finished and accepted including cost of furnishing all
materials, labour, tools and equipment and operations necessary to
complete the work as specified in this section.
711-12 RATE ADJUSTMENT
Where the average thickness of concrete pavement is deficient by more

than 5mm, but not more than 25mm, payment will be made at an
adjusted rate as given in Table hereunder:
Deficiency in thickness (mm) Percentage of price paid
0.0 to 5.0 100

5.1 to 8.0 80
8.1 to 10.0 72
10.1 to 13.0 68
13.1 to 19.0 57
19.1 to 25.0 50
711.13 PAYMENT.
Pay Item No.711-13.1 Plain Cement Concrete

Pavement Per Cu.m. (m3)
or Per cft (ft 3)
Pay Item No.711-13.1 Reinforced Cement Concrete

Pavement Per Cu.m.(m3)
or Per cft (ft 3)
Pay Item No.711-13.1 Concrete Lug Anchors

Per meter
or Per foot
*****************
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SECTION 721
PLUM CONCRETE
721-1 DESCRIPTION
The work specified in this section shall consist of placing plum

concrete, consisting of 40 percent plum and 60 percent cement
concrete (lean) (Section 701), proportioned and mixed as provided in
these specifications and shall be constructed where, and of the form,
dimensions and design shown on the drawings.
721-2 MATERIALS
721-2.1 Cement Concrete
It shall be lean concrete and conforming to specifications as contained

in Section 701.
721-2.2 Plum
Plum shall be of approved quality of stones or boulders having a size

of 100 mm (4 inches) and above. The quality of stones should be got
approved from the Engineer Incharge.
721-3 OTHER REQUIREMENTS
In all other requirements this shall conform to specifications for

Cement Concrete (Section 701) except that plum shall be placed in
such a way that it is covered by lean concrete on all the sides.
721-4 MEASUREMENT
The quantity of plum concrete placed, cured, finished and accepted

shall be computed by volume. The unit of measurement shall be one
cubic meter or one cubic foot.
721-5 RATE
The unit rate for plum concrete placed and accepted, shall be full
compensation for all the work specified in this section and shall
include all materials and labour, all forms, false work, joints, weep
holes, setting anchor bolts and dowels, surface finish and cleaning up
as shown on the drawings or as directed by the Engineer Incharge.
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721-6 PAYMENT
Item No.721-6.1 Plum Concrete Per cubic meter (m3)or

Consisting 40% plum per cubic foot (cft)
and 60% Lean
Concrete
*************
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CHAPTER 800
HIGHWAY STRUCTURES
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SECTION 801
BRICK MASONRY
801-1 DESCRIPTION
The work specified in this section shall consist of providing all

materials, equipment and labour required for constructing brickwork.
All brickwork shall be first class and finished in a workman like
manner, true to dimensions and grades shown on the drawings
according to these specifications.
801-2 MATERIALS
801-2.1 Bricks.
The size of bricks shall be standard size 22.9 cm x 11.4 cm x 7.6 cm

(9”x 4 ½ ” x 3”). They shall be well-bunt without being vitrified. They
shall be of uniform colour, regular in shape and size with sharp and
square corners and parallel faces. They must be homogenous in texture
and emit a clear ringing sound when struck. They shall be free from
flaws and cracks. They shall not absorb more than 1/6 th of their weight
of water after being soaked for one hour, and shall show no signs of
efflorescence on drying. Compressive Strength shall not be less than
140 Kg/cm2(2000 Psi)
.
801.2.2 Portland Cement
Portland cement shall conform to the requirements for Portland cement

as contained in section 1001.
801.2.3 Sand
Sand for mortar used in brickwork shall conform to the requirement for
the fine aggregate specified in section 1033.
801.2.4 Water
The water used in the preparation of mortar shall be free from

objectionable quantities of silt, organic matter, salts or other impurities.
No water shall be used without the written approval of the Engineer
Incharge.
801.3 TOOLS AND SCAFFOLDING
All equipment used for mixing mortar, transporting it and for laying
bricks shall be clean and free from set mortar, dirt, or other injurious
foreign substances. It shall be thoroughly cleaned at the end of each
day’s work.
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The contractor shall provide all scaffolding, staging, and ladders,

necessary for the work. All walls or others brickwork shall be securely
braced and protected against damages by wind and storm during the
construction period. No extra rate shall be paid for this item.
801.4 BOND
Unless otherwise specified, all brickwork shall be laid in English Bond

with frogs upward.
801.5 CONSTRUCTION REQUIREMENT
801.5.1 Mixing of Mortar
Methods and equipment used for mixing mortar shall be subject to the
If a mixer is used, it shall be of approved design and the mixing time

after all the ingredients are in the mixer, except for the full amount of
water, shall be not less than two minutes.
801.5.2 Brick Laying
Brick work shall not be placed during rain sufficiently heavy of

prolonged to wash the mortar from the bricks. Mortar already spread
which becomes diluted by rain shall be removed and replaced before
continuing the work.
All bricks to be used in brickwork with mortar joints shall be immersed
in water for at least 2 hours before they are used.
All bricks shall be skillfully laid with level courses, uniform joints,
square corners, plumb verticals and true surface, except where
otherwise shown on the drawings.
All walls and abutments below formation level shall be provided with
weep holes. Unless otherwise shown on the drawings or directed by the
Engineer Incharge the weep holes shall be placed at the lowest points
where free outlets can be obtained and shall be spaced not more than 2
meter (6 feet) center to center, in case of deeper walls/ abutments, the
weep holes shall be placed in more than one row not to exceed the
vertical spacing from 2 meter( 6 feet). In such cases the weep holes
shall be staggered in vertical planes.
801.5.3 Curing
All bricks work shall be cured for at least 7 days after laying. The
curing methods shall be to the satisfaction of the Engineer Incharge.
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801.5.4 Progress
Brickwork shall be carried up in a uniform manner. No portion shall be

raised more than one meter (3 feet) above another at the same time.
Temporary spaces left during construction shall be raked and not
toothed. The brick layer shall be provided with measuring rods or
straight edge having courses marked on them with saw and the height
of courses shall be checked all over the during from time to time so as
to keep all courses level.
801.5.5 Putlogs
Only headers shall be left out to allow a putlog to be inserted and not
more than one brick shall be left out for each putlog. Under no
circumstances shall putlogs be made immediately under or next to the
impost or skew back of arches.
801.6 JOINTS
801.6.1 Horizontal Joints
Horizontal points shall be parallel and truly level.
Vertical joints in alternate courses shall come directly over one another.
Thickness of joints, unless otherwise specified, shall not be less than
6.3 mm (1/4”) and shall not be more than 9.5 mm (3/8’). The height of
4 courses and 3 joints as laid shall not exceed more than 25 mm (1
inch) the height of 4 bricks as piled dry one upon the other.
801.6.2 Jointing Works
When fresh masonry is to join masonry that has partially or fully set,
the exposed joining surface of the set masonry shall be cleaned,
roughened and wetted so as to affect the best possible bond with the
new work. All loose bricks and mortar shall be removed.
801.6.3 Striking of Joints
Where in the case of brickwork in cement mortar, pointing of

plastering to the face work is not provided as a separate item the joints
in face work shall be struck. This operation shall be paid for separately.
801.6.4 Ranking Joints
The joints of brickwork, which is to be pointed or plastered, shall be

raked out with a hook to a depth of 12.5 mm (1/2’). The raking shall be
done before the mortar sets each day.
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801.7 CORNERS
At all corners alternate courses of bricks shall be laid header wise and
stretcher-wise so as to bond the two walls together.
Where particularly required, cut or mould bricks shall be used in
jambs, arches and projecting corners, so as to eliminate sharp angles
from the inside of a building. This shall be included in the unit rate if
the radius of the finished (Plastered) corners does not exceed 19 mm
(3/4 of an inch). In case it exceeds 19 mm (3/4 of an inch) extra
payment shall be made by marking linear measurements.
801.8 ROUND PILLARS
Round pillars shall be built with quadrant shaped bricks, if the pillars
are of considerable height flat circular discs of stone or cement
concrete of the same diameter as the pillar and about 75 mm (3 inches)
thick shall be introduced at every 1.0 m to 2 m (3 to 6 feet) as bond
stone. The cost of this operation will be included in the unit rate.
801.9 PLUMB BOBS AND STRAIGHT EDGES
All brickwork shall be truly plumbed and each set of 4 brick course
shall be checked with plumb bob and straight edge.
801.10 FACE WORK
All face work shall be finished with neat drawn joints and pointed out
if it has not be plastered. If it has to be plastered the joints shall be
raked out before any plaster is laid on. For face work the bricks shall
be of true edges, uniform colour and correct dimensions. If specially
required, face work shall be laid up with pressed bricks. It shall be
measured and paid for separately. All brick courses shall be
proportioned that they will work out evenly with the height of
windows and doors.
801.11 CUT BRICK WORK
Bricks shall be cut, dressed or grooved, as required for architectural

features. Corners shall be made with cut bricks.
801.12 FIXTURES
Holdfasts and similar fixtures shall be built in with the surrounding

brickwork in their correct position in specified mortar. They shall be
built in as the work progresses and not inserted later on into space left
for them.
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801.13 BED PLATES
Bed plates of concrete or stone shall be provided under each beam and
joint. They shall conform to the dimensions given in the drawings and
shall be carefully laid in specified cement mortar to correct level.
801.14 CENTERING
Centering for all openings shall be strong enough to support the lintels
of arches spanning the opening. They shall be subject to the approval
of the Engineer Incharge and shall remain in position till the brickwork
has set. No additional payment will be made to the contractor for this
item of work.
801.15 COPING
Unless otherwise specified, the top courses of all plinths, parapets,

stops etc., shall be built in brick on edge in specified mortar. In case of
parapet walls the outside half of the brick shall be weathered and
throated. The corners shall be made by cutting selected bricks or by
special bricks to given a radiated and keyed joint.
801.16 BRICK WORK INARCHES
The brickwork in arches shall conform to specifications for first class

brickwork, but shall not commence till abutments have been built to
their full width and upto the level of skew backs. Arch work shall be
carried up evenly from both abutments and as soon as the arch is
complete, masonry shall be built up evenly on both sides to the heights
of crown so as to load the haunches.
801.17 MEASUREMENT
Brickwork shall be measured by volume. The unit if measurement

shall be 1 cubic meter or 100 Cft. The measurement of cut bricks shall
be in number. The unit of measurement shall be 1000 bricks. No
deduction shall be made for opening having a superficial area 0.093
square meter (one square foot) or less. The item of coping shall be
measured by length. The unit of measurement shall be one linear meter
or one linear foot.
801.18 RATE
The unit rate shall be full compensation for carrying out 1 st class
brickwork including the cost of bricks mortar and any other material
required, including curing and protection as per above specifications. It
shall further include the cost of providing using and removing
scaffolding, shuttering, centering, staging, ladders, supports and other
tools and plants, required for carrying out 1st class brickwork.
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801.19 PAYMENT
Payment shall be made under: -
Item No.801-19.1 1st class brick work in

Cement Mortar as
Specified. Per cu. meter (m3)
or
per 100 cft
Item No.801-19.2 Coping in specified

Cement mortar as Per cu. meter (m)
or
per foot
Item No.801-19.3 Brick work in Arches Per cu. meter (m3)

or
per 100 cft
Item No.801-19.4 Cut bricks Per thousand No.
Item No.801-19.5 Striking Joints Per sq. meter

or
per 100 sft
*************
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SECTION 802
STONE MASONRY
802-1 DESCRIPTION
This work shall consist of furnishing all materials, equipment and

labour required for constructing stone masonry work of the class
mentioned in the Bid-Schedule and as shown on the drawings and in
accordance with the specifications.
Unless otherwise specified all stone masonry shall be finished in a

workman like manner true to dimensions and lines shown on the
drawings.
802-2 CLASSIFICATIONS
802.2.1 Ashlars Masonry
Ashlar masonry shall consist of first class cut stone masonry laid in
regular courses and shall include all work in which, as distinguished
from rubble masonry, the individual stones are dressed or tooled to
exact dimensions, and laid in cement mortar.
802-2.2 Rubble Masonry
Rubble masonry, as specified hereunder shall include the classes

commonly known as Coursed, Random and Dry Rubble work and shall
consist of roughly squared and dressed stone laid in cement mortar or
laid dry.
802-3 MATERIALS
802.3.1 Stone General Requirements
Stone shall be procured from an approved source and shall conform to

specifications in Section 1046. Approved samples of stone shall be
retained as standard of material to be furnished at the site of work. All
stone used in the work shall be equal in all respects to the approved
sample.
Through Bond Stones shall be procured and stacked separately and

shall be marked on the face with bitumen or paint- Marks shall be
made on the inner face or the face to be plastered.
Stone shall be sufficiently wetted before laying, to prevent absorption

of water from mortar. The stone shall be kept free from dirt, oil or any
other injurious material that may prevent the proper adhesion on the
mortar.
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802.3.2 Ashlar Stone
Stone for ashlar masonry shall be of the kind specified on the drawings
or in the contact. The stone shall be tough, dense, sound and durable,
resistant to weathering action, reasonably fine grained, uniform in
color, and free from seams, cracks, pyrite inclusions, or other structural
defects. Preferably stone shall be from a quarry, the product of which is
known to be of satisfactory quality. Stone shall be of such character
that it can be brought to such lines and surfaces, whether curved or
plane, as may be required. Any stone having defects that have been
repaired with cement or other materials shall be rejected.
The stone shall be kept free from dirt, oil or any other injurious
materials, which may prevent the proper adhesion of the mortar or
detract from the appearance of the exposed surfaces.
802-3.3 Rubble Stone.
Stone for mortar rubble or dry rubble masonry shall be of approved

quality, sound and durable, and free from segregations, seams, cracks,
and other structural defects or imperfections tending to destroy its
resistance to the weather. It shall be free from rounded, worn, or
weathered surfaces. All weathered stone shall be rejected.
802.3.4Portland Cement.
Portland cement shall conform to the requirements for Portland cement

as contained in section 1001.
802-3.5 Sand
Sand for mortar used in brickwork shall conform to the requirement for
the fine aggregate specified in Section 1033.
802-3.6 Water
The water used in the preparation of mortar shall be free from

objectionable quantities of silt, organic matter, salts or other impurities.
No water shall be used without the written approval of the Engineer
Incharge.
802.4 TOOLS AND SCAFFOLDING
All equipment used for mixing and transporting mortar and for laying
stone shall be clean and free from set mortar, dirt or other injurious
foreign substances. The equipment shall be thoroughly cleaned at the
end of each day’s work.
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The Contractor shall provide all scaffolding, staging ladders, etc,

necessary for the work. All walls or other stone masonry of the
building shall be securely braced and protected against damages by
wind and storms during construction. No extra rate will be paid for this
item of work.
802-5 LAYING OF STONE MASONRY,
a. Every stone shall be laid in the work on its natural quarry bed or in
such a manner that the stresses borne by it come normal to such
bed.
b. Whenever possible, the entire masonry in any structure shall be

carried up at uniform level. Where breaks are unavoidable, joints
shall be made in gradual steps. Gross walls shall be carefully
bonded into the main wall and all junctions of wall shall be formed
at the time the walls are being built.
c. Each stone shall be set with both bed and vertical joints filled with
mortar, except in case of dry stone masonry, and thoroughly bedded
in.
d. All masonry shall be taken up truly plumb or at the specified slope

in the case of batter.
e. Quoins and jambs shall be laid at a true right angle to the bed, the
corners being straight and vertical. In the case of masonry with
hammer dressed stone, a chisel draft 25 mm (1 inch) wide shall be
given on each external face to allow accurate plumbing; Quoins
shall be laid headers and stretchers alternately.
802-6 CONSTRUCTION REQUIREMENTS FOR ASHLAR

MASONRY.
802-6.1 General
Ashlar masonry shall be finished in line with the specified architectural

details, dimensions and grades in a workman like manner according to
following specifications.
802-6.2 Dressing
Every stone in fine ashlar shall be dressed on all beds, joints and faces,
full true and out of winding. Surfaces shall be plain or to uniform
curves as specified or as shown on the drawings.
802-6.3 Thickness of Joints.
Stone shall be set in specified mortar the beds or joints being in no case
more than 3 mm (1/8 inch) in thickness. Each stone shall be struck
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with a maul, when laid to bring it to a solid bearing, both to the bed
and the joints.
802-6.4 Size of Stone.
Stone shall be laid in regular courses not less than 125 mm (5 inches)
in height. All courses shall be of the same height, unless otherwise
specified. No stone shall be less in breadth than 1.50 times it s height
of less in length than 1.5 times its breadth.
802.6.5 Bond
The faced stone shall be laid header and stretcher alternately, unless
otherwise specified. The headers are arranged to come as nearly as
possible in the middle of the stretchers below and the stone in adjacent
layers shall break joints on the face for at least half the height of the
course and the bond shall be carefully maintained throughout.
802.6.6 Through Stone
In walls 75 cm (2.5 feet) thick and less the header shall run right
through the wall.
802.6.7 Courses
The course line shall be horizontal and side joint vertical throughout.
802.6.8 Jambs
Jambs shall be formed with quoins of the full height of the course.
Unless otherwise specified the quoins shall not be less in breadth than
1.5 times or in length less than twice the depth.
802.6.9 Rough Tooled Ashlar
The faces exposed to view shall have a fine dressed chisel draft, one
inch wide, all round the edges and be rough tooled between the drafts,
and on all beds and joints, which shall not exceed 1 cm (3/8 inch) in
thickness.
802.6.10 Other Respect
In all other respects the work shall comply with the specifications
under Section 802-3 to 802-5.
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802.7 CONSTRUCTION REQUIREMENTS FOR COURSE RUBBLE

MASONRY.
802.7.1 General
Course rubble masonry shall be finished in a workman like manner and
in line with the dimensions given on the drawings according to the
following specifications:-
802.7.2 Height of Course
Stone shall be laid in horizontal courses not less than 125 mm

(5 inches) in height. All stones in a course shall be of equal height and
all courses of the same height, unless otherwise specified. But no
course shall be thicker than the course below it. All stones shall be set
full in specified mortar in beds and joints.
802.7.3 Dressing
The face stone shall be square on all joints in masonry. The beds shall
be hammer or chisel-dressed, true and square, for at least 75 mm (3
inches), back from the face, and the joints for a at least 37.5 mm (1½
inch). The face of the stone shall be hammer dressed and “bushing” not
to project more than 37.5 mm (1½ inch).
802.7.4 Thickness of Joints.
All side joints shall be vertical and beds horizontal, and no joint shall
be more than 20 mm (3/4 inch) in thickness. No pinning shall be
allowed on face.
802.7.5 Size of Stone
No face stone shall be less in breadth than its height, nor shall it tail
into the work to a length less than its height, at least 1/3 rd of the
stones shall tail into the work at least twice its height or in walls
thicker than 60 cm (2 feet), three times its height.
802.7.6 Through Stone and Headers
Through stones shall be inserted 1.5 m to 2 meter (5 to 6 feet) apart in

every course, and shall run right through the wall, not more than 0.6
meter (2 feet) thick. When the wall is more than 0.6 meter (2 feet)
thick, a line of two or more headers shall be laid from face to back,
which shall overlap each other at least 150 mm (6”). The headers shall
have a length of at least three times the height.
802.7.7 Breaking of Joints
Stone shall break joints by at least half the height of the course.
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802.7.8 Quoins
Quoins shall be of the same height as the course in which they occur,
shall be formed of stone at least 0.38 meter (1.25 feet) long and shall
be laid stretcher and header alternately. The shall be laid square on
their beds which shall be fairly dressed to a depth of at least 100 mm
(4 inches).
802.7.9 Interior Face
The work on the interior face shall be precisely the same as on the
exterior face, except that side joints need not be vertical.
802.7.10 Hearting
The interior of the wall, called hearting, shall consist of flat-bedded

stones carefully laid on their proper beds and solidly bedded in mortar.
Chips and spawls of stone are wedged in, wherever necessary so as to
avoid thick beds or joints of mortar. No dry work or hollow spaces
shall be left anywhere in the masonry and shall not exceed 10 percent
of the quantity of masonry. The face work and hearting shall be
brought up evenly but the hearting shall not be leveled up at each
course by the use of chips.
802.7.11 Other Respects
In all other respects it shall conform to specification under Section

802-3 to 802-5
802.8 CONSTRUCTION REQUIREMENTS FOR RANDOM RUBBLE

MASONRY.
802.8.1 General
Random Rubble masonry shall be finished in line with the specified

architectural details, dimensions and grades in a workman like manner
according to following specifications:-
802.8.2 Dressing of Stones
Stone shall be hammer dressed on the face and on the face and on the
sides and beds to such an extent that weak corners are chipped off and
the stones come into close proximity, when laid. Each stone shall be
laid on its quarry bed and shall be wedged or pinned strongly into
position in the wall by spawls or chips, which may show on the face.
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802.8.3 Joints
No stone shall tail into the wall less than 1½ times its height. The stone
shall be arranged to break joints as much as possible. Care shall be
taken to avoid long continuous vertical joints.
802.8.4 Through Stone or Headers
One header stone shall be inserted at least every 0.5 square meter
(5 square feet) of the surface (face) and shall run right through the wall
if it is not more than 0.6 meter (2 feet) thick. If the wall is more than
60 cm
(2 feet) thick, a line of headers shall be laid from face to back which
shall overlap each other at least 150 mm (6 in).
802.8.5 Hearting
Hearting or interior filling between the front and back face consist of
rubble stone less than 150 mm (inches) in any direction, carefully laid,
hammered down with a wooden mallet into place and solidly bedded in
mortar. Chips and spawls of stone shall be used wherever necessary as
to avoid thick beds or joints of mortar but shall not exceed 20 percent
of the quantity of stone masonry. No dry work or hollow spaces shall
be left anywhere in the body of the masonry. Hearting shall be laid
nearly level with each course except that at about one meter (3 feet)
interval vertical.
802.8.6 Other Respects
In all other respects, the work shall comply with the specifications
under Section 802-3 to 802-5
802-9 CONSTRUCTION REQUIREMENTS FOR DRY RUBBLE

MASONRY
802-9.1 General
Dry rubble masonry shall be finished in line with the specified

architectural details, dimensions and grades in a workman like manner
according to following specifications:-
802-9.2 Size of Stone
Dry rubble masonry shall be constructed with the largest practicable

size of the stone available the larger stone being used in the lower
courses. In no case the size of stone be less than that specified under
section 1046.
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802-9.3 Beds
Stone shall be roughly dressed to secure the maximum bedding surface
without unduly reducing the size of the stone. Each course shall be
built through the entire thickness of the wall.
802-9.4 Bond Stone
Bond stone shall be provided in each course at an interval of 1.5 meter

(5 ft). It shall be of the height of the course in which it is to be used, at
least as broad and of the greatest length procurable. No bond stone
shall be less than 0.6 meter (2 feet) long. When the length is less than
the thickness of the wall 2 or more stones shall be used overlapping
each other by at least 150 mm (6 inches) to provide through bond from
front to back. All bond stones shall be separately stacked before use
and marked so that they can be identified after having been built in the
wall.
802-9.5 Filling
Whenever required, filling behind dry stone walls shall be done

immediately with stone refuse or chips or dry granular material.
802-10 CONSTRUCTION REQUIREMENTS FOR COPINGS,

CORNICES AND COLUMNS.
802-10.1 General
Stone cornices, copings, pillars, string courses, corbels, brackets, and

similar works shall be made from stone of uniform colour and texture
and of the kind specified for each.
802-10.2 Dressing
The stone shall be dressed full or to the approved templates. Unless

otherwise specified, the exposed faces shall be fine chisel dressed. All
visible angles and edges shall be free from chipping.
802-10.3 Size of Stone
No stone shall either be less than 450 mm (18 inch) in length or less in
height than the height of the copings.
In cornices and string courses which do not extend right through walls,
every stone shall tail into the wall by at least as much as the projection
behind the face of the wall and in no case less than 6 inches. Coping
stone shall extend the entire depth of the coping, unless otherwise
specified or directed by the Engineer Incharge in writing.
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802-10.4 Joints
No joint shall be more than 3 mm (1/8 inch) in thickness.
802-10.5 Weathering and Throughting
All outside cornices, copings, corbels and similar projecting courses

shall be weathered on the top and throated underneath.
802.10.6 Dowels
Coping stones and other similar works are to be cramped or dowelled

and courses of pillars, skew back and similar works shall be joggled
whenever specified.
802-11 CONSTRUCTION REQUIREMENTS FOR ARCHES
802-11.1 General
Unless otherwise specified, all stone masonry in arches shall be

finished in workman like manner, true to dimensions and grades shown
on the drawings according to the following specifications.
802-11.2 Cutting, Dressing of Stone Centering
Stone to be cut and dressed shall follow the specification Section

802-6.2
802-11.3 Centering
Centering shall be strong enough to bear the weight of an arch without

any deflection. The surface of centering shall be correctly struck to the
curvature of the soffit of the arch.
802-11.4 Wedges and Sand Boxes
Centers of arches of over 1.5 meter (5 feet) span shall be erected on

wedges. Centers of over 3 meter (10 feet) span shall be on double
wedges and of these over 6 meter (20 feet) span on sand boxes so as to
allow the gradual lowering of centre.
802-11.5 Building of Arches
The building of arches shall not begin until the abutments have been
built to their full width and upto the level of skew backs. Arch work
shall be done evenly from both abutments, and as soon as the arch is
completed, masonry shall be built evenly on both sides to the height of
the crown so as to load the haunches.
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Stone masonry in arches shall conform to specifications under Section

802-3 to 802-5 for stone masonry work, except with the following
modification:-
a. In all arches, the recussoir joints shall be truly radial. Stone shall be
laid in full beds of mortar and shall be well rubbed and pressed into
their beds so as to squeeze out surplus mortar and level the joints as
thin as possible.
b. Joints in arches shall not exceed 6.3 mm (1/4 inch) in thickness at

any point. Radial joints in gauged arches shall not exceed 3 mm
(1/8 inch) thickness.
c. Skew backs shall be formed of stone correctly shaped to radiate

from the centre of curvature and shall not be packed with mortar of
chips. Before the building of an arch is started abutments shall be
exactly at the same level and skew backs in place.
d. For gauged arch work, the arch shall be laid cut full size on the
ground on lime plaster and all joints carefully marked out.
Templates shall then be made as a guide for the special shapes of
stones. Stones shall be carefully cut and then rubbed to the required
shape. All the stones for any arch shall be prepared in full and set
up dry on the ground before commencing work.
e. Flat arches shall be built in the same manner as gauged arches but
with all the recussoir joints converging on the apex of an
equilateral triangle described on the soffit of the arch. Cross joints
and extrados shall be parallel to the soffit. The arch shall be built
with a camber of 10 mm per meter (1/8 inch per feet of span).
f. Arches shall be built in concentric rings and each ring shall be

completed before work on the ring above is started. In all cases,
care shall be taken that the centre line of the stone face is radially
placed. The arch rings shall in all cases, be bonded together by
special bond stones.
802.11.6 Size of Stone
Unless otherwise specified, the height of each stone shall be equal to

the thickness of the arch upto 375 mm (15 inches). Above this two
stones may be used, but no stone shall be less than 150 mm (6 inch) in
height. The intrados of all stone shall be rectangular, no side being less
than 100 mm (4 inches) rehembold in skew arches.
802-11.7 Breaking joints
All stones in arches shall have their ends inside the walls squarely
dressed. All joints shall break with each other and no stone shall lie
over a circumferential joint by less than half the width of the extrados.
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802-12 FIXTURES
Fixtures shall be built in with the surrounding stone masonry in their

correct position in specified mortar. These shall be built in as the work
progresses and not inserted later on into space left for them.
802-13 LINTEL AND INSIDE STONE.
All lintels, not to be plastered over, shall be of the full width of the
wall in which they are laid, including the thickness of the plastered
face or faces.
802-14 OPENINGS.
Opening shall have flat or relieving arches or lintels spanning across

them as shown on the drawings or as specified.
802-15 CENTERING
The centering for all openings shall be strong enough to support lintels
or arches spanning the opening. They shall be subject to the approval
of the Engineer Incharge and shall remain in position till stone
masonry has set. No additional payment will be made to the Contractor
for this item of work.
802-16 PUTLOGS
Only headers shall be left out to allow a putlog to be inserted and not
more than one stone shall be left out for each putlog. Under no
circumstances shall putlogs be made immediately under or next to the
impost or skew back of arches.
802-17 ROUNDED CORNER
Corners shall be rounded where specified. (Such work shall be payable

separately in the case of exposed masonry but not in the case of
masonry to be plastered)
802-18 BED PLATES
Bed plates shall be provided under all beams and joints. They shall be
chisel dressed on all faces and conform to the dimensions given in the
drawings and shall be carefully laid having fine joints, with the
specified packing to give the correct level.
802-19 CRAMPS
Cramps, joggles and dowels shall be used whenever specified or

directed by the Engineer Incharge. Cramps shall be of copper or lead
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and shall be from 150 mm (6 inches) to 300 mm (12 inches) in length

9.5 mm (3/8 inch) to 25 mm (1 inch) in thickness and 25 mm (1
inches) to 50 mm (2 inches) in width, as specified. They shall have
each end turned at right angle copper cramps shall be forged, and set
with neat cement. Lead cramps shall be formed by running molten lead
into the dove-tail channels. Joggles and dowels shall be double wedge
form and made of copper, slate or similar stone and set in neat cement.
On no account iron cramps, joggles or dowels, whether galvanized or
otherwise shall be used.
802-20 COPINGS AND CORNERS
Coping stone shall be full size throughout, or dimensions indicated on

the drawings or as specified, if not shown on the drawing. Beds joints
and top shall be fine pointed. All copings shall be dowelled or
cramped, as specified, and the corners of pillars, skew backs and
similar work shall be joggled to the stone below, if so specified.
802-21 STRING COURSES
The string courses shall tail at least 225 mm (9 inches) into the work
with a full bearing for at least 100 mm (4 inches) and shall be paid for
at a rate per running meter or foot along the course. They shall also be
throated on the underside, if so directed by the Engineer Incharge.
802-22 PARAPET WALLS
Selected stones, squared and pitched to line and with heads dressed
shall be used in ends of parapet walls in all exposed angles and
corners. Headers shall be well interlocked and as many as possible
shall extend entirely through the wall. Both the headers and stretchers
in the two faces of wall shall be well interlocked in the heart and shall
comprise practically the whole volume of the wall. All interstices in the
wall shall be completely filled with cement grout or with spawls
completely surrounded with mortar or grout.
802-23 POINTING
The pointing or finishing of all joints shall be as shown on the

drawings or as specified in the special provisions but shall not be
leaner than 1:3 cement sand mortar.
When raked joints are called for, all mortar in exposed face joints and
beds shall be raked out squarely to the depth noted on the drawings.
The mortar in the joints on top surface shall be crowned slightly at the
centre of the masonry to provided drainage.
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802-24 WEEP HOLES
All walls and abutments below formation level shall be provided with
weep holes. Unless otherwise shown on the drawings or directed by the
Engineer Incharge. The weep holes shall be placed at the lowest points
where free outlet can be obtained and shall be spaced not more than 2
m (6 feet) centre to centre. In case of deeper walls/abutments, the weep
holes shall be placed in more than one row not to exceed the vertical
spacing from 2 meters (6 feet). In such cases, weep holes shall be
staggered in vertical planes.
802-25 PROTECTION AND WATERING
All stone masonry shall be protected during construction from the

effects of rain and frost by suitable covering. The masonry laid in
cement and lime shall be kept moist for a period of 10 days
802-26 CLEANING EXPOSED FACES.
Immediately after being laid, and while the mortar is fresh, all face
stone shall be thoroughly cleaned of mortar stains and shall be kept
clean until the work is completed. Before final acceptance and if
directed by the Engineer Incharge the surface of the masonry shall be
cleaned using brushes.
802-27 MEASUREMENTS.
All types of stone masonry shall be measured by volume. The unit of

measurement shall be one cubic meter (m3) or one hundred cubic feet
(cft).
Cornices and string course shall be measured by length. The unit of

measurement shall be one meter (m) or one feet (ft). Copings shall be
measured by volume. The unit of measurement shall be one cubic
meter (m3) or one hundred cubic feet (% cft).
802-28 RATE
The unit rate for each specific type of masonry shall be full
compensation for that type of masonry, which shall include furnishing
and placing of all materials, including mortar, and for all labour, tools,
equipment and incidentals necessary to complete the work prescribed
in this section, except steel anchors which shall be paid for at the
contract unit price per kilogram or per pound for reinforcing steel
under Section 821
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802.29 PAYMENT.
Item No.802-29.1 Ashlar Masonry Per cubic meter (m3) or one hundred
cubic feet (cft)
Item No.802-29.2 Course Rubble Per cubic meter (m3) or one hundred
masonry cubic feet (cft)
Item No.802-29.3 Random Rubble Per cubic meter (m3) or one hundred
Masonry cubic feet (cft)
Item No.802-29.4 Dry Rubble Per cubic meter (m3) or one hundred
Masonry cubic feet (cft)
Item No.802-29.5 Cornices, String Per cubic meter (m) or per feet
Courses.
Item No.802-29.6 Copings Per cubic meter (m3) or one hundred
cubic feet (cft)
Item No.802-29.7 Stone Masonry in Per cubic meter (m3) or one hundred
arches. cubic feet (cft)
****************
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SECTION 803
GABIONS
803-1 DESCRIPTION
This work shall consist of wire-mesh gabions, furnished and placed in

accordance with these specifications, and the specifications for the
other work items involved, and at the locations and in conformity with
lines and grades shown on the drawings or as directed by the Engineer
Incharge. The work in general, covers gabions used for construction of
retaining & breast walls and stream stabilization works.
803- 2 MATERIAL REQUIREMENTS
803-2.1 General
Gabions shall be enclosed by galvanized steel wire mesh, which shall

be supplied folded flat to facilitate transport and handling.
Gabions shall be furnished in accordance with the various lengths and

heights required by the drawings, or as directed by the Engineer
Incharge. If not otherwise required, all gabions shall be one meter (3.3
feet) in width. The length shall be multiples of 2,3 or 4 times the width
of the gabion and heights shall be 0.33 m, 0.66 m or 1.0 m (1.1 ft, 2.2
ft, 3.3 ft).
803-2.2 Wire
All wire shall be good commercial quality of steel and size as per
drawings coated with a prime western speller or equal (AASHTO M
120) applied at a rate of not less than 0.8 ounces per square foot (0.25
Kg/Sq. M) of uncoated wire.
Uniformity of coating shall withstand ten (10) one-minute dips by the

Preece Test in accordance with AASHTO T-66. “Uniformity of Coating
by the Preece Test (Copper Sulphate Dip) on Zinc Coated (Galvanized)
Iron or Steel Articles”. Wire mesh shall withstand 220 hours of
exposure before failure by rusting of any part when subjected to a salt
spray test in accordance with ASTM B 117.
The tensile strength of the wire shall be in the range of four thousand
(4000) to six thousand (6000) Kg./Sq. cm. And shall have an elasticity
to permit elongation of the mesh equivalent to minimum of ten (10) %
without reducing the gauge or tensile strength of the wire.
The minimum size of the wire used in fabrication of the gabion baskets
shall be as follows.
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Diameter US Steel
mm Wire Gauge
Body Wire (2.3) 11

Selvedge or Perimeter Wire (2.8) 09
Tying and Connecting Wire (1.95) 13
803-2.3 Fabrication
Gabions shall be in the form of rectangular baskets of the required

dimensions and shall be manufactured form wire as specified above.
Gabions shall be made of steel wire triple twisted forming a uniform
hexagonal mesh pattern with openings eight (8) cm (3 inches) by ten
(10) cm (4 inches) or ten (10) cm by twelve (12) cm (4” x 5”). The
edges shall be formed into securely connected salvages adequate to
prevent raveling. Individual basket ties and connections shall be made
by using a quantity of wire not less than 8 percent of the weight of
each basket.
When the gabion length exceeds its width, it shall have securely tied
diaphragms connect at all edges to form individual cells of equal
length and width. Diaphragms shall be of the same material and
manufactured as specified above for the gabions.
All the characteristics, values and figures given in the above

specifications are subject to the tolerance of plus or minus five(5)
percent.
803.2.4 Rock Fill
Fill for gabions shall consist of hard, durable rock pieces that will not
deteriorate when submerged in water or exposed to severe weather
conditions. Rock pieces shall be generally uniformly graded in sizes
ranging from twelve (12) cm (5”) to twenty (20) cm (8”)
The rock fill shall be of approved quality & from an approved source.
Installation shall be performed in a workmanlike manner as approved

by the Engineer Incharge. Beds for gabions shall be suitably leveled.
Gabions forming elements of structures shall be securely connected
along the complete length of top contact edges by mean of the above-
specified tying and connection wire.
Before the rock fill is placed the gabions shall be tensioned in such
manner as will permit proper shape, alignment and compaction of fill.
Rock fill for exposed faces of gabions walls shall be carefully selected
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for uniformity of size, and the pieces shall be hand placed to provide a
neat appearance as approved by the Engineer Incharge.
The vertical joints of gabion baskets shall be staggered as in running

bond brickwork.
803-4 MEASUREMENT AND UNIT RATE
The quantities to be paid for shall be measured as under:-
803-4.1 Wire Mesh
The galvanized steel wire mesh furnished, placed and accepted shall be
the theoretical number of kilograms or pounds calculated from the
weight per square meter or per square foot of mesh by the
manufacturer. The area of mesh to be measured shall be the net area of
the gabion in position.
803.4.2 Rock Fill
Fill for gabions shall consist of hard, durable rock pieces that will not
deteriorate when submerged in water or exposed to severe weather
conditions. Rock pieces shall be generally uniformly graded in sizes
ranging conditions. Rock pieces shall be generally uniformly graded in
sizes ranging from ten (10) cm to twenty (20) cm. Filled gabions shall
have a minimum density or one thousand three hundred sixty (1,360)
kg per cubic meter. Void spaces shall be evenly distributed and shall
not exceed a maximum of thirty (30) percent.
The rock shall meet the requirements of AASHTO M 63 except that

the Sodium Sulphate Soundness Loss shall not exceed nine (9) % after
five (5) cycles.
803-5 PAYMENT
Pay item No.803-5.1 Steel Wire mesh

For Gabions Per Kilogram (kg) or
Pound (Lbs)
Pay item No.803-5.2 Rock Fill in

Gabions Per cubic meter (m3) or
cubic feet (cft)
***************
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SECTION 811
PRE-STRESSED CONCRETE CONSTRUCTION
811-1 DESCRIPTION
This work shall consist of pre-stressing pre-cast or cast-in-place

concrete by furnishing, placing and tensioning of pre-stressing steel in
accordance with details shown on the drawing and as specified in these
general specifications and the special provisions or as directed by the
Engineer Incharge.
The work shall also include the furnishing and installation of any
appurtenant items necessary for the particulars pre-stressing system to
be used. It shall therefore include all operations required for the
manufacture of members consisting of form work, assembly for pre-
stressing cables, placing of cable sheaths in proper position provisions
of anchorages, fabrication of reinforcing steel work, placing and curing
cement concrete, transfer of stress, granting of duct holes and all other
operations necessary for the construction and erection of such a
member in place, all according to these specifications and according to
the lines, thickness, dimensions and notes shown on the drawings.
811-2 MATERIAL
This will comply with the requirements of Section 701. Cement

concrete Type D2 shall be used, unless or otherwise specified.
811-2.2 Reinforcing Steel
This will comply with the requirements of Section 821. Only deformed
steel bars shall be used
811-2.3 High Tensile Steel
This will comply with the requirements of Section 1061.
811-2.4 Core helix Metal Sheath, Pre-stressing Anchorages and Binding

Tape
These will conform to special specifications attached with tender

documents or as given on the drawings or as directed by the Engineer
Incharge.
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811-3 PRE-STRESSING EQUIPMENT
Hydraulic jacks shall be equipped with accurate pressure gauges. The

Contractor may select to substitute screw jacks or other types for
hydraulic jacks. In that case, proving rings or other approved devices
shall be used in connection with the jacks. All devices, whether
hydraulic jack gauges or otherwise, shall be calibrated so as to permit
the stress in the pre-stressing steel to be computed all times. A certified
calibration curve shall accompany each device. Safety measures shall
be taken by the Contractor to prevent accidents due to possible
breaking of the pre-stressing steel or the slipping of the grips during
the pre-stressing process.
811-4 PRE-STRESSING METHODS
811-4.1 General
The methods of pre-stressing to be used shall be optional with the

Contractor, subject to all requirements hereinafter specified.
The Contractor shall well in advance submit to the Engineer Incharge

for approval complete details of the methods, and equipment he
proposes to use in the pre-stressing operations. Such details shall
outline the method and sequence of stressing, complete specifications
and details of the pre-stressing steel and anchoring devices proposed
for use, anchoring stresses, type of enclosures, and all other data
pertaining to the pre-stressing operating, including the proposed
arrangement of the pre-stressing units in the members.
811.4.2 Pretensioning
The pretensioning elements shall be accurately held in position and

stressed by jacks. A record shall be kept of the jacking force and the
elongation produced thereby. Several units may be cast in one
continuous line and stressed at one time. Sufficient space shall be left
between ends of units, if necessary to permit access for cutting after
the concrete has attained the required strength. No bond stress shall be
transferred to the concrete, nor and anchorages released, until the
concrete has attained a compressive strength, as shown by cylinder
tests, of at least 280 Kg/cm2 (4000 Psi) and as approved by the
Engineer Incharge. Corresponding cube strength shall be 50
Kg/cm2(5000 psi).
811-4.3 Post-Tensioning.
Post tensioning of pre-stressing reinforcement shall not be commenced

until tests on concrete cylinders/cubes, manufactured of the same
concrete and cured under the same conditions, indicate that the
concrete of the particular member to be prestressed has attained a
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compressive strength of at least 280 Kg/cm2 (4000 psi) in case of

cylinder and 350 kg.cm2 (5000 psi) in case of cube testing.
After the concrete has attained the required strength the pre-stressing
reinforcement shall be stressed by means of jacks to the required
tension and stress transferred to the end anchorage(s). The tensioning
process shall be so conducted that the tension being applied and the
elongation of the pre-stressing elements may be measured at all times.
The friction loss in the elements, that is the difference between the
tension at the jack and the minimum tension in the pre-stressing steel
shall be determined by the formula.
Ft = 2) F1- (ace/d)]
Where
Ft = Total friction loss
F1 = Observed tension at the jack.
a= Cross-sectional area of the pre-stressing element.

c= Observed elongation of the element when the force
at the jack is F1
E= Secant modulus of elasticity of the element for the stress.
F1 = As determined from the stress-strain diagram of the element.
d= Distance from the jack to the point of lowest tension in the

element. Where jacking is done from both ends of the
members, the point of minimum tension is the centre of the
member. Where jacking is done from one end only, d is the
distance to the other end of the member.
A record shall be kept of gauge pressures and elongation at all times

and submitted to the Engineer Incharge for his approval.
811-5.1 General
Unless otherwise directed by the Engineer Incharge, the contractor

shall certify for the Engineer Incharge approval that a technician
skilled in the approved pre-stressing method will be available to the
Contractor to give aid and instruction in the use of the pre-stressing
equipment and installation of materials as may be necessary to obtain
the required results.
The tensioning process shall be conducted so that the tension being

applied and the elongation may be measured at all times.
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811-5.2 Construction Requirements for Pre-stressing Cables
a) General
Pre-stressing cable will be made out of high tensile steel wire,

core helix, metal sheath, pre-stressing anchorages and binding
tape.
b) Assembly
The cable shall be assembled by drawing the high tensile steel

wire through a metal spacer plate inserting the helix core and
taping or tying at close intervals.
c) Sheathing
The assembled cable shall be sheathed in a approved metal

sheath of internal diameter shown on the drawings. The sheath
shall be rigid and adequately strong to withstand handling and
placing of concrete without sagging between its supports. The
taping of the cables shall be removed as it is inserted into the
sheath.
d) Positioning
The cables in the sheaths shall be positioned accurately as

shown on the drawings and securely held in position both
horizontally and vertically while the concrete is being placed.
Unless self-joining sheath is used, all joints between sheathing
or between sheathing and anchorage shall be made with
approved couplers specially designed for this purpose. All
joints shall be adequately and securely taped to prevent the
ingress of grout from the concrete and/or any relative
displacement, which might cause difficulties when treading or
grouting the cables.
e) Anchorage
The female cone anchorage shall be securely wired to the form

work and the cable sheath slipped on the protruding part of the
female cone. The junction shall be well wrapped with plastic
tape to ensure water tightness.
f) Inspection
Every cable sheath shall be carefully inspected immediately

prior to concreting in order to ensure that the alignment is
correct, the joints are secure and the sheathing is undamaged.
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811-5.3 Placing Steel
All steel units shall be accurately placed in the position shown on the
drawings or directed by the Engineer Incharge and firmly held during
the placing and setting of the concrete.
Distance from the forms shall be maintained by stays, blocks, ties, or

hangers approved by the Engineer Incharge. Blocks for holding units
from contact with the forms shall be pre-cast mortar blocks of
approved shape and dimensions. Layers of units shall be separated by
mortar blocks or other equally suitable devices. Wooden blocks shall
not be left in the concrete.
Suitable horizontal and vertical spacers shall be provided, if required,

to hold the wires in place in true position in the enclosure.
811-5.4 Placing Concrete
Concrete shall be controlled, mixed, and handled as specified in

Section 701 unless otherwise specified herein.
Concrete shall not be deposited in the forms unit the Engineer Incharge
has inspected the placing of the reinforcement, conduits, anchorages,
and pre-stressing steel and has given his approval thereof.
The concrete shall be vibrated internally or externally, or both, as

ordered by the Engineer Incharge. The vibrating shall be done with
care in such a manner as to avoid displacement of reinforcing conduits,
or wires.
811-5.5 Stressing Cables
a) General
Cables shall be stressed by using jacks at both ends, or from

one end as specified. The sequence in which the cables are
stressed shall follow exactly the instructions shown on the
drawings or approved by the Engineer Incharge
b) Stressing Schedule
Stressing schedules are stipulated for all cables, given the

required cable extensions and the initial and final jack
pressures. These schedules are based on estimated friction and
other losses and on an assumed value of young’s modulus. This
value of the modulus shall be checked against that given on the
wire in manufacturers test certificate for each individual batch
of wire and the extensions shall be adjusted accordingly before
stressing is started after approval of the Engineer Incharge.
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c) Stressing Operation
Stressing operations shall be at all times under the personal

supervision of an Engineer experienced in this type of work.
During the operation there may be a possible difference of
approximately five percent in indicated stress between jack
pressure and elongation. In such an event the error shall be so
placed that the discrepancy will be on the side of a slight
overstress rather than under stress. In the event of an apparent
discrepancy between gauge pressure and elongation of as much
as ten percent, the entire operation shall be carefully checked
and the source of error determined before proceeding further.
d) Stressing Record
The stressing record shall be prepared and maintained on the

Performa approved by the Engineer Incharge. This Performa
shall be signed by the Contractor’s engineer and the authorized
representative of the Engineer Incharge. Copies will be
dispatched to various offices as mentioned on the Performa
soon after the stressing operation.
811-5.6 Grouting Cable Ducts.
After completion of stressing, the annular space between the sides of

cable and sides of duct shall be grouted in the following manners.
All duct holes shall be thoroughly cleaned before grouting. The holes
shall be flushed with water just prior to grouting and all surplus water
shall be removed by compressed air. With the grouting vent open at
one end of the core hole, grout shall be applied continuously under
moderate pressure at the other end until all entrapped air is forced out
through the open grout vent, as evidenced by a steady stream of grout
at that vent, where upon the open vent shall be closed under pressure.
The grouting pressure shall be gradually increased to at least 5.25
kg/cm2(75 psi) and held at this pressure for approximately 15 seconds,
and the vent shall then be closed.
The grout shall consist of neat Portland cement having a water cement
ratio of not more than 0.50. The consistency of the grout mixture
during operations shall be that of heavy paint. The grout shall be mixed
in a high speed motor driven mixer specially designed for the purpose
and shall then be sieved into a pump unit where it shall be
continuously mixed at a slow speed by means of a mechanical or hand
operated agitator. The pump unit shall be of the diaphragm type,
preferably motor driven, with a by –pass pipe to enable constant
circulation of grout except when injection is actually taking place.
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811-5.7 Cutting Wire
After all stressing operations are completed, the projecting wire ends
shall be cut off approximately 40 mm (1.5”) from the face of the
anchorage either by mechanical means for example with a high speed
cutting disc designed for this purpose or by using a very small and very
hot oxyacetylene flame for not more than 3 seconds per wire. If flame
cutting is used, it is of utmost importance to ensure that there is no
appreciable heating of the wire studs at the anchorages.
811-5.8 Making Good Recesses
After completing all grouting operations the various grout holes shall
be neatly plugged and the recesses at the anchorages shall be made
good with properly placed and compacted cement concrete Type ‘A’.
Recesses in beams at the end of diaphragm bars, any holes left by form
ties, and any other surface irregularities shall be carefully cleaned and
patched with non shrinking mortar.
811-5.9 Curing
This shall be done in accordance with specifications in section 701.
811-5.10 Handling
Pre-cast prestressed concrete members shall be transported in an

upright position and the points of support with respect to the member
shall be approximately the same during transportation and storage as
when the member is in its final position. In the event that the
Contractor deems it expedient to transport or store pre-cast members in
other than this position it should be done at his own risks.
Care shall be taken during storage, hoisting, and handling of he pre-

cast units to prevent cracking or damage. Units damaged by improper
storing or handling shall be replaced by the Contractor at his expense.
Prestressed structural members shall be constructed or placed in the

structure in conformity with the drawings and special provisions
governing the particular type of structure to be built or as directed by
811-6 MEASUREMENT
Prestressed beams, slabs and diaphragms constructed under this

Section and placed in proper position shall be measured in cubical
contents. The unit of measurement shall be one cubic meter (m 3) or one
cft.
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Lifting, transporting and placing pre-cast prestressed beams shall be

measured in cubical contents.
811-7 RATE
The unit rate for various items of work under this Section shall be full
compensation for all material, labour, equipment and operation
required for satisfactory completion of work under this section.
811-8 PAYMENT
Pay Item No.811-8.1 Prestressed Beam

of Specified Size Per Cubic meter (m3)
or cubic ft (cft)
Pay Item No.811-8.2 Prestressed diaphragm

of Specified Size Per Cubic meter (m3)
or cubic ft (cft)
Pay Item No.811-8.3 Prestressed Slab of

Specified thickness Per Cubic meter (m3)
or cubic ft (cft)
Pay Item No.811-8.4 Lifting, Transporting

And placing beam
diaphragms or slabs Per Cubic meter (m3)
etc. cubic ft (cft)
****************
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SECTION 821
REINFORCING STEEL WORK
821-1 DESCRIPTION
The work specified in this Section consists of furnishing and placing

structural port-land cement concrete, reinforcing steel of the quality,
type, size and quantity designated all as required by these
Specifications as shown on the drawing or directed by the Engineer
Incharge.
821-2 COMPOSITION
Mild steel shall contain copper between 0.2% and 0.5% and shall not
contain more than 0.06% of Phosphorous.
821-3 QUALITY
All finished mild steel (plain or deformed bars) shall be cleanly rolled.
It shall be free from cracks, surface flaws, Lamination roughness,
jagging and imperfect edges and all other defects and shall be finished
in a workmanlike manner. The steel reinforcement of deformed bars
shall conform to AASHTO-M-31,90 OR ASTM (A-615)-88.
821.4 TENSILE AND ELONGATION TESTS.
The tensile breaking strength of round bars of grade 40 and 60 shall

range between 482 N/mm2 to 621/Nmm2 (32 to 40 tons per square
inch) respectively
Tensile Requirements.
Grade-40 Grade-60
Tensile strength, min. N/mm2 (Psi) 483 (70.000) 621 (90.000)
Yield strength, min. N/mm2 (Psi) 276 (40.000) 414 (60.000)
Elongation shall be in range for 200mm (8.0) bar between 7% to 12%

minimum respectively as shown in the Table below:-
Bar No. Grade-40 Grade-60

3 11 9
4,5,6 12 9
7,8 - 8
9,10 - 7
11,14,18 - 7
Grade 40 bars are furnished only in sizes 3 through 6.
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821-5 YIELD POINT
The yield point of mild steel of 40 grade and 60 grade will be 276
N/mm2 (18 tons/square inch) and 414 N/mm2 (27 ton/square inch) for
the bar sizes as shown in previous table.
821-6 COLD BEND TESTS
For bend tests, except in the case of round bars 25mm (1 inch) in
diameter and under, the test piece when cold shall stand, from hammer
until the internal radius is not greater than 1-1/2 times the thickness of
the test piece and the sides are parallel. In the cases of round bars
25mm (1 inch) in diameter and under, the internal radius of bend shall
not be greater than the diameter of the bar.
Bend Test Requirements.
Pin Diameter for Bend Test a

Bar Designation No. d = Nominal diameter of specimen
Grade-40 Grade-60
3,4,5 3.5d 3.5d
6 5 d 5 d
7,8 - 5 d
9,10 - 7 d
11 - 7 d
14,18 (90°) - 9 d
ñ Test bends 180° unless noted otherwise

ñ d- nominal diameter of specimen.
821-7 YOUNG’S MODULUS (E)
The value of the E for steels used in structural works shall be of the
order of 21 x 104 N/mm2 (30 x 106 Lbs. Per square inch).
821-8 PROTECTION OF MATERIAL.
Steel reinforcement shall be stored above the surface of the ground

upon platforms from mechanical injury & surface deterioration caused
by exposure to conditions producing rust. When placed in the work it
shall be free from dirt rust scale, dust paint oil or other foreign
material.
821-9 BENDING.
The reinforcement shall be bent cold to the shapes as indicated on the

drawings.
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821.10 PLACING AND FASTENING.
Steel reinforcement shall be placed in the exact position, as shown on

the drawings before the concrete is poured and shall be held accurately
in place during the placing of concrete. Vertical stirrups shall always
pass around to main tension members and shall be accurately attached
thereto.
The reinforcing steel shall be spaced at proper distance from the face
of the forms by means of approved pre-cast mortar or concrete blocks
or other approved device.
All reinforcing steel shall be wired, welded or otherwise fastened

together at the intersections as shown on the drawings or as directed by
the Engineer Incharge. Where splices are authorized the bars shall be
rigidly clamped or wired in a manner approved by the Engineer
Incharge. The splice lap shall be as specified.
Before any concrete is placed all mortar shall be cleaned from the
reinforcement.
821-11 UNIT WEIGHT
The unit weights to be used for measurement of quantities of steel shall

be as shown in the following tables:
TABLE 821-1
DEFORMED BAR DESIGNATION NUMBERS, NOMINAL WEIGHTS,

NOMINAL DIMENSIONS AND DEFORMATION REQUIREMENT
Nominal Dimensions Deformation Requirement in.
Bar Nominal Diameter Cross- Perimeter Max Min Max Gap

Design weight (inch)z sectional (inch) average average (Chord of
ation (Lb/ft) Area spacing height 12.5% of
No. (inch2) Nominal
Perimeter)
3 0.376 0.375 0.11 1.178 0.262 0.015 0.143
4 0.668 0.500 0.20 1.571 0.350 0.020 0.191
5 1.043 0.625 0.31 1.963 0.437 0.028 0.239
6 1.502 0.750 0.44 1.356 0.525 0.038 0.286
7 2.044 0.875 0.60 2.749 0.612 0.044 0.334
8 2.670 1.000 0.79 3.142 0.700 0.050 0.383
9 3.400 1.128 1.00 2.544 0.790 0.056 0.431
10 4.303 1.270 1.27 3.900 0.889 0.064 0.487
11 5.313 1.410 1.56 4.430 0.987 0.071 0.540
14 7.650 1.693 2.25 5.320 1.185 0.085 0.648
18 13.60 2.257 4.00 7.090 1.580 0.102 0.864
TABLE 821-2
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UNIT WEIGHT FOR PLAIN ORDERED BARS

(Weight of imperial (Inch) bars in pounds per foot)
Size (inch) Weight per ft.(Lbs) Length per ton (ft)

¼ 0.1669 13421
5/16 0.2608 8590
3/8 0.3755 5965
7/16 0.5111 4383
½ 0.6676 3355
5/8 1.0431 2147
¾ 1.5021 4191
7/8 2.0445 1096
1 2.6704 839
1-1/8 3.3797 663
1-1/4 4.1724 537
1-1/2 6.0083 373
Note:- In case of mild steel bars rolling margin shall be as follows:
Description of Rolling margin above or below the Total rolling

material specified weight for individual bar margin (%)
(%)
Bars upto and
including 9.5 mm
(3/8 inch) diameter 4 8
of thickness.
Over 9.5 mm (3/8
inch Diameter or 2.5 5
thickness.
TABLE 821-3
DEFORMED REINFORCING BARS (Metric)
Bar Nominal Weight per Nominal cross Nominal
number diameter (mm) meter (kg/m) sectional area perimeter
(sq.mm.) (mm)
2 06.350 00.285 0032.28 019.96
3 09.520 00.5595 0070.87 029.92
4 12.700 00.9941 0129.03 039.905
5 15.875 01.5521 0200.00 049.86
6 19.050 02.2352 0283.87 059.84
7 22.220 03.0418 0387.09 069.82
8 25.400 03.9734 0509.67 079.81
9 28.650 05.0597 0645.15 090.02
10 32.260 06.4036 0819.34 101.35
11 35.810 07.9066 1006.43 112.52
14s 43.000 11.3844 1451.59 135.13
18s 57.330 20.2390 2580.60 180.09
TABLE 821-4
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DEFORMED REINFORCING BARS (FPS)
Bar Nominal Weight Nominal Nominal

Number Diameter (kg/m) Cross sectional area perimeter
(inch) (sq. inch) (inch)
2 0.250 00.167 0.05 0.787
3 0.375 00.376 0.11 1.178
4 0.500 00.668 0.20 1.571
5 0.625 01.043 0.31 1.963
6 0.750 01.502 0.44 2.356
7 0.875 02.044 0.60 2.749
8 1.000 02.670 0.79 3.142
9 1.128 03.400 1.00 3.544
10 1.270 04.303 1.27 3.990
11 1.410 05.313 1.56 4.430
14s 1.693 07.650 2.25 5.320
18s 2.257 13.600 4.00 7.090
Note:- Permissible variation for deformed bars is given as follows:-
Description of Rolling margin above or below the Total

Material Specified weight for individual Rolling
bar (%) Margin
(%)
Deformed bars 6 3.5
821-12 MEASUREMENTS
The quantity of reinforcing steel to be paid for under the section shall
be computed from Table 821-1 through 821-4 kg. The length to be
used in the calculation shall be detailed length to be paid for and as
The unit for measurement of steel shall be 100 Kg.
821-13 RATE
Reinforcement shall be measured in length separately for different

diameters as actually used in the work excluding overlaps. From the
length so measured the weight of reinforcement shall be calculated in
% Kg. Length shall include hooks at end. Wastage, overlaps, space
bars and binding wire/welding shall not be measured and cost of these
items shall be deemed to the included in the rates for reinforcement.
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821.14 PAYMENT.
Item No.821-14.1 Furnishing and placing

Plain reinforcing Steel bars Per % Kg.
Item No.821-14.2 Furnishing and placing

Deformed reinforcing steel bars Per % Kg.
****************
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SECTION 831
STRUCTURAL STEEL WORK
831-1 DESCRIPTION
The work specified in this Section consists of furnishing, preparing,

fabricating, assembling and erecting the following:
1. Steel Structures.
2. Structural steel portions of other structure.
3. Wrought iron.
4. Castings and forging.
5. Rivets, nut & bolts including washers used in the structures as
fasteners.
All the above mentioned works shall be done in accordance and in

conformity with the design and with the lines, grades, dimensions and
notes shown on the drawings.
Moreover the work will include all labor, materials, equipment and
required manufacturing processes such as shearing, grinding, cutting,
drilling, milling, shaping, straightening and welding along with heat
treatment and anti-rust treatment wherever required.
831-2 SPECIFICATIONS
The execution of above work shall conform to either of the following

specifications as agreed upon between the Engineer Incharge and the
contractor:
1) AASHTO
2) AWS D1.5 Bridge Welding Code.
3) ASTM.
4) British Standards.
However in these succeeding details the specs are based upon AASHTO
& ASTM
831-3 NOTICE OF BEGINNING OF WORK AND SUBMISSION OF

WORKING DRAWINGS:
The contractor shall give the Engineer Incharge ample notice (not less
than 10 days) of the beginning of work in the shop so that inspection
may be provided. The term shop means any premises where the
material is to be arranged/stacked and work of manufacturing is to take
place. Simultaneously the contractor shall submit to the Engineer
Incharge working drawings for steel structures etc. for approval prior to
initiation of manufacturing and use in construction. The working
drawings shall show details without any ambiguity so that there should
not be any disagreement at the time of manufacturing and erection of
steel structures etc.
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831-4 INSPECTION
The steel structure will be inspected at the fabrication site by the

Engineer Incharge. The contractor shall furnish to the Engineer
Incharge a copy of all shop orders and certified shop test reports. The
material to be used shall be made available to the Engineer Incharge so
that each piece can be examined. The Engineer Incharge shall have free
access at all time to any portion of the fabrication site where the
material is stored or where work on the material is being performed.
831-5 INSPECTING AUTHORITY
The Inspector shall have the authority to reject materials or

workmanship, which do not fulfill the requirements of these
specifications. In cases of dispute, the contractor may appeal to the
Engineer Incharge, whose decision shall be final.
The acceptance of any material or finished members by the Inspector

shall not be a bar to their subsequent rejection, if found defective.
Rejected materials and workmanship shall be replaced as soon as
possible or corrected by the contractor.
831-6 MATERIALS
All the steel materials used in the manufacturing/fabrication of steel

structures etc. shall conform to the following specifications:
1. All steel for use in main load-carrying member components

subject to tensile stresses shall conform to AASHTO M 270
(ASTM A 709).
2. Welded girders made of ASTM A 709, Grade HPS70W steels
shall be fabricated in accordance with the AASHTO Guide
Specifications for Highway Bridge fabrication with HPS70W
Steel, which supplements the ANSI/AASHTO/AWS D1.5
Bridge Welding Code.
Note: The Steel Materials used other than above should be of Grade 1
quality steel according to BS.15 or corresponding AASHTO
Specifications.
831-6.1 Carbon Steel
Unless otherwise specified, structural carbon steel for bolted or welded

construction shall conform to Structural Steel for Bridges, AASHTO M
270 (ASTM A 709) Grade 36.
831-6.2 High-Strength Low-Alloy Structural Steel
High strength low alloy steel shall conform to:

Structural Steel for Bridges, AASHTO M 270 (ASTM A 709) Grade 50
or 50W.
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831-6.3 High-Strength Low-Alloy, Quenched &Tempered Structural Steel

Plate.
High-strength, low-alloy quenched and tempered steel plate shall

conform to AASHTO M 270 (ASTM A 709) Grade 70W, or Grade
HPS70W.
831-6.4 High-Yield Strength, Quenched and Tempered Alloy Steel Plate
High-yield strength, quenched and tempered alloy steel plate shall

conform to:
(a) Structural Steel for Bridges, AASHTO M 270 (ASTM A 709)

Grades 100 or 100W.
(b) Quenched and tempered alloy steel structural shapes and
seamless mechanical tubing, meeting all of the mechanical and
chemical requirements of AASHTO M 207 (ASTM A 709)
Grade 100 or 100W steel, except that the specified maximum
tensile strength may be 140,000 psi for structural shapes and
145,000 psi for seamless mechanical tubing, shall be considered
as AASHTO M 270 (ASTM A 709) Grades 100 and 100W steel.
(c)
831-6.5 Eyebars
Steel for eyebars shall be of a weldable grade. These grades include

structural steel conforming to:
(a) Structural Steel for Bridges, AASHTO M 270 (ASTM A 709)

Grade 36.
(b) Structural Steel for Bridges, AASHTO M 270 (ASTM A 709)
Grade 50 and 50W.
831-6.6 Structural Tubing
Structural tubing shall be either cold-formed welded or seamless tubing

conforming to ASTM 500, Grade B or hot-formed welded or seamless
tubing conforming to ASTM 501.
831-7 HIGH-STRENGTH FASTENERS (RIVETS, NUT & BOLTS

INCLUDING WASHERS)
831.7.1 Material
High-strength bolts for structural steel joints shall conform to either
AASHTO M 164 (ASTM A 325) or AASHTO M 253 (ASTM A 490).
When high-strength bolts are used with unpainted weathering grades of
steel, the bolts shall be Type 3.
The maximum hardness for AASHTO M 164 (ASTM A 325) bolts 1

inch or less in diameter shall be 33 HRC.
Proof load tests (ASTM F 606 Method I) are required in accordance
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with Section 8.3 of AASHTO M 164, Galvanized bolts shall be wedge

tested after galvanizing. Proof load tests (AASHTO M 291) are
required for the nuts. The proof load tests for nuts to be used with
galvanized bolts shall be performed after galvanizing overtapping and
lubricating.
Except as noted below, nuts for AASHTO M 164 (ASTM A 325) bolts
shall conform to AASHTO M 291 (ASTM A 563) Grades DH, DH3, C,
C3 and D. Nuts for AASHTO M 253 (ASTM A 490) bolts shall
conform to the requirements of AASHTO M 291 (ASTM A 563)
Grades DH and DH3.
 Nuts to be galvanized (hot-dip or mechanically galvanized) shall

be heat treated Grade DH or DH3.
 Plain (un-galvanized) nuts shall have a minimum hardness of 89
HRB.
 Nuts to be used with AASHTO M 164 (ASTM A 325) Type 3
bolts shall be of Grade C3 or DH3. Nuts to be used with
AASHTO M 253 (ASTM A 490) bolts shall be of Grade DH3).
All galvanized nuts shall be lubricated with a lubricant containing a

visible dye. Black bolts must be oily to touch when delivered and
installed.
Washers shall be hardened steel washers conforming to the

requirements of AASHTO M 293 (ASTM F 436).
Note: In case of using Rivets the same specs will be applicable.
831-8 ALTERNATIVE FASTENERS
Other fasteners or fastener assemblies, such as those conforming to the

requirements of ASTM F 1852, which meet the materials,
manufacturing and chemical composition requirements of AASHTO M
164 (ASTM A 325) or AASHTO M 253 (ASTM A 490), and which
meet the mechanical property requirements of the same specification in
full sized tests and which has body diameter and bearing areas under
the head and nut, or their equivalent, not less than those provided by a
bolt and nut of the same nominal dimensions prescribed in AASHTO
Article 11.32.3, may be used, subject to the approval of the Engineer
Incharge. Such alternate fasteners may differ in other dimensions from
those of the specified bolts and nuts.
Subject to the approval of the Engineer Incharge, high-strength steel

lock-pin and collar fasteners may be used as an alternate for high-
strength bolts as shown on the plans. The shank and head of high-
strength steel lock-pin and collar fasteners shall meet the requirements
of AASHTO Article 11.3.2.3. Each fastener shall provide a solid shank
body of sufficient diameter to provide tensile and shear strength
equivalent to or greater than that of the bolt specified, shall have a cold
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forged head on one end, of type and dimensions as approved by the

Engineer Incharge, a shank length suitable for material thickness
fastened, locking groves, breakneck groove and pull grooves (all
annular grooves), on the opposite end. Each fastener shall provide a
steel locking collar of proper size for shank diameter used which, by
means of suitable installation tools, is cold swaged into the locking
grooves forming head for the grooved end of the fastener after the pull
groove section has been removed. The steel locking collar shall be a
standard product of an established manufacturer of lockpin and collar
fasteners, as approved by the Engineer Incharge.
831-9 STEEL CASTINGS
831-9.1 Mild Steel Castings
Steel castings for use in highway bridge components shall conform to

Standard Specifications for Steel Castings for Highway Bridges,
AASHTO M 192 (ASTM A 486) or Carbon-Steel Castings for General
Applications, AASHTO M 103 (ASTM A 27). The Class 70 or Grade
70-36 of steel, respectively, shall be used unless otherwise specified.
831-10 IRON CASTINGS
831-10.1 Materials
(1) Gray Iron Castings –Gray iron castings shall conform to the
Specification for Gray Iron Castings AASHTO M 105 (ASTM
A 48), Class No.30 unless otherwise specified.
(2) Ductile Iron Castings –Ductile iron castings shall conform to the
specifications for Ductile Iron Castings, ASTM A 536, Grade
60-40-18 unless otherwise specified. In addition to the specified
test coupons, test specimens from parts integral with the
castings such as risers, shall be tested for castings weighing
more than 1,000 pounds to determine that the required quality is
obtained in the castings in the finished condition.
(3) Malleable Castings – Malleable castings shall conform to the
specifications for Malleable Iron Castings, ASTM A 47, Grade
No.35018 shall be furnished unless otherwise specified.
831-10.2 Workmanship and Finish
Iron castings shall be true to pattern in form and dimensions, free from
pouring faults, sponginess, cracks, blow holes and other defects in
positions affecting their strength and value for the service intended.
Castings shall be boldly filleted at angles and the arrises shall be sharp
and perfect.
831-10.3 Cleaning
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All castings must be sandblasted or otherwise effectively cleaned of

scale and sand so as to present a smooth, clean and uniform surface.
831-11 FABRICATION
831-11.1 Identification of Steels During Fabrication
The Contractor’s system of assembly-marking individual pieces and the

issuance of cutting instructions to the shop (generally) by cross-
referencing of the assembly marks shown on the shop drawings with the
corresponding item covered on the shop purchase order) shall be such
as to maintain identity of the original piece. The Contractor may furnish
from stock, material that can be identified by heat number and shop test
report.
During fabrication, up to the point of assembling members, each piece
of steel, other than Grade 36 steel, shall show clearly and legibly its
specification.
Any piece of steel, other than Grade 36 steel, which prior to assembling
into members, will be subject to fabricating operations such as blast
cleaning, galvanizing, heating for forming or painting which might
obliterate marking shall be marked for grade by steel die stamping or by
a substantial tag firmly attached. Steel die stamps shall be low stress-
type.
Upon request, by the Engineer Incharge, the Contractor shall furnish an
affidavit certifying that throughout the fabrication operation the
identification of steel has been maintained in accordance with this
specification.
831-11.2 Storage of Materials
Structural material, either plain or fabricated shall be stored above the

ground on platforms, skids, or other supports. It shall be kept free from
dirt, grease and other foreign matters and shall be protected as far as
practicable from corrosion.
831-11.3 Plates
1. Unless otherwise shown on the plans, steel plates for main

members and splice plates for flanges and main tension
members, not secondary members, shall be cut and fabricated so
that the primary direction of rolling is parallel to the direction of
the main tensile and/or compressive stresses.
2. Sheared edges of plate more than 5/8” in thickness and carrying
calculated stress shall be planed, milled, ground or thermal cut
to a depth of ¼ inch.
3. Visual inspection and repair of plate cut edges shall be in
accordance with the current ANSI/AASHTO/AWS D1.5 Bridge
Welding Code.
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831-12 OXYGEN CUTTING
Oxygen cutting of structural steel shall conform to the requirements of

the current ANSI/AASHTO/AWS D1.5 Bridge Welding Code.
831-13 WELDING
1) Welding materials, welding, welder qualification and inspection

of welding shall conform to the requirements of the American
Welding Society Structural Welding Code or other accepted
codes as shown on the plans or as approved by the Engineer
Incharge Correction of weld faults shall be carried out in the
presence of the Engineer Incharge.
2) Surfaces and edges to be welded shall be smooth, uniform,
clean and free of defects, which would adversely affect the
quality of the weld. Edge preparation shall be done in
accordance with the current ANSI/AASHTO/AWS D1.5 Bridge
Welding Code.
3) The presence of any of the following defects will result in
rejection of the weld:
(i) Cracks, regardless of length or location.
(ii) Overlaps, lack of penetration or incomplete fusion.
(iii) Inclusions of slag, porosity and other deleterious
materials less than 1.5 mm in size, unless well
dispersed.
(iv) Inclusions outside the size limits given in Table 831-
13-1.
(v) Any line of inclusions in a length of 12T that have an
aggregate length greater than T.
Table showing weld defect limits:

Welded plate thickness Maximum allowable defect dimension
(T) (mm) (mm)
19 or less 6.5
19-57 T/3
Greater than 57 19
831-13.1 Removal of Defects
Defects pointed out by the Inspector/the Engineer Incharge shall be

removed by mechanical means or by oxygen grooving as per given
instructions after which the joints shall be re-welded.
831-14-1 Construction Drawings
Construction drawings, consisting of shop drawings and erection and

other working drawings showing detail dimension, sizes of material and
other information and data necessary for the complete fabrication and
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direction of the steel work shall be approved by the Engineer Incharge.

Such approval constitutes approval of design only and shall not relieve
the contractor of responsibility for accuracy of details.
831-14-2 Shop Assembly
The component parts of a built member shall be assembled, drift pinned

to prevent lateral movement and firmly bolted to draw the parts into
close contact before reaming, drilling or riveting is begun. The
members shall be free from twists, bends or other deformations.
Preparatory to shop connecting full size punched material, the holes
shall be cleaned for admission of rivets or bolts by reaming.
End connection angles, stiffener, angles, etc. shall be carefully adjusted

to correct locations and rigidly bolted, clamped or otherwise firmly held
in place until connected.
Connecting parts assembled in the shop for the purpose of reaming or

drilling holes in field connection shall be match-marked and a diagram
showing such marks shall be furnished.
831-14.3 Field Assembly
The field assembling of the component parts of structure shall be done

by the use of methods and appliances not likely to produce injury by
twisting, bending or otherwise deforming the metal. No members
slightly bent or twisted shall be put in place until its defects are
corrected and any members seriously damaged in handling will be
rejected. Before the beginning of the field riveting the structure shall be
adjusted to correct grade and alignment.
831-15 METHOD OF MEASUREMENT
The quantity of Structural Steel entering into and becoming a part of the
completed structure and accepted by the Engineer Incharge shall be the
computed weight in CWT or hundred Kilograms. The length to be used
in the calculation shall be detailed length to be paid for and as shown on
the drawings.
Structural steel weight shall be the computed weight, assuming the

weight per cubic foot or cubic meter of the various metals to be as
follows:
1- Structural and Rivet Steel 7849 Kg./m3(490 lbs. per Cu.ft.)

2- Steel Castings and Forging 7849 Kg./m3 (490 lbs. per Cu.ft.)
3- Gray Iron Castings 7208 Kg./m3 (450 lbs. per Cu.ft.)
4- Wrought Iron 7769 Kg./m3 (485 lbs. per Cu.ft.)
5- Malleable Iron 7529 Kg./m3 (470 lbs. per Cu.ft.)
The weights of rolled shapers, bars, plates and pipe railings shall be
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computed on the basis of the nominal weight as given in manufacturers

catalogue using the dimensions shown on the drawings.
No deductions from the computed weight of rolled steel shall be made

for caps, clips, sheared edges, punching, borings, drilling, milling and
no allowances shall be made for the weight of weld metal or for overrun
in weight.
The weights of shop and field rivets and of high strength bolts,
including nuts and washers, all as installed and accepted shall be
computed on the basis of average lengths in accordance with the
following tables:
Diameter of Rivet or Bolt 19 mm(3/4”) 22 mm(7/8”) 25 mm(1”)
Weight per 100 Nos. 22.7 Kg. 45.4 Kg. 68 Kg.

(50 lbs.) (100 lbs.) (150 lbs.)
The quantity to be paid for shall be the original drawing quantity,

determined as provided above.
831-16 RATE
The unit rate shall be full compensation for all the works described in
this Section, including cutting, drilling, riveting, bolting and welding
except that the weight of rivets and nut bolts including washers shall be
accounted for as described above. No separate payment will be made
for false work or other erection expenses.
831-17 PAYMENT
Pay Item No. 831-17-1 1- Steel Structures.

2- Structural steel portions of other
structure.
3- Wrought iron.
4- Castings and forging.
Per 100 Kg.
Pay Item No. 831-17-2 Rivets, nuts & bolts including washers
used in the structures as fasteners.
Per Kg.
**************
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SECTION 841
WELL FOUNDATION
841-1 DESCRIPTION
The work specified in this section shall consist of furnishing all plants,
equipment, materials, labour and the performance of all operations in
connection with the construction of a well to be used as foundation for
the pier or abutment of a bridge and comprises of five separate
operations, the casting of a well curb in proper position, the erection of
well staining by stages, the sinking of the erected curb and well
staining to the required elevation, the proper plugging of wells and
sand filling, all according to the lines, dimensions and form shown on
the drawings.
841-2 CONSTRUCTION REQUIREMENTS.
841-2.1 Construction Equipment
It shall conform to the requirements of Section 201.
841-2.2 Structural Steel Work
841-2.3 Reinforcing Steel Works.
841.2.5 Masonry Work.
841-3 WELL CURBS
841-3.1 Cutting edge
Cutting edge of the well curb will be structural steel prefabricated and
supplied in segments convenient for site assembly by bolting together
as per lines and dimensions shown on the drawings. The segments of
the cutting edge shall be interchangeable. The fitting together shall be
checked at the fabrications work by the assembly of at least two
complete cutting edges, formed of segments, chosen at random before
these are accepted for dispatch to the site of work. None of the steel
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work is to be painted and no surface preparation is called for other than

the removal of rust and loose adhering mill scale.
841-3.2 Reinforcing Steel Work
Reinforcing steel work in the cutting edge will be properly bolted to

the structural steel and placed and assembled as shown on the
drawings.
Cement concrete for the cutting edge will be Type C and shall be
finished to the form and dimensions shown on the drawings.
841-4 WELL STAINING
Well staining shall be made either of brick masonry work in (1:3)

cement mortar according to dimensions shown on the drawings or
Portland cement concrete type C as indicated and of the form
dimensions as shown on the drawings.
Reinforcing steel work will continue from the cutting edge into the
well staining with spacers made of structural steel work consisting of
mild steel plates of the size and dimensions as shown on the drawings.
841-5 WELL SINKING
Well sinking process includes all operations required to sink the well in
position and to the required elevation.
841-5.1 Positioning
Each well curb shall be correctly positioned in place and approved by

the Engineer Incharge before commencement of further work
.
841-5.2 Support
Well curbs shall be adequately supported to prevent shift or tilt during

the initial operations of excavation and sinking whether the well has
been started on made up ground or in water or in excavation.
841-5.3 Excavation for Sinking
The soil from inside the well shall be removed by mechanical grabbing
or other device as approved by the Engineer Incharge. The accuracy of
sinking well be the responsibility of the contractor.
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841-5.4 Dewatering
The water from inside the well will be pumped out and the
arrangements will be commensurate with the site conditions. The
Contractor will be responsible for the safety of plant and labour during
these operations.
841-5.5 Use of Explosive.
Explosives shall not be generally used as an aid for well sinking.

However in cases where explosives are to be used prior approval of the
Engineer Incharge shall be obtained. Blasting of any sort shall only be
done in the presence of Engineer Incharge and not before the
concrete/masonry in the staining has hardened sufficiently and is more
than 7 days old. For wells going through boundary strata requiring use
of explosives as an aid for well sinking, the entire inside surface of the
well curb staining upto a minimum height of 1 meter (3 feet) above the
well curb shall be protected by a 6 mm (1/4 inch) thick mild steel plate
which shall be suitably stiffened.
841-5.6 Shift and Tilt
The limit of departure from true vertical position of any well shall not
exceed one unit measured horizontally in a vertical distance of sixty
units. The maximum horizontal displacement of any well away from
its correct position shall not exceed 150 mm (6 inch).
It will be entirely the responsibility of the Contractor to keep the tilt

and shift within the specified tolerances. If the above limits are
exceeded, the contractor will be required to carry out at his own cost
suitable approved remedial measures to overcome the adverse effects,
such as tilts and shifts.
In any case the maximum pressure at the base of the foundations after
accounting for all tilts and shifts has to remain within the specified
limits. In all these case suitable penalty for substandard work will be
imposed on the Contractor as per decision of the Engineer Incharge.
841-5.7 Kentledge
The sinking effort can be augmented by the use of sand bags, rails and
other heavy weights and as aid in correcting errors of tilts and
horizontal shift. All precautions will have to be taken to prevent
damage to well staining during sinking.
841-5.8 Limit of Sinking
Each and every well shall be sunk to the elevation indicated on the
drawings or to any other elevation approved by the Engineer Incharge
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according to the nature of soil strata. Suitable trips 10 cm (4 inch) wide

shall be provided in cement plaster along the depth of the well to be
sunk and provided with permanent markings of vertical distances with
zero starting from the bottom of the curb.
841-5.9 Soil Samples
The Contractor will have adequate arrangements to the satisfaction of

the Engineer Incharge to collect disturbed samples of soil at every 1.5
meter (5 feet) elevation and at every change of soil strata and to deliver
it is a proper bag to the representative of the Engineer Incharge. The
contractor will also be required to obtain three samples of the natural
soil at the elevation at which the well curb has been stopped and
another samples 3 meter (10 feet) below that elevation before he is
allowed to plug the well. These samples are required to ascertain the
bearing capacity of the soil below the curb to evaluate the design
assumptions.
841-6 PLUGGING OF WELL
When the well has reached the final elevation to which it is to sink and
has been approved by the Engineer Incharge the bottom of the well
will be plugged by depositing type C concrete under water using 10%
additional quantity of cement. To prevent segregation the concrete
shall be carefully placed in the final position by means of a clamp
bucket or other approved method and shall not be allowed to be
disturbed after being deposited. The concrete shall be placed in one
continuous operation.
841-7 SAND FILLING
When the well bottom has been plugged the well hole be filled with
sand as specified and shown on the drawings. The sand shall be free
from deleterious substance.
841-8 TRANSOM SLAB
When the well bottom has been plugged the well top will be provided
with a transom slab made of Portland cement concrete type C and
Reinforcing Steel work all according to the lines dimensions and forms
841-9 METHOD OF MEASUREMENT AND UNIT RATE
841-9.1 General
For the various items of work constructed under this Section

measurements shall be made as specified in the respective sections.
The quantity to be paid for shall be the original drawings quantity
measured as provided in the respective section, except where change
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has been made by the Engineer Incharge and other has been given in
writing. No measurements or other allowances will be made for work
or material for forms, supports, bracings, kentledge and pumping.
841-9.2 Well Sinking
For any item of work carried out under this head, measurements shall
be made for the volume of material excavated, out of the job. The
volume of well sinking shall be computed on the basis of outer
dimension of the well curb and below the bed level as shown on the
drawings. The unit of measurement for well sinking will be per cubic
meter (m3) or per hundred cubic feet (% cft), excavated as measured
above. Separate measurements shall be recorded for each type of strata
excavated that is ordinary soil, hard soil, shingle or gravel and
separately for different sub-soil water conditions that is ‘dry’ or wet
sinking.
The unit rate for sinking of wells shall include excavation, pumping,
support, bracing, kentledge, tilt correction, soil sampling, all according
to the requirements given under section 841-5
841-9.3 Structural Steel Work for Cutting Edge
It shall be measured and paid for according to provisions in Section

831.
841-9.4 Portland cement Concrete Type C
For well curb staining, plugging of well and transom slab shall be
measured and paid for according to the provision of Section 701. The
unit rate includes the cost of 10% extra cement to be used where
required.
841-9.5 Reinforcing Steel Work
For well curb staining and transom slab shall be measured and paid for
according to the requirements of Section 821.
841-9.6 Brick Work
Brick work in (1-3) cement mortar for steining shall be measured and
paid for according to the requirements of Section 801.
841-9.7 Filling Sand
Sand in well hole shall be measured as the volume of well hole

required to be filled. The unit of measurement shall be one cubic meter
or hundred cubic feet (ft3).
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841-10 PAYMENT
Item 841-10.1 Structural steel work for

Cutting edge Per 100 Kg
Item 841-10.2 Cement concrete type C

for Well Curb plugging of
well Steining or Transom
Slab Per Cu. meter(m3)
or per cubic
foot (cft)
Item 841-10.3 Furnishing and placing

(a) Deformed Reinforcing
Steel Bars for Well Curbs,
Steining and Transom Slab. Per 100 Kg
(b) Furnishing and placing

intermediate grad
Deformed Reinforcing
Bars for Well Curbs,
and Transom Slab. Per 100 Kg
(c) Furnishing and placing

Mild Steel Reinforcing
bars for Ring Beams and
Well steining. Per 100 Kg
Item 841-10.4 Dry sinking of Wells in

(a) ordinary Soil Per Cubic meter
(m3) or per
hundred Cubic
feet (% cft)
(b) Dry sinking of Wells in

hard Soil Per Cubic meter
(m3) or per
hundred Cubic
feet (% cft)
(c) Dry sinking of Wells in hard

strata such as Shingle,
Gravel etc. Per Cubic meter
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(m3) or per
hundred Cubic
feet (% cft)
(d) Wet sinking of Wells in

ordinary Soil Per Cubic meter
(m3) or per
hundred Cubic
feet (% cft)
(e) Wet sinking of Wells in

Cohesive Soil (“C” more
than 5) Per Cubic meter
(m3) or per
hundred Cubic
feet (% cft)
(f) Wet sinking of Wells in

hard strata such as
Shingle Gravel etc. Per Cubic meter
(m3) or per
hundred Cubic
feet (% cft)
Item 841-10.5 Sand filling in Well holes Per Cubic meter

(m3) or per
hundred Cubic
feet (% cft)
***************
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SECTION 851
DRILLED/BORED PILES
851.1 DESCRIPTION
This work shall consist of constructing drilled/bored foundation piles, with or

without bell footings, including the placing of reinforcing steel and concrete
all in accordance with the plans, these specifications and the special
provisions.
851.2 MATERIALS
851.2.1 Concrete
Concrete shall conform to the requirements of Section 701. The concrete shall
be class D2 unless otherwise specified.
NOTE: The concrete mix for drill/bored piles shall be fluid, consolidate
under self-weight, be resistant to segregation, and have a set time that will
assure that fluidity is maintained throughout the shaft concrete placement, and
removal of temporary casing. The time for initial set of the shaft concrete
should generally not exceed 12 hours.
851.2.2 Reinforcing Steel
Reinforcing steel shall conform to the requirements of 821" Reinforcing

Steel."
851.2.3 Casing
Casing which are required to be incorporated as part of the permanent work

shall conform to the requirements of Section 831, "Steel Structures." Steel
shall be AASHTO M 183 (ASTM A 36), AASHTO M 270 (ASTM A 709)
Grade 36, or ASTM A 252, Grade 2 or 3 unless otherwise specified.
851.3 CONSTRUCTION
851.3.1 Protection of Existing Structures
All precautions shall be taken to prevent damage to existing structures and

utilities. These measures shall include but are not limited to, selecting
construction methods and procedures that will prevent excessive caving of the
piles excavation, monitoring, and controlling the vibrations from the driving of
casing or sheeting, drilling of the piles or from blasting, if permitted.
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851.3.2 Construction Sequence
Where drilled/bored piles are to be installed in conjunction with embankment

placement, they shall be constructed after the placement of the fill and
completion of any specified settlement periods unless shown otherwise in the
plans.
851.3.3 General Methods and Equipment
Excavations required for piles and bell footings shall be constructed to the
dimensions and elevations shown on the plans. The methods and equipment
used shall be suitable for the intended purpose and materials encountered.
Generally either the dry method, wet method, temporary casing method, or
permanent casing method will be used as necessary to produce sound, durable
concrete foundation piles free of defects. The permanent casing method shall
be used only when required by the plans or authorized by the Engineer
Incharge. When a particular method of construction is required on the plans,
that method shall be used. If no particular method is specified for use, the
Contractor shall select and use the method, as determined by site conditions,
subject to approval of the Engineer Incharge that is needed to properly
accomplish the work.
The excavation shall be completed in a continuous operation. If the

excavation operation is stopped, the pile cavity shall be protected by
installation of a safety cover. It shall be the Contractor's responsibility to
ensure the safety of the piles excavation, surrounding soil and the stability of
the side walls. A temporary casing, slurry or other methods approved by the
Engineer Incharge shall be used if necessary to ensure such safety and
stability. Excavations shall not be left open overnight unless cased full depth.
The Contractor shall use appropriate means such as a cleanout bucket or air
lift to clean the bottom of the excavation of all piles. When unexpected
observations are encountered, the Contractor shall notify the Engineer
Incharge promptly. The removal of such obstructions and the construction of
excavation shall be as directed by the Engineer Incharge.
851.3.4 Dry Construction Method
The dry construction method shall be used only at sites where the groundwater
table and site conditions are suitable to permit construction of the pile in a
relatively dry excavation, and where the sides and bottom of the pile remain
stable without any caving, sloughing or swelling and may be visually
inspected prior to placing the concrete. The dry method consists of drilling the
pile excavation, removing accumulated water and loose material from the
excavation, and placing the pile concrete in a relatively dry excavation.
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851.3.5 Wet Construction Method
The wet construction method shall be used at sites where a dry excavation
cannot be maintained for placement of the pile concrete. This method consist
of using water or mineral slurry to contain seepage, groundwater movement,
and to maintain stability of the hole perimeter while advancing the excavation
to final depth, placing the reinforcing cage and pile concrete. This procedure
may require desanding by means of a bailing bucket, air lift, submersible
pump, cleanout bucket or other devices; and requires placing the pile concrete
with a tremie. Temporary surface casings shall be provided to aid pile
alignment and position, and to prevent sloughing of the top of the pile
excavation, unless it is demonstrated to the satisfaction of the Engineer
Incharge that the surface casing is not required from the ground surface to a
point in the pile excavation where sloughing of the surrounding soil does not
occur.
851.3.6 Temporary Casing Construction Method
The temporary casing construction method shall be used at all sites where the
stability of the excavated hole and / or the effects of groundwater cannot be
controlled by other means.
Temporary casing may be installed by driving or vibratory procedures in

advance of excavation to the lower limits of the caving material.
Temporary casings shall be removed while the concrete remains workable

(i.e., a slump of 4 inches or greater). As the casing is being withdrawn, a 5 foot
minimum head of fresh concrete in the casing shall be maintained so that all
the fluid trapped behind the casing is displaced upward without contaminating
the pile concrete. The required minimum concrete head may have to be
increased to counteract groundwater head outside the casing. Movement of the
casing by rotating, exerting downward pressure and tapping to facilitate
extraction or extraction with a vibratory hammer will be permitted. Casing
extraction shall be at a slow, uniform rate with the pull in line with the pile
axis.
851.3.7 Permanent Casing Construction Method
The permanent casing construction method shall be used only when required
by the plans. This method generally consists of driving or drilling a casing to a
prescribed depth before excavation begins. If full penetration cannot be
attained, the Contractor may either excavate material within the embedded
portion of the casing or excavate a pilot hole ahead of the casing until the
casing reaches the desired penetration. The pilot hole shall be no larger than
one-half the diameter of the pile and shall be centered in the pile. Over
reaming to the outside diameter of the casing shall not be performed unless
specifically stated in the Plans or Special Provisions.
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The casing shall be continuous between the elevations shown on the plans.
Unless shown on the plans, the use of temporary casing in lieu of or in
addition to the permanent casing shall not be used.
After the installation of the casing and the excavation of the pile is complete,
the reinforcing steel shall be placed, followed by the placement of the pile
concrete. After the permanent casing has been filled with concrete, any voids
between the pile excavation and the casing shall be pressure grouted with
cement grout. The method of pressure grouting the voids shall be submitted to
the Engineer Incharge for approval.
Note:- Pressure grouting is required to assure contact (bearing) between the casing
and any surrounding soil layer that is utilized for lateral support.
851.3.8 Alternative Construction Methods
The Contractor may propose alternative methods to prevent caving and control
ground water. Such proposals, accompanied by supporting technical data, and
are subject to the approval of the Engineer Incharge.
851.3.9 Excavation
The bottom elevation of the drill/bored pile shown on the plans may be
adjusted during construction if the Engineer Incharge determines that the
foundation material encountered during excavation is unsuitable or differs
from that anticipated in the design of the drilled pile.
When specified or shown in the plans, the Contractor shall take soil samples or
rock cores to determine the character of the material directly below the pile
excavation. The Engineer Incharge will inspect the samples or cores and
determine the final depth of required pile excavation.
Excavated materials which are removed from the pile excavation and any
drilled/bored fluids used shall be disposed of in accordance with the special
provision and in compliance to the directions of Engineer Incharge.
When bell footings are shown in the plans they shall be excavated to form a
bearing area of the size and shape shown.
851.3.10 Casings
Casings shall be metal, clean, watertight, and of ample strength to withstand

both handling and driving stresses and the pressure of both concrete and the
surrounding earth materials. The outside diameter of casing shall not be less
than the specified diameter of the pile. The inside diameter of the casing shall
not be greater than the specified diameter of the pile plus 6 inches unless
otherwise approved by the Engineer Incharge. Where the minimum thickness
of the casing is specified in the Plans, it is specified to satisfy structural design
requirements only. The Contractor shall increase the casing thickness as
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necessary to satisfy the casing strength requirements for handling and driving
stresses.
Temporary casings may be corrugated and non-watertight if conditions permit.
851.3.11 Slurry
Slurry used in the drilling process shall be a mineral slurry. The slurry shall
have both a mineral grain size that will remain in suspension and sufficient
viscosity and gel characteristics to transport excavated material to a suitable
screening system. The percentage and specific gravity of the material used to
make the suspension shall be sufficient to maintain the stability of the
excavation and to allow proper concrete placement. The level of the slurry
shall be maintained at a height sufficient to prevent caving of the hole.
The mineral slurry shall be premixed thoroughly with clean fresh water and
adequate time allotted for hydration prior to introduction into the pile
excavation. Adequate slurry tanks will be required when specified. No
excavated slurry pits will be allowed when slurry tanks are required on the
project without written permission of the Engineer Incharge. Adequate
desanding equipment will be required when specified. Steps shall be taken as
necessary to prevent the slurry from "setting up" in the pile excavation, such
as, agitation, circulation, and adjusting the properties of the slurry.
Control tests using suitable apparatus shall be carried out by the Contractor on
the mineral slurry to determine density, viscosity, and pH. An acceptable range
of values for those physical properties is shown in the following table:
Range of Values (at 68º F)

Time of Time of
Property Slurry Concreting Test
(Units) Introduction (In Hole) Method
Density 64.3 to 64.3 to Density
(pcf) 69.1 75.0 Balance
Viscosity 28 to 45 28 to 45 Marsh
(seconds Cone
per quart) PH paper or
pH 8 to 11 8 to 11 meter
Notes
(a) Increase density values by 2 pcf in salt water.
(b) If desanding is required; sand content shall not exceed 4% (by volume) at
any point in the shaft excavation as determined by the American
Petroleum Institute sand content test.
Tests to determine density, viscosity, and pH values shall be done before or

during the shaft excavation to establish a consistent working pattern.
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Prior to placing shaft concrete, the Contractor shall use an approved slurry-
sampling tool to take slurry samples from the bottom and at midheight of the
shaft. Any heavily contaminated slurry that has accumulated at the bottom of
the shaft shall be eliminated. The mineral slurry shall be within specification
requirements immediately before shaft concrete placement.
851.3.12 Excavation Inspection
The Contractor shall provide equipment for checking the dimensions and
alignment of each shaft excavation. The dimensions and alignment shall be
determined by the Contractor under the direction of the Engineer Incharge.
Final shaft depth shall be measured after final cleaning.
No more than ½ inch of loose or disturbed material shall be present at the

bottom of the shaft just prior to placing the concrete for end bearing shafts. No
more than 2 inches of loose or disturbed material shall b present for side
friction shafts. End bearing shafts shall be assumed unless otherwise noted in
the Plans. The excavated shaft shall have the approval of the Engineer
Incharge prior to proceeding with construction.
851.3.13 Reinforcing Steel Cage Construction and Placement
The reinforcing steel cage consisting of the steel shown on the plans plus cage
stiffener bars, spacers, centralizers, and other necessary appurtenance shall be
completely assembled and placed as a unit immediately after the shaft
excavation is inspected and accepted and prior to shaft concrete placement.
The reinforcing cage shall be rigidly braced to retain its configuration during
handling and construction. Individual or loose bars shall not be used. The
Contractor shall show bracing and any extra reinforcing steel required for
fabrication of the cage on the shop drawings.
The reinforcement shall be carefully positioned and securely fastened to

provide the minimum clearances listed below, and to ensure that no
displacement of the reinforcing steel bars occurs during placement of the
concrete.
Place bars as shown in the contract plans with concrete cover as shown in the
table below:
Concrete Cover
Shaft Casing Casing
Diameter Uncased Remains Withdrawn
2' 0" or less 3" 3" 4"

3' 0" 3" 3" 4"
4' 0" 4" 4" 4"
5' 0" or larger 6" 6" 6"
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Rolling spacers for reinforcing steel shall be used to minimize disturbance of

the side walls of the shaft and to facilitate removal of the casing during
concrete placement.
Concrete spacers or other approved non-corrosive spacing devices shall be
used at sufficient intervals not exceeding 5 feet along the shaft to insure
concentric location of the cage within the shaft excavation. When the size of
the longitudinal reinforcing steel exceeds one inch diameter, the maximum
spacing of the spacing devices may be increased to 10 feet (maximum).
Approved non-corrosive bottom supports shall be provided for the rebar cage
to assure that the reinforcing is the proper distance above the base.
Other types of spacers may be used if approved by the Engineer Incharge. The
Contractor shall submit details of the proposed reinforcing cage spacers along
with the shop drawings. Shaft excavation shall not be started until the
Contractor has received approval from the Engineer Incharge for the
Contractor proposed spacers.
851.3.14 Concrete Placement, Curing and Protection
Concrete placement shall commence immediately after completion of

excavation, inspection and setting of the reinforcing cage, and shall continue
in one operation, to the top of the shaft, or to a construction joint identified on
the plans. An unforeseen stoppage of work may require a horizontal
construction joint during the shaft construction. For this reason, an emergency
construction joint method shall be submitted to the Engineer Incharge for
approval prior to starting shaft construction.
For concrete to be placed in water slurry shall be placed through a tremie

using methods specified in Section 701, "Underwater Placement." Before
placing any new concrete against concrete deposited in water, the Contractor
shall remove all scum, laitance, loose gravel and sediment on the upper
surface of the concrete deposited in water and chip off any high spots on the
upper surface of the existing concrete that would prevent any subsequent shaft
reinforcing from being placed in the position required by the Plans.
Concrete to be placed in dry shafts shall be placed and consolidated as
specified below.
At all times prior to the placing of concrete in the driven shells, the Contractor
shall have available a suitable light for the inspection of each shell throughout
its entire length.
No concrete shall be placed until all driving within a radius of 15 feet of the
pile has been completed, or all driving within the above limits shall be
discontinued until the concrete in the last pile cast has set at least 5 days.
Concrete for cast-in-place piles shall be dense and homogeneous. Vibration or

rodding of concrete for cast-in-place piles will only be required to a depth of 5
feet below the ground surface.
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Concrete shall be placed for each pile in a single continuous operation with the
flow of concrete directed down the center of the pile so as to consolidate the
concrete by impact. Accumulations of water in shells shall be removed before
the concrete is placed. After the concrete has hardened, the top surface shall be
cut back to remove laitance and to expose the aggregate.
For shafts less than 8 feet in diameter, the elapsed time from the beginning of
concrete placement in the shaft to the completion of placement shall not
exceed 2 hours unless a shaft concrete retarder is approved by the Engineer
Incharge. For shafts 8 feet and greater in diameter, the concrete placing rate
shall be not less than 30 feet of shaft height per each 2-hour period providing a
4 inch minimum slump is maintained throughout the concrete placement based
on tests of a trial mix. The concrete mix shall be of such design that the
concrete remains in workable plastic state throughout the 2-hour placement
limit.
When the top of shaft elevation is above ground, the portion of the shaft above
ground shall be formed with a removable form or with a permanent casing,
when specified.
The shaft concrete shall be vibrated or rodded to a depth of 5 feet below the
ground surface except where soft uncased soil or slurry remaining in the
excavation will possibly mix with the concrete.
After placement, the temporarily exposed surfaces of the shaft concrete shall
be cured in accordance with the provisions in Section 701, "Cement
Concrete."
For at least 48 hours after shaft concrete has been placed, no construction
operations that would cause soil movement adjacent to the shaft, other than
mild vibration, shall not be conducted. Mild vibration is defined as operation
of light construction equipment adjacent to the shaft.
Portions of drilled shafts exposed to a body of water shall be protected from

the action of water by leaving the forms in place for a minimum of seven days
after concrete placement or until the shaft concrete reaches a minimum
strength of 2500 psi, whichever occurs first.
851.3.15 Construction Tolerances
The following construction tolerances shall be maintained in constructing

drilled shafts:
(a) Piles shall be constructed so that the center at the top of the Pile is within the
following tolerances:
Pile Diameter Tolerance

2'-0" or less 2"
3' to 4' 3"
4' to 5' 4"
5'-0" or larger 5"
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(b) Piles shall be within 1% of plumb. For rock excavation, the allowable
tolerance can be increased to 1.5% max.
(c) After all the pile concrete is placed, the portion of the pile reinforcing steel
cage embedded in the pile shall be no more than 1 inch above no more than 3
inches below plan position, and shall be at least 1 inch below the top the pile.
(d) The minimum diameter of the drilled/bored pile shall be the diameter shown
on the plans for diameters 24 inches or less and not more than 1 inch less than
the diameter shown on the plans for diameters greater than 24 inches. The
maximum pile diameter shall be the diameter shown in the plans, plus 6
inches.
(e) The bearing area of bells shall be excavated to the plan bearing area as a
minimum. All other dimensions for the bells shall be as shown on the
approved working drawings.
During drilling or excavation of the pile, the Contractor shall make frequent
checks on the plumbness, alignment, and dimensions of the pile. Any
deviation exceeding the allowable tolerances shall be corrected with a
procedure approved by the Engineer Incharge.
Drilled/bored pile excavations constructed in such a manner that the concrete

pile cannot be completed within the required tolerances are unacceptable.
Correction methods shall be submitted by the Contractor for the approval.
Approval will be obtained before continuing with the drilled/bored pile
construction.
Materials and work necessary to effect correction for out-of-tolerance

drilled/bored pile excavations shall be furnished at no additional cost to the
Department.
851.3.16 Integrity Testing
When called for in the special provisions, the completed pile will be subjected
to nondestructive testing to determine the extent of any defects that may be
present in the pile.
Work and materials required for testing which are to be furnished by the
Contractor shall be as shown on the plans or special provisions.
In the event testing discloses voids or discontinuities in the concrete which, as

determined by the Engineer Incharge, indicate that the drilled pile is not
structurally adequate, the pile shall be rejected. The Contractor shall repair,
replace or supplement the defective work in a manner approved by the
Engineer Incharge. The construction of additional drilled piles shall be
discontinued until the Contractor demonstrates the adequacy of the pile
construction method and any subsequent method changes to the satisfaction of
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the Engineer Incharge. Any additional work required as a result of pile defects
shall be at no additional cost to the Department.
851.4 DRILLED SHAFT LOAD TESTS
When the contract documents include load testing, all tests shall be completed
before construction of any production drilled/bored piles. The Contractor shall
allow two weeks after the last load test for the analysis of the load test data by
the Engineer Incharge before specified drilled/bored pile tip elevations will be
provided for production piles.
The locations of load test piles and reaction piles, the maximum loads to be
applied, the test equipment to be furnished by the Contractor, and the actual
performance of the load testing shall be as shown on the plans or specified in
the special provisions.
After testing is completed, the test piles and any reaction piles, if not also to be
used as production piles, shall be cutoff at an elevation 3 feet below the
finished ground surface. The portion of the piles cutoff shall be disposed of by
the Contractor is a manner approved by the Engineer Incharge.
NOTE: Load tests should generally be performed as a separate contract in

advance of the bridge construction.
851.5.1 Measurement
851.5.1.1 Drilled Pile
Drilled piles, complete in place, will be measured by the linear foot for each
size of pile listed in the schedule of bid items. Measurement will be along the
centerline of the pile based on the tip and pile cut-off elevations shown on the
plans or as ordered by the Engineer Incharge.
851.5.1.2 Bell Footings
Bell footings will be measured by the cubic yard, computed by using the
dimensions and shape specified on the plans or as revised by the Engineer
Incharge. The bell shall consist of the volume outside the plan or authorized
dimensions of the pile, which will extend to the bottom of the bell for the
purpose of measurement.
851.5.1.3 Test Piles
Test Piles of the specified diameter will be measured from the elevation of the
ground at the time drilling begins, by the linear foot of acceptable test pile
drilled.
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851.5.1.4 Test Bells
Test bells will be measured by the cubic yard computed by using the
dimensions specified in Article 851.5.1.2.
851.5.1.5 Exploration Holes
Exploration holes will be measured by the linear foot measured from the
bottom of pile elevation to the bottom of the exploration hole, for each
authorized hole drilled.
851.5.1.6 Permanent Casing
Permanent casing will be measured by the linear foot for each size of casing
authorized to be used. Measurement will be along the casing from top of
casing or top of pile, whichever is lower, to the bottom of the casing at each
pile location where permanent casing is authorized and used.
851.5.1.7 Load Tests
Load tests will be measured by the number of load tests performed for each
designated pile load capacity.
851.5.2 Payment
851.5.2.1 Drilled/Bored Pile
Drilled/Bored Piles will be paid for at the contract price per linear foot for
drilled/bored pile of the diameter specified. Such payment shall be considered
to be full compensation for all costs involved with pile excavation, disposal of
excavated material, and the furnishing and placing of concrete, including all
labor, materials, equipment, temporary casing, and incidentals necessary to
complete the drilled/bored piles, except for steel reinforcement.
851.5.2.2 Steel Reinforcement
Steel reinforcement will be paid at the contract price per kilogram.
851.5.2.3 Bell Footings
Bell footings constructed to the specified or authorized dimensions will be

paid for at the contract unit price per cubic yard for bell footings. Such
payment shall be full compensation for excavation, and concrete beyond the
diameter of the drilled/bored pile including all labor, materials, equipment and
incidentals necessary to complete the bell footings.
851.5.2.4 Test Piles
Test piles of the specified diameter will be paid for at the contract unit price
per linear foot for test piles. Such payment shall be full compensation for
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excavation and concrete or backfill material including all labor, materials,

equipment, and incidentals necessary to complete the test piles, except cost of
steel reinforcement.
851.5.2.5 Test Bell
Test bells for the diameter and shape specified or authorized and approved will
be paid for at the contract unit price per cubic meter or cubic foot for test bells.
Such payment shall be full compensation for excavation and concrete or
backfill material including all labor, materials, equipment, and incidentals
necessary to complete the test bells.
851.5.2.6 Exploring Holes
When specified or shown in the plans, exploration holes for soil samples or
rock cores will be paid for at the contract unit price per linear meter or foot for
exploration holes. Such payment shall be full compensation for drilling or
coring the holes, extracting and packaging the samples or cores and delivering
them to the Department and all other expenses necessary to complete the
work.
851.5.2.7 Permanent Casing
Permanent casing will be paid for at the contract unit price per linear foot for
permanent casing. Such payment shall be full compensation for furnishing and
placing the casing above the costs attributable to the work paid for under
associated pay items.
Load tests will be paid for at the contract unit price for each load test. Such
payment shall be full compensation for all costs related to the performance of
the load tests including load test report.
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SECTION 852
DRIVEN FOUNDATION PILES
852.1 DESCRIPTION
This work shall consist of furnishing and driving foundation piles of the
type and dimensions designated on the plans or in the special provisions
including cutting off or building up foundation piles when required. This
specification also covers providing test piles and performing loading tests.
Piling shall conform to and be installed in accordance with these
specifications, and at the location, and to the elevation, penetration, and
bearing capacity shown on the plans or as directed by the Engineer
Incharge.
Any improperly driven, broken, or otherwise defective pile shall be

corrected to the satisfaction of the Engineer Incharge by removal and
replacement, or the driving of an additional pile, at no extra cost.
Except when test piles are required, the Contractor shall furnish the piles
in accordance with dimension shown on the plans or special provisions.
When test piles are required, the pile lengths shown on the plans are for
estimating purposes only and the actual lengths to be furnished for
production piles will be determined by the Engineer Incharge after the test
piles have been driven. The lengths given in the Engineer Incharge’s order
list will include only the lengths anticipated for use in the completed
structure. The Contractor shall, without added compensation, increase the
lengths shown or ordered to provide for fresh heading and for such
additional length as may be necessary to suit the method of operation.
852.2 MATERIALS
852.2.1 Steel Piles
The structural steel used for foundation piling shall conform to the
Specification for Structural Steel for Bridges, AASHTO M 270 (ASTM A
709) Grades 36, 50, or 50W, or to the Specification for Piling for Use in
Marine Environment, ASTM A 690.
852.2.1.1 Painting
Unless otherwise provided, when steel piles or steel pile shells extend
above the ground surface or water surface they shall be protected by the
paint system specified for painting new steel in a high pollution or coastal
environment as described in Section 1081, “Painting.” This protection
shall extend from an elevation 2 feet below the water or ground surface to
the top of the exposed steel.
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852.2.1.2 Concrete Piles
Concrete piles shall consist of either precast concrete piles or cast-in-

place concrete piles cast in steel shells. Portland cement concrete shall
conform to the requirements in Section 701, "Portland Cement Concrete,”
and unless another class is shown on the plans or specified, concrete shall
be class D2. Reinforcing steel shall conform to the requirements of
Section 821, “Reinforcing Steel,” and prestressing shall conform to the
requirements of Section 811, “Prestressing.”
Steel shells for cast-in-place concrete piles shall be of not less than the
thickness shown on the plans. The Contractor shall furnish shells of
greater thickness if necessary to provide sufficient strength and rigidity to
permit driving with the equipment selected for use without damage, and
to prevent distortion caused by soil pressures or the driving of adjacent
piles. The shells shall also be watertight to exclude water during the
placing of concrete. The shells may be cylindrical or tapered, step-
tapered, or a combination of either, with cylindrical sections.
852.3 MANUFACTURE OF PILES
852.3.1 Precast Concrete Piles
852.3.1.1 Forms
Forms for precast concrete piles shall conform to the general

requirements for concrete from work as provided in Section 701, Forms
shall provide access for vibration and consolidation of the concrete.
852.3.1.2 Casting
Handling and placing of concrete shall conform to the requirements of

Section 701, and these specifications. Special care shall be taken to place
the concrete so as to produce satisfactory bond with the reinforcement
and avoid the formation of “stone pockets,” honeycomb, or other such
defects.
To secure uniformity, the concrete in each pile shall be placed

continuously and shall be compacted by vibrating or by other means
acceptable to the Engineer Incharge. The forms shall be overfilled, the
surplus concrete screeded off, and the top surface finished to a uniform,
even texture similar to that produced by the forms.
852.3.1.3 Finish
Portions of piling exposed to view shall be finished in accordance with

the provisions governing the finishing of concrete columns. Other piling
shall not be finished except as set forth above.
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852.3.1.4 Curing and Protection
Concrete piles shall be cured as provided in Section 701, "Portland

Cement Concrete" Structure,” and these Specifications. As soon as the
piles have set sufficiently to avoid damage, they shall be removed from
the forms and stacked in a curing pile separated from each other by wood-
spacing blocks.
No pile shall be driven until at least 21 days after casting and, in cold
weather, for a longer period as determined by the Engineer Incharge.
Concrete piles for use in sulfate soils shall be cured for not less than 30
days before being used. Concrete shall be protected from freezing until
the compressive strength reaches at least 0.8 fc´.
852.3.1.5 Prestressing
Prestressing of concrete piles shall conform to the provisions of Section

811, “Presressing.”
852.3.1.6 Storage and Handling
Removal of forms, curing, storing, transporting, and handling of precast

concrete piles shall be done in such a manner as to avoid excessive
bending stresses, cracking, spalling, or other injurious results.
Piles to be used in sulfate soils shall be handled so as to avoid surface

abrasions or other injuries exposing the interior concrete.
852.3.2 Cast-in-Place Concrete Piles
852.3.2.1 Inspection of Metal Shells
At all times prior to the placing of concrete in the driven shells, the
Contractor shall have available a suitable light for the inspection of each
shell throughout its entire length.
852.3.2.2 Placing Concrete
No concrete shall be placed until all driving within a radius of 15 feet of

the pile has been completed, or all driving within the above limits shall be
discontinued until the concrete in the last pile cast has set at least 5 days.
Concrete for cast-in-place piles shall be dense and homogeneous. In lieu

of the provisions concerning vibration of concrete as specified in Section
701, vibration or rodding of concrete for cast-in-place piles will only be
required to a depth of 5 feet below the ground surface.
Concrete shall be placed for each pile in a single continuous operation

with the flow of concrete directed down the center of the pile so as to
consolidate the concrete by impact. Accumulations of water in shells
shall be removed before the concrete is placed. After the concrete has
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hardened, the top surface shall be cut back to remove laitance and to
expose the aggregate as specified in Section 701.
852.4 DRIVING PILES
852.4.1 Pile Driving Equipment
Driving equipment that damages the piling shall not be used.
All pile driving equipment, including the pile driving hammer, hammer
cushion, drive head, pile cushion and other appurtenances to be furnished
by the Contractor shall be approved in advance by the Engineer Incharge
before any driving can take place. Pursuant to obtaining this approval, the
Contractor shall submit, at least 2 weeks before pile driving is to begin, a
description of pile driving equipment to the Engineer Incharge.
Whenever the bearing capacity of piles is specified to be determined by

Method B, “Wave Equation Analysis,” the Contractor shall also submit
calculations, based on a wave equation analysis, demonstrating that the
piles can be driven with reasonable effort to the ordered lengths without
damage.
The following hammer efficiencies shall be used in a wave equation

analysis:
Hammer Type Efficiency in Percent

Single acting air/steam 67
Double acting air/steam 50
Diesel 72
In addition to the other requirements of these specifications, the criteria

which the Engineer Incharge will use to evaluate the driving equipment
consists of both the required number of hammer blows per inch and the
pile stresses at the required ultimate pile capacity. The required number of
hammer blows indicated by calculations at the required bearing capacity
shall be between 3 and 10 per inch for the driving equipment to be
acceptable.
In addition, for the driving equipment to be acceptable, the pile stresses,

which are indicated by the calculations, to be generated by the driving
equipment shall not exceed the values where pile damage impends. The
point of impending damage in steel piles is defined herein as a
compressive driving stress of 90% of the yield point of the pile material.
For concrete piles, tensile stresses shall not exceed 3 multiplied by the
square root of the concrete compressive strength f´ c, plus the effective
prestress value, i.e., (3√ f´c. + prestress), and compressive stresses shall
not exceed 85% of the compressive strength minus the effective prestress
value i.e. (0.85 f´c. – prestress). For timber piles, the compressive driving
stress shall not exceed three times the allowable static design strength
listed on the plans. These criteria will be used in evaluating calculated
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results to determine acceptability of the Contractor’s proposed driving

system.
During pile driving operations, the Contractor shall use the approved
system. Any change in the driving system will only be considered after
the Contractor has submitted revised pile driving equipment data and
calculations. The Contractor will be notified of the acceptance or rejection
of the driving system changes within 7 calendar days of the Engineer
Incharge receipt of the requested change. The time required for
submission, review, and approval of a revised driving system shall not
constitute the basis for a contract time extension to the Contractor.
Approval of pile driving equipment shall not relieve the Contractor of his
responsibility to drive piles, free of damage, to the bearing and tip
elevation shown on the plans or specified in the special provisions.
852.4.1.1 Hammer
852.4.1.1.1 General
Piles may be driven with a drop hammer, an air/steam hammer, or diesel

hammer conforming to these specifications.
Pile driving hammers, other than drop hammers, shall be of the size
needed to develop the energy required to drive piles at a penetration rate
of not less than 0.10 inch per blow at the required bearing value.
852.4.1.1.2 Drop Hammers
Drop (gravity) hammers shall not be used for concrete piles or for piles
whose design load capacity exceeds 30 tons. When gravity hammers are
permitted, the ram shall weigh not less than 2,000 pounds and the height
of drop shall not exceed 15 feet. In case shall the ram weight of gravity
hammers be less than the combined weight of the drive cap and pile. All
gravity hammers shall be equipped with hammer guides to insure
concentric impact on the drive head or pile cushion.
852.4.1.1.3 Air Steam Hammers
The weight of the striking part of air/steam hammers used shall not be
less than 1/3 the weight of pile and drive cap, and in no case shall the
striking part weigh less than 2,750 pounds. The plant and equipment
furnished for air/steam hammers shall have sufficient capacity to
maintain, under working conditions, the pressure at the hammer specified
by the manufacturer.
852.4.1.1.4 Diesel Hammers
Open-end (single acting) diesel hammers shall be equipped with a device

to permit the Engineer Incharge to determine hammer stroke at all times
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during pile driving operations. Closed-end (double acting) diesel

hammers shall be equipped with a bounce chamber pressure gauge, in
good working order, mounted near ground level so as to be easily read by
the Engineer Incharge. A correlation chart of bounce chamber pressure
and delivered hammer energy shall be provided by the Contractor.
852.4.1.1.5 Vibratory Hammer
Vibratory or other pile driving methods may be used only when

specifically allowed by the Special Provisions or in writing by the
Engineer Incharge. Except when pile lengths have been determined from
load test piles, the bearing capacity of piles driven with vibratory
hammers shall be verified by redriving the first pile driven in each group
of 10 piles with an impact hammer of suitable energy to measure the pile
capacity before driving the remaining piles in the group.
852.4.1.1.6 Additional Equipment or Methods
In case the required penetration is not obtained by the use of a hammer

complying with the above minimum requirements, the Contractor may be
required to provide a hammer of greater energy or, when permitted, resort
to supplemental methods such as jetting or preboring.
852.4.1.2 Driving Appurtenance
852.4.1.2.1 Hammer Cushion
All impact pile driving equipment except gravity hammers shall be

equipped with a suitable thickness of hammer cushion material to prevent
damage to the hammer or pile and to insure uniform driving behaviour.
Hammer cushions shall be made of durable, manufactured materials,
which will retain uniform properties during driving. Wood, wire rope, and
asbestos hammer cushions shall not be used. A striker plate shall be
placed on the hammer cushion to insure uniform compression of the
cushion material. The hammer cushion shall be inspected in the presence
of the Engineer Incharge when beginning pile driving and after each 100
hours of pile driving. The hammer cushion shall be replaced by the
Contractor before driving is permitted to continue whenever there is a
reduction of hammer cushion thickness exceeding 25% of the original
thickness.
852.4.1.2.2 Pile Drive Head
Piles driven with impact hammers shall be fitted with an adequate drive
head to distribute the hammer blow to the pile head. The drive head shall
be axially aligned with the hammer and the pile. The drive head shall be
guided by the leads and not be free-swinging. The drive head shall fit
around the pile head in such a manner as to prevent transfer of torsional
forces during driving while maintaining proper alignment of hammer and
pile.
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For steel and timber piling, the pile heads shall be cut squarely and a
drive head provided to hold the longitudinal axis of the pile in line with
the axis of the hammer.
For precast concrete and prestressed concrete piles, the pile head shall be
plane and perpendicular to the longitudinal axis of the pile to prevent
eccentric impacts from the drive head.
For special types of piles, appropriate driving heads, mandrels or other

devices shall be provided so that the piles may be driven without damage.
852.4.1.2.3 Pile Cushion
The heads of concrete piles shall be protected by a pile cushion when the
nature of the driving is such as to unduly injure them. When plywood is
used, the minimum thickness placed on the pile head prior to driving shall
not be less than 4 inches. A new pile cushion shall be provided if, during
driving, the cushion is either compressed more than one-half the original
thickness or begins t burn. The pile cushion dimensions shall be such as
to distribute the blow of the hammer throughout the cross section of the
pile.
852.4.1.2.4 Leads
Pile driving leads which support the pile and the hammer in proper
positions throughout the driving operation shall be used. Leads shall be
constructed in a manner that affords freedom of movement of the hammer
while maintaining alignment of the hammer and the pile to insure
concentric impact for each blow. The leads shall be of sufficient length to
make the use of a follower unnecessary and shall be so designed as to
permit proper alignment of battered piles.
852.4.1.2.5 Followers
Followers shall only be used when approved in writing by the Engineer

Incharge, or when specifically allowed in the special provisions. When a
follower is permitted, in order to verify that adequate pile penetration is
being attained to develop the desired pile capacity, the first pile in each
bent and every 10th pile driven thereafter shall be furnished sufficiently
long and shall be driven full length without a follower. The follower and
pile shall be held and maintained in equal and proper alignment during
driving. The follower shall be of such material and dimensions to permit
the piles to be driven to the length determined necessary from the driving
of the full length piles. The final position and alignment of the first two
piles installed with followers in each sub-structure unit shall be verified to
be in accordance with the location tolerances specified in Article 4.4.3
before additional piles are installed.
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852.4.1.2.6 Jets
Jetting shall only be permitted if approved in writing by the Engineer

Incharge or when specially allowed in the special provisions. When
jetting is not required, but approved after the Contractor’s request, the
Contractor shall determine the number of jets and the volume and
pressure of water at the jet nozzles necessary to freely erode the material
adjacent to the pile without affecting the lateral stability of the final in-
place pile. The Contractor shall be responsible for all damage to the site
caused by jetting operations. When jetting is specifically required in the
special provisions, the jetting plant shall have sufficient capacity to
deliver at all times a pressure equivalent to at least 100 pounds per square
inch at two ¾-inch jet nozzles. In either case unless otherwise indicated
by the Engineer Incharge, jet pipes shall be removed when the pile tip is a
minimum of 5 feet above prescribed tip elevation and the pile shall be
driven to the required bearing capacity with an impact hammer. Also, the
Contractor shall control, treat if necessary, and dispose of all jet water in a
manner satisfactory to the Engineer Incharge.
852.4.2 Preparation for Driving
852.4.2.1 Site Work
852.4.2.1.1 Excavation
In general, piles shall not be driven until after the excavation is complete.
Any material forced up between the piles shall be removed to the correct
elevation before concrete for the foundation is placed.
852.4.2.1.2 Preboring to Facilitate Driving
When required by the special provisions, the Contractor shall prebore

holes at pile locations to the depths shown on the plans, specified in the
special provisions, or allowed by the Engineer Incharge. Prebored holes
shall be smaller than the diameter or diagonal of the pile cross section and
sufficient to allow penetration of the pile to the specified depth. If
subsurface obstructions, such as boulders or rock layers are encountered,
the hole diameter may be increased to the least dimension which is
adequate for pile installation. Any void space remaining around the pile
after completion of driving shall be filled with sand or other approved
material. The use of spuds (a short strong driven member which is
removed to make a hole for inserting a pile), shall not be permitted in lieu
of preboring, unless specifically allowed by the special provisions or in
852.4.2.1.3 Predrilled Holes in Embankments
Please to be driven through newly constructed embankments shall be

driven in holes drilled or spudded through the embankment when the
depth of the new embankment is in excess of 5 feet. The hole shall have a
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diameter of not less than the greatest dimension of the pile cross section
plus 6 inches. After driving the pile, the space around the pile shall be
filled to ground surface with dry sand or pea gravel. Material resulting
from drilling holes shall be disposed of as approved by the Engineer
Incharge.
852.4.2.2 Preparation of Piling
In addition to squaring up pile heads prior to driving, piles shall be further

prepared for driving as described below.
852.4.2.2.1 Pile Shoes and Lugs
Pile shoes used to protect all types of piles when hard driving is expected
and pile lugs used to increase the bearing capacity of steel piles shall be
of the types shown on the plans and shall be used at the locations
specified or ordered by the Engineer Incharge. Steel pile shoes shall be
fabricated from cast steel conforming to ASTM A 27.
Such pile shoes or lugs used at the option of the Contractor shall be of a
type approved by the Engineer Incharge.
852.4.3 Driving
Piles shall be driven to the minimum tip elevations and bearing capacity
shown on the plans, specified in the special provisions or approved by the
Engineer Incharge. Piles that heave more than ¼-inch upward during the
driving of adjacent piles shall be redriven.
852.4.3.1 Driving of Test Piles
Test piles and piles for static load tests, when shown on the plans, shall be
furnished to the lengths ordered and driven at the locations and to the
elevations directed by the Engineer Incharge before other piles in the area
represented by the test are ordered or driven. All test piles shall be driven
with impact hammers unless specifically stated otherwise in the special
provisions or on the plans. In general, the ordered length of test piles will
be greater than the estimated length of production piles in order to
provide for variation in soil conditions. The driving equipment used for
driving test piles shall be identical to that which the Contractor proposes
to use on the production piling. Approval of driving equipment shall
conform to the requirements of these Specifications. Unless otherwise
permitted by the Engineer Incharge, the Contractor shall excavate the
ground at each test pile to the elevation of the bottom of the footing
before the pile is driven.
Test piles shall be driven to a hammer blow count established by the

Engineer Incharge at the estimated tip elevation. Test piles which do not
attain the hammer blow count specified above at a depth of 1 foot above
the estimated tip elevation shown on the plans shall be allowed to “set
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up” for a period of from 12 to 24 hours, as determined by the Engineer

Incharge, before being redriven. When possible, the hammer shall be
warmed up before redriving begins by applying at least 20 blows to
another pile. If the specified hammer blow count is not attained on
redriving, the Engineer Incharge may direct the Contractor to drive a
portion or all of the remaining test pile length and repeat the “set up”
redrive procedure. When ordered by the Engineer Incharge, test piles
driven to plan grade and not having the hammer blow count required shall
be spliced and driven until the required bearing is obtained.
852.4.3.2 Accuracy of Driving
Piles shall be driven with a variation of not more than ¼ inch per foot
from the vertical or from the batter shown on the plans, except that piles
for trestle bents shall be so driven that the cap may be placed in its proper
location without inducing excessive stresses in the piles. Foundation piles
shall not be out of the position shown on the plan by more than ¼ of their
diameter or 6 inches, whichever is greater, after driving. Any increase in
footing dimensions or reinforcing due to out-of-position piles shall be at
the Contractor’s expense.
852.4.4 Determination of Bearing Capacity
852.4.4.1 General
Piles shall be driven to the bearing capacity shown on the plans or

specified in the special provisions. The bearing capacity of piles will be
determined by the Engineer Incharge as provided in the special provisions
using one or a combination of the following methods. Method A,
Empirical Pile Foundation, will be used in the absence of special
provisions to the contrary.
852.4.4.2 Method A – Empirical Pile Formulas
When not driven to practical refusal, the design bearing capacities of piles
will be determined by an empirical pile formula. Unless otherwise
provided in the special provisions, the following formulas (ENR) will be
used.
2 WH for drop (gravity) hammers

P=
S + 1.0 (4 – 1)
2E for all other hammers

P=
S + 0.1 (4 – 2)
Where:
P = bearing capacity in pounds.

W = weight, in pounds, of striking parts of the hammer
H = height of fall in feet
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E = energy produced by the hammer per blow in foot/pounds. Value

based on actual hammer stroke or bounce chamber pressure
observed (double acting diesel hammer)
S = the average penetration in inches per blow for the last 5 to 10
blows for gravity hammers and the last 10 to 20 blows for all
other hammers.
The above formulas are applicable only when:
The hammer has a free fall (gravity and single-acting hammers only).
The hard of the pile is not broomed, crushed, or otherwise damaged.
The penetration is reasonably quick and uniform.
There is no appreciable rebound of the hammer.
A follower is not used.
The penetration per blow may be measured either during initial driving or
by redriving with a warm hammer operated at full energy after a pile set
period, as determined by the Engineer Incharge.
In case water jets are used in connection with the driving, the bearing
capacity shall be determined by the above formulas from the results of
driving after the jets have been withdrawn.
852.4.4.3 Method B – Wave Equation Analysis
When specified, ultimate bearing capacity of a pile will be determined

by using a wave equation analysis. Soil, pile, and driving equipment
properties to be used in this analysis will be as shown on the plans, as
specified in the special provisions or as determined by the Engineer
Incharge using data obtained from the Contractor, test borings and,
when used, dynamic pile tests (Method C).
The design bearing capacity of a pile shall be 0.364 of the calculated

ultimate bearing capacity as determined from a wave equation analysis
alone. When the ultimate bearing capacity is determined from a wave
equation analysis that has been calibrated to the results of a dynamic
pile test, the design bearing capacity shall be 0.444 of the calculated
ultimate bearing capacity.
852.4.4.4 Method C – Dynamic Load Tests
Dynamic measurements will be taken by the Engineer Incharge during

the driving of piles designated as dynamic load test piles. The ultimate
capacity of the pile will be determined with the use of pile analyzer
instruments.
Prior to placement in the leads, the Contractor shall make each

designated concrete and/or timber pile available for taking of wave
speed measurements and shall predrill the required instrument
attachment holes. Predriving wave speed measurements will not be
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required for steel piles. When wave speed measurements are made, the
piling shall be supported off the ground in a horizontal position and not
in contact with other piling. The Engineer Incharge will furnish the
equipment, materials, and labor necessary for drilling holes in the piles
for mounting the instruments.
The Contractor shall either attach the instruments to the pile after the
pile is placed in the leads, or provide the Engineer Incharge reasonable
means of access to the pile for attaching instruments after the pile is
placed in the leads. A platform with minimum size of 4 x 4 feet (16
square feet) designed to be raised to the top of the pile while the pile is
located in the leads shall be provided by the Contractor,
The Contractor shall furnish electric power for the dynamic test
equipment. The power supply at the outlet shall be 10 amp, 115 volt,
55-60 cycle, A.C. only. Field generators used as the power source shall
be equipped with functioning meters for monitoring voltage and
frequency levels.
The Contractor shall furnish a shelter to protect the dynamic test

equipment from the elements. The shelter shall have a minimum floor
size of 8 x 8 feet (64 square feet) and minimum roof height of 7 feet.
The inside temperature of the shelter shall be maintained above 45º. The
shelter shall be located within 50 feet of the test location.
The Contractor shall drive the pile to the depth at which the dynamic
test equipment indicates that the design bearing capacity shown in the
contract plans has been achieved, unless directed otherwise by the
Engineer Incharge. If directed by the Engineer Incharge, the Contractor
shall reduce the driving energy transmitted to the pile by using
additional cushions or reducing the energy output of the hammer order
to maintain acceptable stresses in the piles. If axial driving is indicated
by dynamic test equipment measurements, the Contractor shall
immediately realign driving system.
When directed by the Engineer Incharge, the Contractor wait up to 24

hours and, after the instruments are attached, redrive the dynamic load
test pile. The hammer shall be warmed up before redrive begins by
applying at least 20 blows to another pile. The maximum amount
penetration required during redrive shall be 6 inches of maximum total
number of hammer blows required will 50, whichever occurs first. After
redriving, the Engineer Incharge will either provide the cut-off elevation
or specify rational pile penetration and testing.
852.4.4.5 Method D – Static Load Tests
Load tests shall be performed by procedures forth in ASTM D 1143

using the quick load compression test method except that the test shall
be taken to plum failure or three times design load or 1,000 tons will
ever occurs first. Testing equipment and measurement systems shall
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conform to ASTM D 1143. The Contractor shall submit to the Engineer

Incharge for approval, detailed plan prepared by a licensed professional
engineer, of proposed loading apparatus. The apparatus shall be
constructed to allow the various increments of the to be placed
gradually without causing vibration to test pile. When the approved
method requires the tension (anchor) piles which will later be used as
permanent piles in the work, such tension piles shall be same type and
diameter as the production piles and be driven in the location of
permanent piles feasible.
The design bearing capacity shall be defined as 50 the failure load.
The failure load of a pile tested under axial compressive load is that
load which produces a settlement at failure of the pile head equal to:
Sf = S + (0.15 + 0.008D)
Where:
Sf = Settlement at failure in inches

D = Pile diameter or width in inches
S = Elastic deformation of total unsupported length in inches
The top elevation of the test pile shall be determined immediately after
driving and again just before loading to check for heave. Any pile which
heaves more than 1/4 inch shall be redriven or jacked to the original
elevation prior to testing. Unless otherwise specified in the contract, a
minimum 3-day waiting period shall be observed between the driving of
any anchor piles or the load test pile and the commencement of the load
test.
852.4.5 Splicing of Piles
852.4.5.1 Steel Piles
Full-length piles shall be used where practicable. If splicing is

permitted, the method of splicing shall be as shown on the plans or as
approved by the Engineer Incharge. The arc method of welding shall be
preferred when splicing steel piles. Welding shall only be performed by
certified welders.
852.4.5.2 Concrete Piles
Concrete piles shall not be spliced, other than to produce short

extensions as permitted herein, unless specifically allowed by the plans,
the special provisions, or by the Engineer Incharge in writing.
Short extensions or "build-ups" may be added to the tops of reinforced

concrete piles to correct for unanticipated events. After the driving is
completed, the concrete at the end of the pile shall be cut away, leaving
the reinforcing steel exposed for a length of 40 diameters. The final cut
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of the concrete shall be perpendicular to the axis of the pile.

Reinforcement similar to that used in the pile shall be securely fastened
to the projecting steel and the necessary form-work shall be placed, care
being taken to prevent leakage along the pile. The concrete shall be of
not less than the quality used in the pile. Just prior to placing concrete,
the top of the pile shall be thoroughly flushed with water, allowed to
dry, then covered with a thin coating of neat cement, mortar, or other
suitable bonding material. The forms shall remain in place not less than
7 days and shall then be carefully removed and the entire exposed
surface of the pile finished as previously specified.
852.4.6 Defective Piles
The procedure incident to the driving of piles shall not subject them to
excessive and undue abuse producing crushing and spalling of the
concrete, injurious splitting, splintering and brooming of the wood, or
excessive deformation of the steel. Manipulation of piles to force them
into proper position, considered by the Engineer Incharge to be
excessive, will not be permitted. Any pile damaged by reason of internal
defects or by improper driving or driven out of its proper location or
driven below the butt elevation fixed by the plans or by the Engineer
Incharge shall be corrected at the Contractor's expense by one of the
following methods approved by the Engineer Incharge for the pile in
question:
The pile shall be withdrawn and replaced by a new and, if necessary, a

longer pile.
A second pile shall be driven adjacent to the defective or low pile. The
pile shall be spliced or built up as otherwise provided herein or a
sufficient portion of the footing extended to properly embed the pile. All
piles pushed up by the driving of adjacent piles or by any other cause
shall be driven down again.
All such remedial materials and work shall be furnished at the

Contractor's expense.
852.4.7 Pile Cut-off
852.4.7.1 General
All piles shall be cut off to a true plane at the elevations required and
anchored to the structure, as shown on the plans.
All cut off lengths shall remain the property of the Contractor and shall
be properly disposed of.
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852.5.1 Method of Measurement
852.5.1.1 Steel and Concrete Piles
852.5.1.1.1 Piles Furnished
The quantities of each type of pile to be paid for will be the sum of the
lengths in feet of the piles, of the types and lengths indicated on the
plans or ordered in writing by the Engineer Incharge, furnished in
compliance with the material requirements of these specifications and
stockpiled or, in the case of driven cast-in-place concrete piles,
installed in good condition at the site of the work by the Contractor,
and accepted by the Engineer Incharge. The footage of piles, including
test piles, furnished by the Contractor to replace piles which were
previously accepted by the Engineer Incharge, but were subsequently
damaged prior to completion of the contract will not be included.
When extensions of piles of each type to be paid for will be the number
of acceptable piles of each type that were driven.
Preboring, jetting, or other methods used or facilitating pile driving

procedures when either required or permitted will not be measured, and
payment will be considered included in the unit price paid for the Piles
Driven.
852.5.1.2 Pile Splices, Pile Shoes, and Pile Lugs
When pile splices, protective pile tip shoes or soil shear lugs are shown
on the plans, the number of pile splices, shoes, or lugs measured for
payment will be those shown on the plans, or ordered in writing by the
Engineer Incharge, and actually installed on piles used in the work. No
payment will be made for splices, shoes, or lugs used at the option of
the Contractor. When not shown on the plans or specified to be used,
pile splices, shoes, or lugs ordered by the Engineer Incharge will be
paid for as extra work.
The quantity of load tests to be paid for will be the number of load tests
completed and accepted, except that load tests made at the option of the
Contractor will not be included in the quantity measured for payment.
Anchor and test piles for load tests, whether incorporated into the
permanent structure or not, will be measured as provided for Piles
Furnished and Piles Driven and will be paid for under the appropriate
pay item.
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852.5.2 Basis of Payment
The quantities, determined as provided, will be paid for at the contract

price per unit of measurement, respectively, for each of the general pay
items listed below for each size and type of pile shown in the bid
schedule.
Pay Item Pay Unit

852.5.2.1 Piles, Furnished Linear Foot
852.5.2.2 Piles, Driven Each
852.5.2.3 Test Piles, Linear Foot
Furnished
852.5.2.4 Test Piles, Driven Each
852.5.2.5 Pile Load Test Each
(Static)
852.5.2.6 Pile Load Test Each
(Dynamic)
852.5.2.7 Splices Each
852.5.2.8 Pile Shoes Each
852.5.2.9 Pile Lugs Each
Payment for furnishing piles includes full compensation for all costs
involved in the furnishing and delivery of all piles, including steel shells
for cast-in-place driven piles, to be project site and all costs involved in
the furnishing and placing of concrete and reinforcing steel for cast-in-
place concrete piles.
Payment for driving piles includes full compensation for all costs
involved in the actual driving and cutting off of piles and pile shells,
and for all costs for which compensation is not provided for under other
pay items involved with the furnishing of labor, equipment, and
materials used to construct the piles as shown on the plans and as
specified or ordered. When mobilization of plant and equipment for the
project is not paid for separately, payment for driving piles also includes
full compensation for the cost of mobilization of all equipment needed
for the handling and driving piles after the piles have been delivered to
the project site.
Payment for load tests includes full compensation for providing labor,
equipment, and materials needed to perform the load tests as specified.
Payment under the appropriate pay items for pile splices, shoes, and
lugs includes full compensation for all costs involved with furnishing
all materials and performing the work involved with attaching or
installing splices, shoes, or lugs to the piles.
**************
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SECTION 861
GUIDE BANK
861.1 DESCRIPTION
This work shall consist of the construction of a guide bank comprising of

an earthen embankment protected by a stone apron and stone pitching on
the slope, all in accordance with these specifications and in conformity
with the lines, thickness and cross sections shown on the Plans.
861.2 MATERIAL
861.2.1 Stone for Pitching / Apron
Stone shall be quarry stone as nearly rectangular in section as is practical.

The stone shall be sound, tough, durable, dense, resistant to the action of
air and water, and suitable in all respects for the purpose intended.
Samples of the stone to be used shall be submitted to and approved by the
Engineer Incharge before any stone is placed. The minimum specific
gravity shall be two and half (2.5) and water absorption shall not exceed
six (6) percent. The stone shall not have an abrasion loss greater than
forty-five (45) percent when subjected to five hundred (500) revolutions in
a Las Angeles Abrasion test.
For the hand packed courses on slope, noses of the guide bank and aprons,
no individual stone shall weigh less than 40 Kg.(90 lbs) or more than 70
Kg.(150 lbs) and the minimum dimension of any stone shall be 15 cm.
(6 inch). Rounded stone shall not be accepted.
861.2.2 Filter
Filter shall comprise of crush stone or gravel free from dust. The grading
of the filter material shall be as specified on the drawings or in the Special
provisions. If not otherwise specified, it will be required that D 15 of the
filter is at least 4 times as large as D 15 for the underlying embankment
materials, and not more than 4 time the D 85 for the embankment material.
Where: D 15 and D 85 are the particle diameters corresponding to fifteen

(15) percent and eighty five (85) percent respectively, passing (by weight)
in a grain size analysis.
861.3 .1 Earthen Embankment
Embankment shall be constructed in accordance with provisions in

Section 411.
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Earth shall be borrowed initially from pits to be prepared to accommodate

the stone apron and the base of the stone pitching. These pits shall be
excavated and leveled as shown on the drawings.
Additional borrow areas shall be on the river side at least 100 meters (300
feet) away from the toe of the guide bank.
861.3.2 Apron
Apron pit shall be excavated, leveled and dressed all according to the lines
and levels shown on the drawings.
The stone in the apron shall be laid roughly hand packed duly wedged upto
a level 0.5 meter (1.5 feet) below the finished top level of the apron, as
shown on the drawings. The top 0.5-meter (1.5 feet) of the apron shall be
neatly and closely hand packed and properly wedged. At intervals of about
60 meters (200 feet) measured along the guide bank, the stone pitching in
the apron shall be completed to its full height over widths of 1.5 meters (5
feet) extending across the full breadth of the apron. The levels of the tops
of the stone in these preliminary works shall be checked and approved by
the Engineer in-charge before the rest of the apron is built up to the full
depth and full breadth.
861.3.3 Slope Protection
General
The river side slope of the guide bank embankment including the nose and
a certain specified length on the return slope shall be protected with
pitching stone. The slopes of the guide bank embankment remote from
attack by the main stream of the river shall be protected from erosion by a
covering of either pilchi or dhub or other approved grass.
861.3.3(a) Stone Pitching
The laying of stone pitching on slope is to proceed after the completion of

apron. The slopes of embankment are normally not steeper than 1:1 or 1:2.
The rough stones are used for pitching. Stones should be packed and
firmly embedded over a bedding filter of thickness 6" to 9", thoroughly
consolidated over the earth slopes to prevent earth from being sucked out
from between the stones by wave action. Pitching should be constructed at
right angle to the slope to be saved against, sliding. Stones should be laid
their broadest face downward, with as large a proportion of through stone
as possible, giving due regard to bond. The final course of the stone
pitching on slope, shall be 0.5 meter (1.5 feet) thick of neatly and closely
hand packed stones, and the remaining thickness of these stone pitching
below the final course and above the base course shall be of pitching stone
roughly hand packed. Each stone in the final course shall be placed and
wedged in position with filter bedding to give an even surface free from
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holes and pockets and with no individual stone protruding from its
neighbours by more than 2.5 cm (one inch).
All inter-sections, hollows and inequalities between the stones shall be

filled with smaller pieces and wedged up tight with the filter driven in with
slight hammering. The outer face of pitching should be made as smooth as
possible so as not to set out eddies that may cause scour.
861.3.3(b) Turfing
The rear sides of guide banks are not subjected to direct attack of flow and
may be protected against ordinary wave splashes. Grass (Turf) should be
grown on the sides of the slopes. Turfing should consist of sods not less
than 4" thick and 9" sq. well beaten into bank before grass is grown the
slopes are properly dressed. It is kept in view that the earth placed on
slopes is suitable for the nourishment of Turfing. Plantation like Pilshi,
sarkanda, willow, or shrubs should be planted in the width of 100 ft. in the
rear toe of the embankment of guide bank. Such plantation breaks the
force of waves.
861.4 CONSTRUCTION PROGRAMME
The Contractor shall programme his construction in such a way that the
entire work is completed in dry season and before the river begins to rise
due to rain or flood.
If the Contractor fails to complete the work before the river commences to
rise and any part of the guide banks gets damaged, it shall be made good
by the Contractor at his own cost.
861.5 MEASUREMENTS AND UNIT RATE
Measurements and unit rate for excavation shall be in accordance with

Section 403.
Measurements and unit rate for making embankment shall be in

accordance with Section 411.
Measurements for stone pitching in apron or slopes shall be made to the

outlines of the stone pitching in place and for the thickness shown on the
plans or established by the Engineer Incharge within the lines to which
regular excavation or the embankment slopes have been measured. The
stone pitching shall be measured by volume. The unit of measurement
shall be one cubic meter or one hundred cubic feet. The unit rate shall be
full compensation for supplying, placing and finishing stone pitching
including all materials, labour, tools and plants required for the work.
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861.6 PAYMENT
The payment shall be made under:-
Item No.861.6.1: Regular Excavation Per Cub meter (m3)

or per 1000 cubic feet.
Item No.861.6.2: Making Embankment Per Cub meter (m3)

Item No.861.6.3: Stone roughly hand packed

in apron Per Cub meter (m3)
Item No.861.6.4: Stone for top layer of aprons Per Cub meter (m3)
tightly hand packed. or per 100 cubic feet.
Item No.861.6.5: Filter /Bedding under.

Stone pitching on slope. Per Cub meter (m3)
Item No.861.6.6: Stone pitching roughly

hand packed on slope. Per Cub meter (m3)
Item No.861.6.7: Stone pitching tightly hand

Packed on slope. Per Cub meter (m3)
Item No.861.6.8: Turfing

Per Sq. meter (m3)
or per 100 Sq. feet.
**************
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SECTION 872
PLASTERING AND POINTING
872-1 DESCRIPTION
The work covered in this Section consists of plastering or pointing

brick work or stone masonry with cement mortar in conformity with
lines and dimensions shown on the drawings and according to these
specifications.
872-2 PREPARATION OF SURFACE
872.2.1 Before plastering or pointing, the joints of old brickwork or masonry

shall be raked out with a hook to a depth of half an inch. In case of new
masonry in cement to be subsequently plastered or pointed the joints
shall be raked out at the end of day’s work before the mortar has set.
872-2.2 The earth and mortar dust coming out of these joints as a result of
raking shall be washed off, and the work watered for 24 hours before
plaster is applied.
872-2.3 All putlog holes shall be filled up before plastering or pointing as the
scaffolding for masonry is being taken down.
872.2.2 MORTAR
872-3.1 Composition
Cement mortar shall consist of Portland Cement, sand and water.

Waterproofing agent shall be added when specially required or directed
by the Engineer Incharge. (This shall be paid separately when added).
872.3.2 Mix
Unless otherwise specified, the mortar shall be mixed by volume. The

ratio of cement and sand shall be either 1:6 or 1:3 unless otherwise
specified for plastering work and 1:2 for pointing work.
872-3.3 Preparation
Cement and sand shall be thoroughly mixed in a dry state on a pucca

platform or in troughs as directed by the Engineer Incharge. It shall be
gauged with a quantity of water sufficient to make the mortar
workable. Water shall be added with a fine rose. Only such quantity of
mortar shall be prepared as can be used before the initial setting time.
Any mortar which has not been used within 30 minutes of the addition
of water shall be discarded.
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872.4 PRECAUTIONS
Before starting work of plastering or pointing the following

precautions shall be taken.
(a) Fine aggregate i.e. sand shall be washed before use.
(b) It shall be ensured that all joints are properly raked.
(c) The surface to be plastered or pointed shall be kept moist but

excessive moisture shall be avoided.
(d) The scaffolding for plastering or pointing shall always be

provided double.
872.5 PLASTERING
Unless otherwise specified or directed by the Engineer Incharge or his

authorized subordinate in writing, wooden screeds eight centimeters
(three inches) wide and having a thickness equal to the plaster shall be
fixed vertically 2.5 meters to 3 meters (8 feet to 10 feet) apart to act as
gauges and guides in applying the plaster.
The arises shall then be plastered for a space of ten centimeters (four
inches) on each side and up to the ceiling except in case of openings
where it shall run around them. This plaster shall also serve as a guide
for thickness etc. Unless otherwise specified or directed by the
Engineer Incharge all corners and arises shall be rounded off to a
radius of two centimeters (3/4 inch) only and no more. This work is
included in the unit rate of plastering.
The mortar shall be laid on the wall between the screeds, using a
plasterer’s float for the purpose and pressing mortar so that the raked
joints are properly filled. The plaster shall then be finished off with a
wooden straightedge reaching across the screeds. The straightedge
shall be worked on the screeds with an upward and sideways motion,
two inches or three inches at a time. Finally the surface shall be
finished off with a plasterer’s wooden float. Metal float shall not be
used.
The plaster shall be laid to a true and plumb surface and tested
frequently with a straightedge and plumb bob. The straightedge shall
not be less than three meters (10 feet) in length. As the work proceeds,
all horizontal lines and surfaces shall be tested with a level, and all
jambs and corners with a plumb bob.
All moulding and decorations shall be worked true to template and

shall be neat, clean, level, and parallel, or truly plumb, as the case may
be.
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Unless otherwise specified, plaster shall not exceed twelve millimeters

(half an inch) in thickness and shall not be less than six millimeters
(quarter of an inch) at the thinnest part.
872.6 POINTING
Unless otherwise specified the following types of pointing shall be

done.
872.6.1 Deep of Struck Cement Pointing.
This type of pointing shall be done to all un-plastered faces of

brickwork where the brickwork is liable to be affected by dampness
and saltpeter, such as in the plinths of buildings.
The mortar shall be prepared as per Specification contained in 872-3.

The mortar shall be filled in the joints flush with masonry or brickwork
with a pointing trowel and then pressed with proper pointing tools.
Lining with a spike on a mass of mortar shall not be allowed.
872-6.2 Flush Cement Pointing
This type of pointing shall be done to all brickwork with an exposed

face, when the finish of the face is not important or when a flush floor
surface is required or when the floor or brickwork is subject to wear or
to the effects of dampness and saltpeter.
The mortar shall be prepared as per specifications contained in 872-3
The mortar shall be filled and pressed into the joints with a pointing
trowel, and finished off level with the edges of the bricks to give the
smoothest possible appearance to the work.
872-6.3 Pointing Tools
The pointing tools for horizontal joint shall be such as to form

weathered and struck joints, and for vertical joint, triangles, so as to
make a (v) notch. Care shall be taken not to develop a cutting edge in
the tools since the idea is to compress the green mortar into the joints
and not to cut it way.
872-6.4 Edge of Bricks
The mortar shall not be spread irregularly over the edges and corners
of the bricks, which shall be left clearly visible. The practice of
smearing mortar over defects in bricks, to hide them, shall not be
allowed and shall render the whole brickwork liable to be rejected.
872.6.5 Washing After Pointing.
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After pointing, the face of the work shall be cleared off all surplus
mortar sticking to the face. No washing shall be done till the pointing
has set.
872-7 PROTECTION DURING
After completion, plastering or pointing shall be kept wet for 10 days

and shall be protected during that period from extreme fluctuations of
temperature and weather.
All defects detected during curing or afterwards shall be treated at the

Contractor’s expense according to directions of the Engineer Incharge.
872-8 MEASUREMENT
Plastering or pointing shall be measured by the superficial area, no

deduction being made for the opening of any size or additions for
returns and soffits. The unit of measurements shall be one square meter
or 100 square feet
872-9 RATE
The unit rate shall be full compensation for all the materials and labour
required for the completion of work mentioned in this Section. It shall
also include for preparing, cleaning, watering the surface, plastering or
pointing surface and corners, curing and protection, providing, erecting
and removal of scaffoldings and all other tools and plants required for
the completion of work.
872.10 PAYMENT
Item No.872-10.1 Cement Plaster in 1:6 Cement Per Sq. Meters (m2) or
Mortar
100 Sft. (% Sft)
Item No.872-10.2 Cement Plaster in 1:3 Cement Per Sq. Meters (m2) or
Mortar
100 Sft. (% Sft)
Item No.872-10.3 Deep cut or Struck Cement Per Sq. Meters (m2) or
Pointing
100 Sft. (% Sft)
Item No.872-10.4 Flush Cement Pointing. Per Sq. Meters (m2) or

100 Sft. (% Sft)
**************
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SECTION 891
PIPE CULVERTS
891-1 DESCRIPTION
This work shall consist of construction, reconstruction or repair of

culverts and water drainage structures in accordance with these
specifications, and in conformity with the lines, grades and dimensions
shown on the drawings or as directed by the Engineer Incharge.
The work shall include furnishing and laying of the pipe, and
construction of such joints and connections to other pipes, catch basins,
or other structures as may be required to complete the work as sown on
the drawings or as directed by the Engineer Incharge.
The work shall also include the removal and disposal of existing
culverts and structures except such portions as may be required or
permitted by the Engineer Incharge to be left in place.
The Engineer Incharge reserves the right to inspect and test the pipe
after its delivery to the work. Injurious defects revealed subsequent to
acceptance of pipe and prior to its installation in the work shall be
cause for rejection.
The contractor shall not order and deliver the pipes for any work until
a list of sizes and lengths has been approved by the Engineer Incharge.
891.2.1 The pipes shall meet the requirements of AASHTO M86 or M 170,
whichever is specified.
891.2.2 Cement, sand and water shall conform to the requirements specified in
Section 701-Cement concrete, except that the grading for sand shall
meet the requirements of Section 1033 Mortar Sand.
891.2.3 Rubber ring gaskets for rigid pipe, if required shall conform to the
requirements of AASHTO M 198.
891-3 METALLIC PIPE CULVERTS
891-3.1 Corrugated Steel Circular Pipe and Pipe Arches
Corrugated steel culvert pipe shall comply with the requirements of

AASHTO M36M and be zinc coated.
A certificate of Guarantee from an approved pipe fabricator shall be

submitted by the Contractor for each shipment of pipe delivered to the
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site. The certificate shall show the quantities of material and state that
the listed materials conform to the specified requirements.
The Engineer Incharge may test any material for compliance with the
specification at any time and reject any material which does not meet
the requirements even though it has received prior approval based on a
certificate of Guarantee.
891-3.2 Bituminous Coated Corrugated Steel Circular Pipe and Pipe

Arches.
Bituminous coated corrugated steel circular pipe and pipe arches shall
comply with AASHTO M 190 and with sub-clauses 801.7 to 801.9
891-3.3 Polymer Coated Steel Circular Pipe and Pipe Arches.
Polymer coated metal pipe and pipe arches shall comply with
AASHTO M 246M and with sub-clauses 801.7 to 801.9.
891-3.4 Pipe Laying
No pipe culvert shall be placed until the foundation has been approved
by the Engineer Incharge. Pipe shall be laid accurately to line and level
shall have a uniform bearing at each joint and along the entire length of
pipe. Pipe laying shall begin at the downstream end and progress
upstream.
Manufactured pipe shall be handled and assembled in accordance with

the manufacturer’s instructions.
891-3.5 Corrugated Metal Pipe and Pipe Arches.
Metal pipe shall be laid with outside laps of circumferential joints

pointing upstream and with longitudinal laps along the sides. If pipe
sections are jointed on the site, the ends shall be butted as closely as
corrugations will permit and shall be joined with a firmly bolted
coupling band of the same material as the pipe. Camber shall be built
into the pipe structure to compensate for settlement from fill loads.
Multiple culverts, unless shown otherwise on the Drawings, shall be

laid with one-half span of pipe or a minimum of 300mm whichever is
the greater, between pipes.
Damage to bituminous or epoxy resin coatings may be repaired on site

by application of a repair material of a brand and type approved by the
Engineer Incharge. Pipe having any localized bends in excess of 5% of
the nominal pipe diameter or dents in excess of 13mm depth will be
rejected. Pipe rejected because of these defects may be used if
satisfactorily repaired and approved by the Engineer Incharge.
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891-4 MANUFACTURING REQUIREMENTS
Reinforced concrete pipe culverts shall conform to the requirements of

AASHTO M-170.
891.3-4.1 Dimensions and Strength Test Requirements
Shell thickness, the quantity of circular reinforcement and the strength

per linear meter for the various sizes of pipe shall conform to the
minimum requirements listed in related Table as per AASHTO M-170
latest addition.
3.2 Reinforcement
Each line of reinforcement shall be assembled into a cage, which shall

contain sufficient longitudinal bars or members extending through the
barrel of the pipe to maintain the reinforcement rigidly in exact shape
and correct position within the form. If the splices are not welded, the
reinforcement shall be lapped not less than 30 diameters for bars and
40 diameters for cold-drawn wire. If welded the member at either a
welded splice or intersection shall develop a tensile strength of not less
than three thousand seven hundred (3.700) Kgf/Sq. cm. The spacing
centres of adjacent rings of the circumferential reinforcement (pitch)
shall not exceed 10 cm . The circumferential reinforcement shall be
located midway between the inner and outer surfaces of the pipe within
a tolerance of + six (6) mm.
3.3 Joints
The ends of reinforced concrete culvert pipes shall be the ogee or

spigot and socket types and of such design that when laid the joints
shall form a continuous conduit with a smooth and uniform interior
surface.
3.4 Tolerances
Variations in internal diameter and wall thickness shall not exceed the
limit specified in relevant “Table for Allowable Tolerances” for
reinforced concrete pipes in these Specifications.
3.5 Absorption
The water absorption of the concrete pipe shall not exceed eight (8) per
cent of the dry weight as determined in AASHTO Designation T-33.
3.6 Curing
Pipes shall be subjected to any one of the methods of curing described

in the following paragraphs or to any other method or combination of
methods, approved by the Engineer Incharge’s Representative, that will
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give satisfactory results, provided that no pipe shall be used within a

period of fourteen (14) days after curing. All pipes shall be marked
with the date of casting.
i) Steam Curing
Pipes shall be placed in a curing chamber, free from outside

draughts, and cured in a moist atmosphere, maintained at a
temperature between thirty eight (38) and fifty four (54) degree
C by the injection of steam for a period of not less than twenty
four (24) hours or, when necessary, for such additional time as
may be needed to enable the pipe to meet the strength
requirements. When a curing chamber is not available, pipes
may be placed in an enclosure of canvas or other closely woven
material and subjected to saturated steam at the temperature
and for the time specified above. The enclosure shall be so
erected as to allow full circulation of steam around the entire
pipe. The interior surface of the curing room or canvas jackets
and the surfaces of the pipes shall be entirely moist at all times.
ii) Water Spray Curing
Under the conditions of enclosure prescribed in (i) above, pipes

may be cured by subjecting them to a continuous or frequently
applied fine spray of water in an enclosure maintained at a
temperature of not less than twenty one (21) degree C for a
period of not less than seventy two (72) hours, or such
additional time as may be necessary to meet the strength
requirements.
(iii) Saturated Cover Curing
The sides and top of each pipe may be covered with heavy
Hessian or other suitable material, saturated with water before
apply and kept saturated with water a temperature of not less
than twenty one (21) degree C for seventy two (72) hours, or
such additional time as may be necessary to meet the strength
requirements. The ends of the pipes shall be so enclosed as to
prevent the free circulation of air through or around the pipe. If
the temperature of the water is less than twenty one (21) degree
C, the curing period shall be increased as may be necessary to
meet the strength requirements. The ends of the pipes shall be
so enclosed as to prevent the free circulation of air through or
around the pipe.
3.7 Workmanship and Finish
All pipes shall be substantially free from fractures, large or deep

cracks, honeycombing, open texture, spells and surface roughness. The
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planes of the ends of the pipe shall be perpendicular to the longitudinal

axis.
3.8 Inspection
The quality of all materials, the process of manufacture and the

finished pipes shall be subject to inspection, test and approval at the
place of manufacture. The Contractor shall make the necessary
arrangements with the manufacturer to set aside in a separate area all
pipes for which he desires approval.
i) Test Specimens
Pipes for the purpose of tests shall be furnished free of cost by

the Contractor and will be selected at random by the Engineer
Incharge. The number of sections required for test will not be
more than two (2) percent except that at least one of every size
will be selected. Pipes for tests shall conform to these
specifications.
ii) Test Equipment
If the manufacturer has equipment for conducting the crushing

strength test, the Contractor shall make the necessary
arrangements to have the required tests conducted in the
presence of the Inspector designated by the Engineer Incharge.
If the testing facilities are not available at the point of
manufacture, the contractor shall make the necessary
arrangements for furnishing & testing, at no cost to the
Employer, the pipe sections selected by the Inspector to a
laboratory approved by the Engineer Incharge.
iii) Rejection
Pipes shall be subject to rejection on account of failure to

conform to any of the above specification requirements or on
account of any of the following:-
a) Fractures or cracks passing through

the shell, except that a single end crack that does not
exceed the depth of the joint shall not be cause for
rejection. If a single end crack that does not exceed the
depth of the joints exist in more than ten (10) per cent of
the pipes inspected, however, the defective pipes shall
be rejected.
b) Defects that indicate imperfect

mixing and moulding.
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c) Surface defects indicating

honeycombing or open texture and exposure of
reinforcement including rust marks caused by
inadequate concrete cover.
d) Spalls deeper than one half the depth

of the joint or extending more than ten (10) cm around
the circumference. If spalls not deeper than one half of
the joint or extending not more than ten (10) cm around
the circumference exist in more than ten (1) per cent of
the pipes, however, the defective pipes shall be rejected.
e) Misplaced reinforcement already

exposed or verified by checking with an approved
concrete reinforcement cover meter.
891-5.1 Excavation
A trench shall be excavated to the depth and grade established by the

Drawings. The bottom of the trench shall be shape to conform to the
shape of the pipe for at least twenty (20) percent of its outside
diameter. The width of the trench shall not be greater than two (2)
times the pipe diameter, to permit satisfactory jointing and thorough
tamping of the bedding material (specified in Section 892) under and
around the pipe. Recesses shall be excavated for any bells involved.
Where rock or hardpan is encountered, the trench shall be excavated to

a depth at least thirty (30) centimeters (1ft) below the grade established
for the bottom of the pipe. This excess depth shall be refilled with
approved material and thoroughly compacted.
Where in the opinion of the Engineer Incharge the natural foundation

soil is such as to require stabilization, such material shall be replaced
by a layer of suitable material. Where an unsuitable material (peat,
muck, etc.) is encountered at or below invert elevation during
excavation, necessary subsurface exploration and analysis shall be
made and corrective treatment shall be given as directed by the
Engineer Incharge.
891-5.2 Placing Pipe
No pipe culvert shall be placed until the foundation has been approved
by the Engineer Incharge. Pipes shall be laid accurately to line and
level and shall have a uniform bearing at each joint and along the
entire length of pipe. Pipe laying shall begin at the downstream end
and progress upstream.
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Manufactured pipe shall be handled and assembled in accordance with

the manufacturer’s instructions.
Pipes shall be laid with hub, bell or groove ends, upstream.
Where lift holes have been used, they shall be filled with an approved
cement sand mortar to provide a watertight section. Mortar shall be
finished flush on the inside of the pipe.
Pipe joints shall be sealed with flexible watertight elastomeric or

rubber gaskets, approved bituminous sealers or plastic sealants.
Bituminous or plastic sealants shall be applied at the time pipe is being
laid. Sealants shall be installed in accordance with the sealant
manufacturer’s instructions so that the joint is completely filled.
When concrete pipe has a gap greater than 10mm between sections
when laid together, the joint inner surface shall be filled with oakum
and a bituminous or plastic sealant. The extended gap between barrel
and bell is not required to be filled. Oakum shall be closely twisted
hemp or jute of suitable diameter to fill the annular space when
caulked and in one piece of sufficient length to pass around the pipe
and lap at the top.
Multiple pipe culverts, unless otherwise shown on the Drawings, shall

be laid with one half diameter of pipe or a minimum of 300mm
whichever is greater, between the pipes.
3-5.3 Backfilling
After the pipe has been installed and the mortar joints sufficiently set,
granular material (sand) and /or selected material from roadway
excavation or borrow shall be placed alongside the pipes in layers not
exceeding twenty (20)cms in depth and compacted minimum ninety
(90) percent the maximum dry density determined as per AASHTO T-
191 Method, so that on each side of the pipe there shall be thoroughly
compacted material at least as wide as external diameter of the pipe
except insofar as undisturbed material obtrudes upon this width. Each
layer shall be moistened, if dry, and then compacted by tamping with
mechanical hammers or by hand tamping with heavy iron tampers to
the densities as specified under Item 108.3.1- Formation of
Embankment with common material. This method of filling and
compacting shall be continued until the embankment has reached an
elevation of twenty 20cms above the top of the pipe. When
construction calls for placing a high embankment over the pipes,
special instructions regarding the method of backfilling shall be given
891.5.4 Construction Plant
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Movement of Construction equipment, over a culvert shall be at the

contractor’s risk. Any pipe injured thereby shall be repaired or placed
at the contractor’s cost.
891-5.5 Headwalls
Where indicated on the Drawings, the ends of the pipe culverts shall be
protected by concrete or masonry headwalls constructed as shown on
the Drawings. When headwalls are constructed, the ends of the pipe
shall be neatly cut off flush with the outside face of the headwalls.
891-5.6 MEASUREMENT
The quantities to be paid for shall be the number of linear meter (or
feet) of pipe placed, completed and accepted.
The removal of existing culverts or pipes, which encroach upon the

excavation, shall not be measured for direct payment.
Direct payment shall be made under Section 892 for furnishing and
installing granular material or concrete in the bed of the culvert as
891.5.7 RATE
The quantities, as measured above, shall be paid for at the contract unit
price respectively, for each of the particular pay items listed below.
Payment shall be full compensation for furnishing and placing all
materials including mortar for joints, for removing existing culverts
and pipes, for excavating trenches and backfilling, and for all other
costs necessary or usual to the proper completion of the work
prescribed in this item. Headwalls, wing walls and aprons together
with the bedding for the concrete pipe culvert, will be measured and
paid for separately.
891.5.8 The quantity of completed and accepted work , measured as provided

for above, will be paid for at the unit rate per linear meter for “Pipe
Culvert and Arch’ in the bill of Quantities, for the various types,
classes and sizes of pipes, which rate shall include the cost of
supplying and placing of pipe, for materials, labour equipment, tools
and other items necessary for proper completion of the work as
specified in relevant clause of specifications and/or agreement.
891.6 PAYMENT
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Non-reinforced Concrete pipe Culvert.
Item No.891-6.1 AASHTO M 86

Diameter 150 mm (6”) Per m or ft
Item No.891-6 .5 AASHTO M 86
Reinforced Concrete Pipe Culvert





Diameter 1070mm (42”) Per m or ft


Metallic Pipe Culverts
Item No.891-6.13 AASHTO M 36M

Corrugated Steel Circular
Pipe
Diameter ____mm ( __”) Per m or ft
Bituminous Coated
Corrugated Steel Circular
Pipe
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Polymer Coated
Steel Circular Pipe
***************
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SECTION 892
BED TO CONCRETE PIPE CULVERTS
892- 1 DESCRIPTION
This work shall consist of furnishing and placing granular material or

concrete as specified for bedding concrete pipe culverts.
892-2.1 Granular Material
Granular material shall be sand or selected sandy soil all of which

passes a 9.5 mm (3/8-inch) sieve and not more than fifteen (15) percent
passes No 200 sieve.
892-2.2 Concrete.
Concrete class D shall be used as specified under section 701 unless

otherwise specified on the drawings or as directed by the Engineer
Incharge.
The bedding material consisting of granular material as specified in

section 892-2.1 shall be laid to the dimensions shown on the drawings.
The top surface shall be accurately shaped by template to fit the
surface of the concrete pipe culvert for at least twenty (20) percent of
its outside diameter.
Granular material shall be deposited in layers not exceeding fifteen 15

cm (6 inches) and shall be compacted to at least ninety five (95)
percent maximum dry density in accordance with AASHTO T 180,
Method D or at least seventy four (74) percent relative density in
accordance with ASTM D 2049, whichever is applicable.
Concrete class B if shown on the drawings shall be mixed, placed

finished and cured all in accordance with Section 701
892-4 MEASUREMENT
The quantities to be paid for shall be the number of cubic meter or

hundred cubic feet of granular material, or concrete class B, placed and
accepted.
892-5 RATE
The quantities measured as provided above shall be paid for at the

contract unit price, for each of the particular pay items listed below,
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which prices and payment shall be full compensation for furnishing

and placing all materials included for completion of the work
prescribed in this item.
892.6 PAYMENT
Item No.892-6.1 Granular Materials in Per cubic meter (m3)

Bed to Concrete Pipe or per hundred cubic
Culvert feet (cft)
Item No.892-6.2 Concrete class B in Per cubic meter (m3)
Bed to Concrete Pipe or per hundred cubic
Culvert. feet (cft)
***************
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SECTION 893
UNDER DRAIN
893-1 DESCRIPTION
The work shall consist of furnishing and installing under drains as

shown in the Drawings.
893-2.1 Perforated Concrete Pipe
This pipe shall conform to the requirements of AASHTO M 175 or to

ASTM C-444 for the specified diameters and strength classes.
893-2.2 Porous Concrete Pipe
This pipe shall conform to the requirements of AASHTO M 176 for the
specified diameters.
893-2.3 Granular Backfill
Granular backfill for bedding and surrounding under drains shall be

aggregate conforming to the requirements of item 501-1 Granular Sub
base Grading C.
In order to avoid intrusion into the sub base of the in place surrounding
earth material, it shall be required that the ratio
D15 (Subbase)
--------------------------- = Less than 5
D85 (Surrounding Earth)
893.3.1 Trench and Bedding
Trenches shall be excavated to the width, line and grade as shown in

the Drawings, unless shown other-wise on the Drawings, the depth
shall vary from 0.7 to 1.4 meters below the bottom of a gutter or ditch
when under drain is sited under a gutter or ditch, and to depths required
for proper drainage, as determined by the Engineer Incharge. A bed of
granular back-fill, ten (10) cm thick, shall be spread, and compacted in
the bottom of the trench throughout its entire length.
893-3.2 Placing Pipe and Backfilling.
The pipe shall be embedded firmly material, bells upgrade, ends fully
entered in the adjacent bells and spot mortared to provide for centering
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of the pipe, but the joint shall not be closed to the desired infiltration of
water Perforated pipe shall be laid with the perforated length of the
pipe on its underside.
After the pipe has been placed and approved by the Engineer Incharge,
granular backfill as specified in item 501-1 shall be placed around the
drain for a thickness of at least thirty (30) cm and care shall be taken
that no pipe is displaced. The upper portion of the trench shall then be
filled with approved fine soil selected from structural, common or
borrow excavation. All filling material shall be thoroughly compacted,
to the satisfaction of the Engineer Incharge.
893-4 MEASUREMENTS AND PAYMENT
The quantities to be paid for shall be:
(1) The number of meters of under drain, of the kind mentioned

below, in place and accepted.
(2) The number of cubic meters of granular backfill, in place, and

accepted.
The quantities, determined as provided above, shall be paid for at the

contact unit price for the pay items lists below. These prices and
payment shall be full compensation for furnishing and placing the
under drain, for excavating the trench in which the under drain is laid
for granular backfill used, for the backfill and all other costs related to
the work prescribed in this item.
Pay Item No. Description Unit of

Measurement
893-4.1 Perforated Concrete Pipe for m or Rft
Under drain, Diameter 150 mm
893-4.4 Porous Concrete Pipe for m or Rft
893-4.5 Porous Concrete Pipe for m or Rft
893-4.6 Granular Backfill to Concrete m3 or 100cft
Pipe under drain.
**************
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SECTION 894
HEADWALLS, WINGWALLS, PARAPETS,
894.1 DESCRIPTION
This work shall consist of construction of concrete sections as mentioned

in the item above in brickwork or stone work for concrete pipe and other
culverts and bridges shown on the Drawings.
894.2 .1 Steel Reinforcement
Quality of Steel reinforcement shall be in accordance with the material

requirements of Section 821, Standard Specifications for Road and Bridge
Construction.
894.2.2 Concrete
Quality requirements of all materials for Concrete of Class D 2, Class A3,

Class C or Lean Concrete as specified on the Drawings and shall be in
accordance with the material requirements of Section 701, Standard
Specifications for Road and Bridge Construction.
894.2.3 Brickwork
Quality of brick and other materials shall be in accordance with the

requirements of Section 521, Standard Specifications for Road and Bridge
Construction.
894.3.1 Excavation
Excavation shall be in accordance with Section 402, Standard

Specifications for Road and Bridge Construction and in conformity with
the Drawings.
894.3.2 Granular Backfill
Granular backfill, if ordered in writing by the Engineer Incharge, shall be

furnished, placed and compacted in accordance with Section 501.3.6,
Standard Specifications for Road and Bridge Construction.
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894.3.3 Formwork
Formwork shall be supplied and fixed in the positions required for the
concrete to be cast as shown on the Drawings and shall be erected and
removed as directed by the Engineer Incharge.
894.3.4 Steel Reinforcement
Steel reinforcement shall be furnished, bend and fixed as shown on the

Drawings. Bending and fixing shall be in accordance with Section 821,
894.3.5 Concrete
Concrete Class D2, A3, C or Y shown on the Drawings shall be placed,

finished and cured, as specified in Section 701, Standard Specifications for
Road and Bridge Construction.
894.3.6 Brickwork
Brickwork as shown on the drawings shall be carried out as specified in

Section 521, Standard Specifications for Road and Bridge Construction.
The formwork in place and accepted shall not be measured for payment
and shall be deemed to have been paid under other items.
Steel reinforcement in place and accepted shall be measured and paid for
as specified in Section 821, Standard Specifications for Road and Bridge
Construction.
Concrete in place and accepted shall be measured and paid for as specified
in Section 701, Standard Specifications for Road and Bridge Construction.
Granular backfill in place and accepted shall be paid for as specified in

Section 501.3.6, Standard Specifications for Road and Bridge
Construction.
Brickwork in place and accepted shall be paid as specified in Section 521,

***************
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SECTION 895
MANHOLES
895-1 DESCRIPTION
This work shall consist of the furnishing and erecting pre-cast concrete
manholes of diameter 1.20 m (4 feet) with the necessary frames and
covers constructed in accordance these specifications and the
specifications for the other work items involved and in conformity with
the dimensions, lines, elevations and design shown on the drawings.
895-2.1 Pre-cast Concrete Units.
These units shall be cast to the dimensions shown on the drawings

Cement concrete shall be type C in accordance with Section 701.
Reinforcement shall be used as per drawings. The pre-case units shall
be cured in accordance with Section 701-11.
A sufficient number of cylinders/cubes shall be cast to permit

compression tests at seven (7) and twenty-eight (28) days, to allow for
at least two cylinders/cubes for each test. If the strength requirement is
met at seven (7) days, the units will be certified for use after fourteen
(14) days from date of casting. If the strength requirement is not met at
twenty eight (28) days, all units made from that batch will be rejected.
Cracks in units, honeycombed or patched areas in excess of 200 sq. cm

(30 sq. inches), and failure to meet strength requirements will be cause
for rejected.
895-2.2 Steel Reinforcement
Steel reinforcement shall be in accordance with the requirements of

Section 821.
895-2.3 Frames, Grates and Covers, and Ladder Rungs
Metal units shall conform to the dimensions shown on the drawings

and to the following requirements for the designated materials.
Gray iron castings shall conform to the requirement of AASHTO M

105. Strength class shall be optional unless other-wise specified.
Carbon steel casting shall conform to the requirements of AASHTO M

103. Grade shall be optional unless otherwise specified.
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Structural steel shall conform to the requirements of AASHTO M 183

or ASTM A 283, Grade B or better.
Galvanizing where specified for these units, shall conform to the

requirements of AASHTO M 111.
Malleable iron castings shall conform to the requirements of AASHTO

M 106. Grade shall be optional unless otherwise specified.
895-2.4 Mortar
Mortar shall be composed of one part Portland cement and two parts of
sand conforming to provision of section 1033 by volume unless
otherwise specified and sufficient water to make the mortar of such
consistency that it can be handled easily and spread with a trowel.
895-2.5 Concrete
Concrete shall be of type C unless otherwise shown on the drawings or

as directed by the Engineer Incharge, and shall conform to the
requirements prescribed under Section 701.
895.3.1 Excavation
Excavation shall conform to the requirement of Section 402.
895-3.2 Backfill
Backfill shall conform to the requirements of Section 402, unless

where granular backfill as specified under section 892 is required by
the drawings, or is specified in writing by the Engineer Incharge.
Cement Concrete shall conform to the requirements of section 701.
895-3.4 Steel Reinforcement
Reinforcing Steel shall conform to the requirements of section 821.
895-3.5 Pre-cast Concrete Units
Pre-cast concrete units shall be erected in positions shown on the

drawings, or as directed by the Engineer Incharge.
During erection of the units the out side of manhole shall be finished
smooth and the joints flushed full with the mortar.
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895-3.6 Connections
Sections of connections pipe shall be incorporated in to the

construction and placed at the elevation, direction and grade required.
The inner ends of the pipes shall be flush with the inner faces of the
walls.
895.3.7 Metal Frames
Metal frames shall e set on full mortar beds of other wise secured as
shown on the drawings and the frames, covers, and gratings shall be
accurately set true to the line and elevation required to fit the adjoining
surface as approved by the Engineer Incharge.
895-3.8 Cleaning
Upon completion each manhole shall be thoroughly cleaned by any

accumulations of silt debris, or foreign matter of any kind and shall be
kept clean of such accumulations until final acceptance of the work.
895-4 MEASUREMENTS
The quantities to be paid for shall be:
1. The number of concrete manholes completes with frames and

covers and all other relevant components in position and
accepted, from one (1) meter to two (2) meters (3.28 feet to
6.56 feet) deep.
2. The number of concrete manholes completes with frames and

covers and all other relevant components in position and
accepted, more than two (2) meter and up to three (3) meters
(6.56 feet to 9.84 feet) deep.
In the determination of the depth of a manhole the distance

shall be measured from the top surface of the manhole cover to
the under surface of the foundation of the manhole.
895-5 RATE
The quantities measured as provided above shall be paid for at the

contract unit price respectively, for each items listed below and as
given in the Bill of Quantities, which prices and payment shall be full
compensation for furnishing and placing all materials, and for all other
costs necessary for the satisfactory completion of work prescribed in
this section.
Excavation shall be paid under section 402 & granular back fill shall
be paid under section 892.
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895-6 PAYMENT
Pay items No.895-6.1 Concrete manhole 1 m to 2 m

(3.28 ft to 6.56 ft) deep Each
Pay Item No.895-6.2 Concrete manhole more than 2 m

To 3 m (6.56 ft up to 9.84 ft) deep Each
*****************
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SECTION 896
DROP INLETS AND CATCH BASINS
896-1 DESCRIPTION
The work shall consist of constructing concrete catch basins, and drop
inlets including the furnishing of metal frames, grates and lids, and the
necessary excavation and backfill in accordance with these
specifications and the specifications for other work items involved and
in conformity with the dimensions, elevations and design shown on the
Drawings.
896-2.1 Steel Frames, Grates and Lids
Steel frames, grates and lids shall conform to the requirements of

AASHTO M-105
896.2.2 Concrete
Concrete shall be as specified in Section 701.
896.2.3 Masonry
When so indicated on the plans or approved by the Engineer Incharge,

brick or concrete block masonry may be used in lieu of concrete for the
walls of catch basins or drop inlets as specified in Section 801, “Brick
Masonry”.
896.2.4 Steel Reinforcement
Quality of reinforcing steel if used in construction of catch basins shall

be in accordance with the material requirements of Section 821.
896-3 CONSTRUCTION REQUIREMENTS.
896-3.1 Excavation and Backfill
Excavation and backfill shall conform to the requirements of Section

402 or 411 as the case may be.
896-3.2 Concrete Construction
Concrete of the specified class shall be supplied, placed finished and

cured as specified in Section 701
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896.3.3 Connections
Inlet and outlet tile, sewer pipe and conduit for connections with such
structures shall be of the same size, type and class as the tile, sewer
pipe, and conduit with which connections are made and shall conform
to the pertinent requirements thereof.
Pipe placed in cement concrete for inlet or outlet connections shall

extend from the inside surface of the wall and beyond the outside
surface of the walls a minimum distance of forty five (45) centimeters
distance to allow for connections with conduits or sewers, and the
concrete shall be carefully constructed around them so as to prevent
leakage around their outer surface.
896-3.4 Frames, Grates and Lids
All frames shall be set on full mortar beds or otherwise secured as

shown on the drawings. Grates and lids shall be fitted or secured to the
frames so that rocking is eliminated.
The frames, grates and lids shall be accurately set so that the complete
installation will be at the correct elevation required to fit the adjoining
surfaces, the grates and lids shall not be in place while the adjoining
concrete is struck-off and finished.
896-3.5 Cleaning
All catch basins and drop inlets shall be thoroughly cleaned of any
accumulations of silt, debris, or foreign matter of any kind, and shall
be kept clear of such accumulations until the final acceptance of the
work.
896-4 MEASUREMENT
The quantities to be measured shall be:
1. The number of drop inlets of the type specified in the

construction of Drop inlets, complete in place and accepted.
2. The number of catch basins of the type specified, complete in

place and accepted.
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896-5 PAYMENT
The quantities measured as provided above shall be paid at the contract
unit price for each of the pay items listed below. Such prices and
payment shall be full compensation for furnishing and placing all
materials, and for all other costs relative to the proper completion of
the work prescribed.
Granular backfill in place and accepted shall be measured and paid for
as specified in Section 402
896-5.1 Excavation. Per m3 or 1000Cft.
896-5.2 Masonry Per m3 or 1000Cft.
896-5.3 Concrete Per m3 or 1000Cft.
896-5.4 Steel Reinforcement Per Kg.
896-5.5 Steel Frames, Grates. Per Kg
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SECTION 897
SLOPE PROTECTION
897.1 GENERAL
897.1.1 Description
This work shall consist of the construction of bank and slope protection
courses other than guide bank in accordance with these Specifications and in
reasonably close conformity with the lines, grades, and thicknesses shown
on the plans or established by the Engineer Incharge.
897.1.2 Types
Types of slope protection are designated as follows:
(1) Riprap
(a) Hand-Placed Riprap-hand-placed stones on earth or gravel bedding.
(b) Grouted Riprap-hand-placed riprap as described above with voids

filled with sand-cement grout.
(2) Wire-Enclosed Riprap (Stones placed in wire fabric enclosures).
(3) Concrete Slope Paving
(4) Precast Concrete Slope Paving-Portland cement concrete slabs, blocks,

or shapes precast prior to placement.
897.2 MATERIALS
897.2.1 Stone
Stone for riprap shall conform to the requirements of Section No.861of

Standard Specifications for Road & Bridge Construction.
897.2.2 Wire-Fabric Enclosures
Wire-Fabric Enclosure shall be constructed of wire mesh. The wire mesh

shall be made of galvanized steel wire having a minimum size of 0.120-inch
diameter (U.S. Wire Gage No.11). The tensile strength of the wire shall be in
the range of 60,000 to 85,000 psi, determined in accordance with ASTM
A-392. The minimum zinc coating of the wire shall be 0.80 oz/sq. ft. of
uncoated wire surface as determined in accordance with ASTM A-90.
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Selvedge, tie, and connection wire shall meet the same strength and coating
requirements specified above for wire used in the wire mesh.
897.2.3 Filer Material
Filter material shall conform to the requirement of Section No.861 of

Standard Specifications for road and bridge construction.
897.2.4 Grout
Grout shall consist of one part Portland cement and three parts of sand,
thoroughly mixed with water to produce a workable mix.
897.2.5 Portland Cement Concrete
Portland cement concrete for cast-in-place slope paving shall conform to the
provisions of Section 701, of Standard Specifications for Road and Bridge
Construction.
Expansion joint filler shall conform to the provisions of Section 921of

897.2.6 Pneumatically Applied Mortar
Materials for mortar shall conform to the requirements of Section , of

Reinforcement shall conform to the provisions in Section 821, of Standard

Specifications for Road and Bridge Construction.
897.3 CONSTRUCTION
897.3.1 Preparation of Slopes
Slopes shall be shaped to allow the full thickness of the specified slope
protection and any bedding, where required. Slopes shall not be steeper than
the natural angle of repose of the slope specified in the contract. Where the
slopes cannot be excavated to undisturbed material, the underlying material
shall be compacted to 95% standard density per AASHTO T 99.
897.3.2 Bedding
When called for on the plans, a layer of filter material shall be placed on the
slope immediately prior to placement of the riprap or slope paving. The layer
of filter material shall be shaped to provide the minimum thickness
specified.
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897.3.3 Hand Placing Stones
For hand placing of stones, the larger stones shall be placed first with close
joints. The larger stones shall be placed in the footing trench. Stones shall be
placed with their longitudinal axis normal to the embankment face and
arranged so that each stone above the foundation course has a three-point
bearing on the under lying stones. The foundation course is the course
placed on the slope in contact with the ground surface. Bearing on smaller
stones that may be used for chinking voids will not be acceptable. Placing of
stones by dumping will not be permitted. Interstices shall be filled with
smaller stones.
897.3.4 Wire-Enclosed Riprap (Gabions)
897.3.4 .1 Fabrication
The wire mesh shall be twisted to form hexagonal openings of uniform

size. The maximum linear dimension of the mesh opening shall not exceed
4½ inches and the area of the mesh opening shall not exceed 8 square
inches. The mesh shall be fabricated in such a manner as to be non-
ravelling is defined as the ability to resist pulling apart at any of the twists
or connections forming the mesh when a single wire strand in a section is
cut.
Gabions shall be fabricated so the sides, ends, lid, and diaphragms can be
assembled at the construction site into rectangular baskets of the specified
size. Gabions shall be of single unit construction-base, lid, ends, and sides
shall be either woven into a single unit or one edge of these members
connected to the base section of the gabion in a manner that strength and
flexibility at the point of connection is at least equal to that of the mesh.
Where the length of the gabion exceeds its horizontal width, the gabion
shall be equally divided by diaphragms of the same mesh and gauge as the
body of the gabions into cells, the length of which does not exceed the
horizontal width. The gabion shall be furnished with the necessary
diaphragms secured in proper position on the base in a manner that no
additional tying at this junction will be necessary.
All perimeter edges of the mesh forming the gabion shall be securely clip
bound or selvedged so that the joints formed by tying the selvedges have at
least the same strength as the body of the mesh.
Selvedge wire used through all the edges (perimeter wire) shall not be less
than 0.148-inch diameter (U.S. Wire Gage No. 9) and shall meet the same
strength and coating specifications as the wire mesh.
Tie and connection wire shall be supplied in sufficient quantity to securely

fasten all edges of the gabion and diaphragms and to provide for at least
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four cross connecting wires in each cell whose height is equal to the width
and at least two cross-connecting wires in each cell whose height is one-
half the width of the gabion. Cross-connecting wires will not be required
when the height of the cell is one-third the width of the gabion. Tie and
connection wire shall meet the same strength and coating specifications as
the wire used in the mesh, except that it may be as much as two gages
smaller.
In lieu of tie wire, two gauge galvanized hog rings may be used to connect
adjacent baskets and to secure basket lids. Spacing of the hog rings shall
not exceed 6 inches.
Vertical joints in the completed work shall be staggered at approximately

1/3 or ½ the length of the full baskets.
897.3.4.2 Installation
The gabions shall be placed on a smooth foundation. Final line and grade
shall be approved by the Engineer Incharge.
Each gabion unit shall be assembled by binding together all vertical edges
with wire ties on approximately 6-inch spacing or by a continuous piece of
connecting wire stitched around the vertical edges with a coil about every
4 inches. Empty gabion units shall be set to line and grade as shown on the
plans or as directed by the Engineer Incharge. Wire ties, hog rings, or
connecting wire shall be used to join the units together in the same manner
as described above for assembling. Internal tie wires shall be uniformly
spaced and securely fastened in each cell of the structure.
A standard fence stretcher, chain fall, or iron rod may be used to stretch the
wire baskets and hold alignment.
The gabions shall be filled with stone carefully placed by hand or machine
to assure alignment and avoid bulges with a minimum of voids. Alternate
placing of rock and connection wires shall be performed until the gabion is
filled. After a gabion has been filled, the lid shall be bent over until it
meets the sides and edges. The lid shall then be secured to the sides, ends
and diaphragms with the wire ties or connecting wire in the manner
described above for assembling.
897.3.5 Grouted Riprap
Stones shall be placed on the slope as specified in Chapter 897 and shall be
thoroughly moistened with water after placement. Grout shall be applied
while the stone is moist and shall be worked into the interstices to
completely fill the voids.
Where the depth is in excess of 12 inches, the stone shall be placed in 12-
inch lifts and each lift grouted prior to placement of the next lift.
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Succeeding lifts shall be constructed and grouted before grout in the

previous lift has set.
Grout shall be placed only when the weather is suitable and shall be
protected from freezing for at least 4 days. The surface shall be cured by
covering with moist earth, wet rugs or curing blankets for at least 3 days
after grout placement.
Weep holes shall be provided through the riprap as shown on the plans or
as directed by the Engineer Incharge.
897.3.6 Concrete Slope Paving
897.3.6.1 Cast-in-Place Slope Paving
Concrete shall be mixed and placed in conformance with the provisions in

Section 701, of Standard Specifications for Road and Bridge Construction,
and shall be spread and tamped until it is thoroughly compacted and
mortar flushes to the surface. If the slope is too steep to permit the use of
concrete sufficiently wet to flush with tamping, the concrete shall be
tamped until consolidated and a mortar surface ¼ inch thick, troweled on
immediately. The mortar shall consist of one part Portland cement and
three parts of fine aggregate. The mortar surface shall be considered as a
part of the concrete and no separate payment will be made therefore.
After striking off to grade, the concrete shall be hand floated with wooden
floats. The entire surface shall be broomed with a fine texture hair push
broom to produce a uniform surface with the broom marks parallel to the
edges of the panel. Edges and joints shall be edged with a ¼ inch radius
edger prior to the brooming.
Expansion joints shall be installed transversely at intervals of 20 feet.

Longitudinal expansion joints shall be installed at the locations shown on
the plans. Expansion joints shall be filled with expansion joint filler ½ inch
thick.
Cast-in-place concrete shall be cured as provided in Chapter 701, of

Weep holes shall be provided through the slope paving as shown on the
plans or as directed by the Engineer Incharge.
Previous backfill material, if required by the plans, shall be placed as

shown. Two cubic feet of previous backfill material wrapped in filter
fabric shall be placed at each weep hole and drain hole.
At the completion of the work, footing trenches shall be filled with

excavated material and compaction will not be required.
897.3.6.2 Precast Slope Paving
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Precast slabs, blocks, and shapes shall be laid on a 3 inch bed of cushion
sand in the pattern shown on the plans. Blocks and shapes shall be
thoroughly rammed in place to provide a uniformly even surface and solid
bedding under each block or shape.
In the areas where grouting is called for, the blocks shall be laid in running
bond with the length parallel to the slope and with ¼ inch joints.
Following the laying of the blocks, in the area to be grouted, sufficient
mortar sand shall be spread over the surface and swept into the joints to fill
the latter to 4 inches from the surface. The blocks shall be wetted to the
satisfaction of the Engineer Incharge before any grout is placed. The joints
shall be filled with grout flush with the top of the block.
After grouting has been completed and the grout has sufficiently hardened,
the blocks shall be wetted, covered and cured with curing blankets or
covers for the first 7 days after grouting. Grout shall not be poured during
freezing weather.
897.3.7 MEASUREMENT AND PAYMENT
897.3.7.1 Method of Measurement
897.3.7.1.1 Stone Riprap and Filter Blanket
Hand-placed riprap, grouted riprap, and filter blanket aggregate will be

measured by the square meter, cubic meter, or 100 cft., as listed in the
schedule of bid items. The area will be that actually placed to the limiting
dimensions shown on the plans, measured along the upper surface. If
measured by the cubic meter & cft., the volume will be computed on the
basis of the measured area and the thickness specified on plans.
897.3.7.1.2 Wire-Enclosed Riprap (Gabions)
Wire-enclosed riprap (gabions) will be measured as the number of square

meter or square foot of surface area.
897.3.7.1.3 Cast-in-Place Concrete Slope Paving
Cast-in-place concrete slope paving will be measured on a square meter or

square ft. or cubic meter or cubic ft. basis. The area will be that actually
placed to the limiting dimensions shown on the plans, measured along the
upper sloped surface. If measured by the cubic meter or foot, the volume
will be computed on the basis of the measured area and the thickness
shown on the plans. No additional compensation will be allowed for
additional concrete placed by reason of low foundation.
897.3.7.1.4 Precast Concrete Slope Paving
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Precast concrete slabs, blocks, or shapes placed as slope paving will be

measured in square meter or square foot computed from the payment lines
shown on the plans.
897.3.8 Payment
897.3.8.1 General
Payment for slope protection of the various types at the unit prices bid
will include full compensation for all labor, materials, equipment, or
other incidentals in connection with the preparation of sub-grade (except
for the furnishing and placement of filter blanket material), excavating
and back filling toe trenches where required, furnishing and placing the
stones, slabs, blocks, shapes, grout, mortar, Portland cement concrete,
reinforcing steel, expansion joint filler, if required, and all other work
and incidental material required to complete the work in accordance with
the plans and specifications.
897.3.8.2 Stone Riprap
Hand-placed riprap, and grouted riprap measured in accordance with

Article 897.3.7.1.1 will be paid for at the price bid per square meter,
square foot, per cubic meter or per cubic foot as set forth in the schedule
of bid items.
897.3.8.3 Wire-Enclosed Riprap (Gabions)
Wire-enclosed riprap (gabions) measured in accordance with Article

897.3.7.1.2 will be paid for at the price bid per square yard. Such price
shall include wire baskets, connection hardware, anchors, stone filling,
labor, and equipment necessary to complete the work in accordance with
the plans and specifications.
897.3.8.4 Cast-in-Place Concrete Slope Paving
Cast-in-place concrete slope paving measured in accordance with Article

897.3.7.1.3 will be paid for at the price bid per square meter, square foot
or per cubic meter or per cubic foot as set forth in the schedule of bid
items.
897.3.8.5 Precast Concrete Slope Paving
Precast concrete slope paving measured in accordance with Article

897.3.7.1.4 will be paid for at the price bid per square meter or foot. Such
price shall include cushion sand and shall include Portland cement grout
or mortar, if required by the plans or specifications.
897.3.8.6 Filter Blanket
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Filter blanket of filter material measured in accordance with Article

897.3.7.1.5 will be paid for at the price bid per square meter, square foot
per cubic meter per cubic foot, or as set forth in the schedule of bid items.
****************
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SECTION 898
KERB AND GUTTER
898-1 DESCRIPTION
This item shall consist of kerb, gutter, or combination of kerb and

gutter, constructed of the following materials and in accordance with
the specifications at the location and of the form, dimensions and
designs shown on the drawings or as directed by the Engineer
Incharge.
The kerb, gutter or combination of kerb and gutter may be constructed

by one of the following ways:
. Cement Concrete Cast in place or
. Pre-cast Cement Concrete
898-2.1 Cement Concrete for Cast in Place Units
The cement concrete for cast-in-place kerb, gutter or combination of

kerb & gutter shall be type C and shall conform to the requirements of
Section 701. The units shall be cast as per details shown on the
drawings.
898-2.2 Cement Concrete for Pre-cast Units
Cement Concrete for pre-cast kerb, gutter or combination of kerb &

gutter shall consist of Type C cement concrete, conforming to the
requirements of Section 701 and to the length, shapes and other details
Reinforcing Steel shall conform to Section 821.
898-2.4 Joint Filler
Expansion joint filler shall be either the preformed type conforming to

the requirements of AASHTO M 153 or shall be pre-cut fiber-board
packing.
898-2.5 Joint Mortar

Joint mortar shall consist of one part cement and two parts of approved
sand with water added to obtain the required consistency.
The mortar shall be used within 30 minutes of preparation. The
bounding compound when used shall conform to AASHTO M-200.
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898-3.1 Cast in Place Units
a Excavation and Bedding.
Excavation shall be made to the required depth and the base

upon which the kerb gutter, gutter or combination of kerb and
gutter is to be set. It shall be compacted to a firm, even surface.
All soft and unsuitable material shall be removed and replaced
with suitable material acceptable to the Engineer Incharge. The
surplus or unsuitable material resulting from Excavation shall
be disposed off as directed by the Engineer Incharge. When
directed by the Engineer Incharge a layer of clean sand and
gravel or other approved quarry material, having minimum
compacted thickness of 15 cm (6 in) shall be placed to form a
bed for the kerb, gutter or combination of kerb and gutter.
b Forms
Forms to hold the cement concrete shall be built and set in

place as described under Section 701-8. Forms for at least 60
meters (200 feet) of kerb, gutter or combination of kerb and
gutter shall be in place and checked for alignments and grade
before concrete is placed. Kerb gutter or kerb and gutter
constructed on curves shall have forms of either wood or metal
and they shall be accurately shaped the radius of curvature
shown on the drawings. Mixing, placing, and curing of concrete
shall be in accordance with Section 701 and the requirements
given below.
c Placing Cement Concrete
Cement Concrete may be placed to the full depth required. The

top of the kerb gutter or combination of kerb and gutter shall be
floated smooth and the edges rounded to the radii shown on the
Drawings. Before finishing, the surface of the gutter or kerb or
combination of both shall be tested with a 3-meter (10 feet)
straight edge and any irregularities of more than 5 mm (3/16
inch) shall be eliminated. In finishing concrete, only mortar
normally present in the concrete shall be permitted for
finishing. The use of a separate mortar finishing coat or the
practice of working dry cement into the surface of the concrete
will not be permitted.
d Joints.
The kerb and gutter shall be constructed in uniform sections of

25 meter (80 feet) in length except where shorter sections are
required to coincide with the location of weakened plane or
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contraction joint of the concrete pavement or for closures but

no section shall be less than 2 meter (6 feet) long. The sections
shall be separated by approved templates set perpendicular to
the face and top of the kerb and gutter. The templates shall be
approximately 5 mm (3/16 inch) in thickness, of the same
width as that of the kerb and gutter and not less than 5 cm (2
inch) greater than the depth of the kerb and gutter. Templates
shall be set carefully and held firmly during the placing of the
concrete and shall be allowed to remain in place until the
concrete has set sufficiently to hold its shape, but shall be
removed while the forms are still in place. When pre-cut
fiberboard packing is used in the expansion joints it may be
used in place of the approved template referred to above, on the
approval of the Engineer Incharge. In this event the fiberboard
shall be pre-cut to the shape of the kerb so that its outer edge
will be flush with the abutting kerb.
Expansion joints shall be formed in the kerb and gutter at

intervals of approximately 25 meter (82 feet) in order to
coincide with the expansion joints of cement concrete
pavement or as shown on the drawings.
e Removal of Forms and Finishing
The forms shall be removed 24 hours after concrete has been

placed except that the form used against the face of the kerb in
a combination of kerb and gutter shall be removed as soon as
the concrete has set sufficiently to hold its shape. Minor defects
shall be repaired with mortar containing one part of Portland
cement and two parts of approved sand. Plastering shall not be
permitted on the face of a kerb or kerb and gutter and all
rejected kerb or gutter shall be removed and replaced without
additional compensation. All surfaces which will be exposed in
the finished construction of the kerb and gutter shall be finished
while the concrete is still “green” by wetting a wooden float
and rubbing the surface until they are smooth.
f Curing
Immediately upon the completion of the rubbing down, the

surface shall be moistened and kept moist for 3 days. Other
methods of curing shall be adopted on the approval of the
Engineer Incharge. The concrete shall be cured by covering
with suitable cotton or Hessian mats and by frequent sprinkling
with water with liquid forming compounds subject to approval
of Engineer Incharge.
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g Backfilling
After the concrete has been cured as specified, spaces on back

of the kerb or kerb and gutter excavated for placing the kerb or
kerb and gutter shall refilled to the required elevation with
suitable earth or granular material, which shall be tamped in
layers of not more than 15 cm (6 inch) each until firm and
solid.
898-3.2 Pre-cast Units
a. Excavation and Bedding.
Excavation shall be made to the required depth as shown on the

drawings. All soft and unsuitable material shall be removed and
replaced with a suitable material acceptable to the Engineer
Incharge. The surplus or unsuitable material resulting from
excavation shall be disposed off as directed by the Engineer
Incharge.
Bedding shall consist of Class B Cement Concrete conforming

to the requirements of Section 701 and shall be to the Section
and dimensions shown on the drawings.
b Placing
The pre-cast concrete kerbs shall be set in 2 cm (3/4 inch) of

cement mortar to the line level grade as shown on the drawings
or as directed by the Engineer Incharge. Pre-cast units which
show surface irregularities of more than 5 mm (3/16”) under a
3 meter (10 feet) straight edge or surface pits more than 12.5
mm (1/2”) in diameter will be rejected.
c Joints
Joints between consecutive units shall be 3 to 5 mm (1/8” to

3/16”) wide & filled with cement mortar to the full section of
the unit.
d Backfilling
Backfilling shall meet the requirements of Para 898-3.1 (g)
898-4 MEASUREMENT
All kerb, gutter or combination of kerb and gutter shall be measured by

the linear meter or foot along the front face of the section at the
finished grade elevation. Deductions in length will be made for
drainage structures installed in the kerbing such as catch basin and
drop inlet, etc.
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Bed course material shall be measured by the cubic meter or hundred

cubic feet of material compacted in place.
Cement concrete and cement mortar that may be required for bedding
to pre-cast concrete kerbs as shown in the drawings shall not be
measured for payment as separate items, but the cost shall be included
in the contract unit price for pre-cast concrete kerbs.
898-5 RATE
The accepted quantities of kerb or gutter or combination of kerb and

gutter shall be paid for at the contract unit price per linear meter or foot
for each of the particular pay items listed below and shown in the Bill
of quantities, which payment shall constitute full compensation for
furnishing and placing all materials for concrete, for reinforcing steel if
required on the drawings, for expansion joints, materials, forms for
drainage opening, excavations bedding, backfilling and dumping and
disposal of surplus materials and for all labor equipment, tools and
incidentals necessary to complete the item. Compacted bed course
material shall be measured in cubic meter or 100 cu feet and shall be
paid separately.
898.6 PAYMENT
Item No. 898-6.1 Cast-in-situ Cement Per meter (m) or foot (ft)
Concrete Kerb
Item No. 898-6.2 Cast-in-situ Cement Per meter (m) or foot (ft)
Concrete Gutter
Item No. 898-6.3 Pre-cast Concrete Kerb Per meter (m) or foot (ft)
Item No. 898-6.4 Pre-cast Concrete Per meter (m) or foot (ft)
Gutter
Item No. 898-6.5 Compacted Bed Per cubic meter (m3) or
Course 100 cubic feet (100 ft3)
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SECTION 899
CEMENT CONCRETE SIDEWALK
899-1 DESCRIPTION
This work shall consist of the construction of cement concrete

sidewalk in accordance with these specifications and to the line, grade,
levels and dimensions shown on the drawings or as directed by the
Engineer Incharge.
Cement Concrete shall be of the Type Specified on the drawings and in

conformance with Section 701.
899-2.2 Expansion joint Filler
Unless otherwise directed the joint filler shall have a thickness of 5

mm (3/16 inch) and conform to the requirements mentioned on the
drawings or as directed by the Engineer Incharge.
899-2.3 Forms
Forms shall be of wood or metal as approved by the Engineer Incharge

and shall extend to the full depth of the concrete. All forms shall be
straight, free from warp and of adequate strength to resist bending.
899-2.4 Bed Course Material
Bed course material shall consist of crushed brick, gravel, crushed

stone or other approved material of such gradation that all particles
will pass through a ¾” (19 mm) sieve.
899-3.1 Excavation
Excavation shall be made to the required depth and to a width that will
permit the installation and bracing of the forms.
The foundation shall be shaped and compacted to minimum 90% of the

maximum dry density as determined by AASHTO T-191 Method. The
surface shall be even conforming to the section shown on the drawings.
All soft material shall be removed and replaced with acceptable
material.
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899-3.2 Placing of Bed Course Material
The bed course material shall be compacted in layers not exceeding 10

cm
(4 inch) to the depth and to the line, grade levels dimensions as shown
on the drawings.
899-3.3 Forms and Expansion Joints
All forms shall be staked securely in position at the correct line and
elevation.
Expansion joint filler shall be set in the position shown on the
drawings before the placing of the concrete is started. The joint filler
shall be placed 5 mm (3/16 inch) below the top surface of the finished
sidewalk.
899-3.4 Placing the Cement Concrete Material

The mixing, placing, finishing, and curing of concrete shall be as
provided under Section 701.
Before the concrete has set, the surface of the concrete shall be
troweled until it is of uniform smoothness and is true to the lines,
elevations, and surface required.
The surface shall be cut through to a depth of 1 cm (3/8”) with a trowel
at intervals of 1 meter (3 feet) or where required, in straight lines
perpendicular to the edge of the sidewalk. The surface shall then be
brushed. The edges of the sidewalk and the transverse cuts shall be
shaped with a suitable tool so formed as to round the edges to a 1.5 cm
(1/2”) radius.
899-4 MEASUREMENT
The quantity to be paid for shall be area of cement concrete sidewalk
complete in place and accepted. The unit of measurement will be
square meter or square feet.
899-5 RATE
The quantity as determined above, shall be paid for at the contract unit
price per square meter or Sq. feet for the pay items listed below and
shown in the Bill of Quantities, which price and payment shall
constitute full compensation for furnishing and placing all materials,
for Portland Cement concrete, expansion joint material, for excavating
and compacting the foundation bed, for furnishing and placing any
crushed brick, gravel or other porous bed course material, for forms,
and for all labour, equipment, tools and incidentals necessary to
complete the item.
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899-6 PAYMENT
Item No.899-6.1Cement Concrete sidewalk Per Sq. meter (m2) or

Per Sq. feet (ft2) sft.
******************
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CHAPTER 900
INCIDENTAL CONSTRUCTION
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SECTION 901
METAL BEAM GUARD RAIL
901-1 DESCRIPTION
This item shall consist of furnishing and construction metal beam

guardrail constructed in accordance with these specifications at the
locations and in conformity with the dimensions, and design shown on
the drawings or as directed by the Engineer Incharge.
901-2.1 Metal Beam Guardrail

The rail elements shall be galvanized corrugated steel beam
conforming to the requirements of AASHTO M 180 of the designated
type and class.
The mechanical properties of the base metals for beams shall conform
to the following requirements:-
Yield Point 3500 kg/cm2 (50,000 Psi) minimum

Tensile Strength 4900 kg/cm2 (70,000 Psi) minimum
Elongation Not less than 12 percent in a
5.o8 cm (2 inch) gage length
when tested in accordance with ASTM E 8
In addition to the above the rail shall withstand a cold bend, without
cracking of 180° around a mandrill of a diameter equal to 2 ½ times
the thickness of the plate.
901-2.2 End of Buffer Sections
The end or buffer sections shall be formed from open health, electric
furnace or basic oxygen steel. The section shall be of the same or
superior class and type used for the beam to which it is attached. The
size of the end or buffer section shall be according to the details given
on the drawings or as directed by the Engineer Incharge.
901-2.3 Connections and Splices
All connections or splices shall be formed with oval shoulder button
headed bolts to minimize projections on the side of the guardrail. All
bolts and nuts for beams shall conform to or exceed the requirements
of ASTM A307 and shall be galvanized as specified in ASTM A 153.
The bolted connection of the rail element to the post shall withstand a
2270 kg (5000 lbs) pull at right angles to the line of the railing.
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901-2.4 Guardrail Posts
Posts shall be of either steel or concrete as specified. Only one type of

post shall be used for any one continuous guardrail, except at junctions
between bridges and embankments.
a. Steel posts shall be galvanized and of the section and length

specified or as shown on the drawings. They shall conform to
the requirements of AASHTO M 183 for the grade specified.
b. Pre-cast reinforced concrete posts shall be of a section and

length as specified or as shown on the drawings. The concrete
shall be Class C as specified under 701. Reinforcement shall
conform to the requirements of section 821.
All bars shall be of the deformed type.
901-2.5 Wooden Spacer Blocks.
Wooden spacer blocks between the guard rail and the posts, if required,
shall be provided to the section and length specified or as shown on the
drawings. Kail, Saal Deodar, Kahu or other similar approved wood
shall be used.
901.2.6 Post Foundation Blocks
Where required, post foundation blocks shall be constructed in Class B

cement concrete as specified under section 701 to the size shown on
the drawings.
All posts shall be set vertically in the position shown on the drawings
and where embedded in a concrete foundation block shall remain
undisturbed for a minimum of 48 hours. The space around the posts
shall be backfilled to the ground line, with selected earth containing no
rocks, in layers of not exceeding 15 cm (6 inches) and each layer shall
be moistened and thoroughly compacted. Where steel posts are driven
into the ground no buckled post or deformed head shall be accepted.
901-3.1 Erection of Rail
All metal work shall be fabricated in the shop and no cutting or

welding shall be done in the field unless otherwise ordered by the
Engineer Incharge. Rail elements shall be lapped so that the exposed
ends will not face approaching traffic. Terminal sections shall be
installed in accordance with the manufacturer’s recommendation or as
shown on the drawings or as directed by the Engineer Incharge.
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901-4 MEASUREMENT
The guardrail shall be measured by the linear meter or foot from center
to center of end posts for each completed section fastened in place and
accepted.
Post for guardrail and end or buffer sections for guardrail shall be
measured by the number erected in place and accepted. Post
foundation blocks provided, if required, shall not be paid separately.
901-5 RATE
The quantities determined as prescribed above shall be paid for at the

contract unit price for the pay item listed below and shown in the Bill
of Quantities which price shall be full compensation for furnishing,
placing all materials, for foundations, for provision and erection of
posts, for excavation and backfill, for installation and fastening, and
for all costs including labour, tools and incidentals necessary to
complete the work prescribed in this item.
901.6 PAYMENT
Item No.901-6.1 Metal Guardrail Per meter (m) or

Per foot (ft)
Item No.901-6.2 Guardrail end or

Buffer Sections Each
Item No.901-6.3 Concrete Post for

Guardrail Each
Item No.901-6.4 Steel Post for

Guardrail Each
***************
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SECTION 902
CEMENT CONCRETE BEAM GUARDRAIL
902-1 DESCRIPTION
This item shall consist of cement concrete beam guardrail constructed

in accordance with these specifications at the locations and in
conformity with dimensions, and design shown on the drawings or as
The beams and guardrails may be the pre-cast units properly joined
together at site with the cement sand mortar.
902-2.1 Cement Concrete Beam Guardrail
The rail shall be of Class C cement concrete as specified under section

701. Reinforcing steel shall conform to requirements of Section 821.
All bars shall be of the deformed type
902-2.2 Cement Concrete Guardrail Posts
Cement concrete posts shall be of a section and length as specified or

as shown on the drawings. The concrete shall be Class C as specified
under section 701. Reinforcing steel shall conform to the requirements
of Section 821. All bars shall be of the deformed type.
902.2.3 Cement Sand Mortar
The cement sand mortar to be used for making good the joints between
the guardrail post holes and the beams of cement concrete shall be one
part of cement and two parts of sand with water cement ratio just
sufficient to make the mortar workable.
902-2.4 Post Foundation Blocks
Where required, post foundation blocks, shall be constructed in Class

B cement concrete as specified under section 701 to the size shown on
the drawings.
902-3 MEASUREMENT
The guardrail shall be measured by the number from center to center of

end posts for each completed unit in place and accepted.
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Post for guardrail shall be measured by the number for each completed
unit in place and accepted. Post foundation blocks provided, if
required, shall not be paid separately
902-4 RATE
The quantities, determined as prescribed above shall be paid for at the

contract price per unit of measurement for the pay item listed below
and shown in the Bill of Quantities which price shall be full
compensation for furnishing, placing all materials, for foundations, for
provision and erection of posts, for excavation and backfill, for
installation and joining with mortar, and for all costs including labor,
tools and incidentals necessary to complete the work prescribed in this
item.
902.5 PAYMENT
Pay item No.902-5.1 Cement Concrete

Beam Guardrail Per meter or Rft
Pay item No.902-5.2 Cement Concrete

Post for Guardrail Each
****************
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SECTION 903
TRAFFIC ROAD SIGNS
903-1 DESCRIPTION
This work shall comprise of furnishing and installing traffic signs in

accordance with the specifications and special provision available in
the Manual of Uniform Traffic Control Devices, Highway Safety
Wing, Ministry of Communications Government of Pakistan or as per
detail shown on the drawings.
903-2.1 Sign Panels
Sign panels for regulatory, warning and informatory signs shall be

manufactured from aluminum alloy conforming to ASTM B 209, alloy
6061 T6 or 5052 – H38 plates of 3 mm thickness or from steel enamel
plated of 3 mm (1/8 inch) thick conforming to ASTM A36 Grade.
The blanks shall be free from laminations, blisters, open seams, pits,
holes or other defects that may affect their appearance or use. The
thickness shall be uniform and the blank commercially flat. Perform
shearing, cutting and punching before preparing the blanks for
application of reflective material.
The blanks shall be cleaned, degreased, and chromate or otherwise

properly prepared according to methods recommended by the sheeting
manufacturer.
903-2.2 Retro-reflective Sheeting
Retro-reflective sheeting shall consist of a white or coloured sheeting

having a smooth outer surface and that essentially has the property of
retro-reflective over its entire surface. The following two types of
sheeting are specified as per ASTM D 4959-99.
Type-II: A medium high intensity retro-reflective sheeting sometimes

referred to as “super engineering grade” and typically enclosed lens
glass-bead sheeting. Typical applications for this material are
permanent highway signing, construction zone devices, and
delineators.
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Performance of Type-II:
Observa Entr- White Yellow Orange Green Red Blue Brown
-tion ance
Angle Angle
0.2º -4º 140 100 60 30 30 10 5.0
0.2º +30º 60 36 22 10 12 4.0 2.0
0.5º -4º 50 33 20 9.0 10 3.0 2.0
0.5º +30º 28 20 12 6.0 6.0 2.0 1.0
Type-IV: A high intensity retro-reflective sheeting. This sheeting is

typically an un-metallized micro-prismatic retro-reflective element
material. Typical applications for this material are permanent highway
signing, construction zone devices, and delineators.
Performance of Type-IV:
Observa Entr- White Yellow Orange Green Red Blue Brown
-tion ance
Angle Angle
0.1º -4º 400 270 160 56 56 32 12
0.1º +30º 120 75 48 13 13 7 3.0
0.2º -4º 250 170 100 35 35 20 7.0
0.2º +30º 80 54 34 9 9 5.0 2.0
0.5º -4º 135 100 64 17 17 10 4.0
0.5º +30º 55 37 22 6.5 6.5 3.5 1.4
903.2.2.1 Sign Faces:
1. The contractor shall submit to the Engineer Incharge for

approval 3 copies of detailed shop drawings of sign faces
required in the works, including the arrangement and spacing of
both Urdu and English wording.
2. The Urdu and English spelling of the names of towns, districts,
roads and streets will be as supplied or confirmed by the
Engineer Incharge.
3. The reverse face of all signs shall be painted with 2 coats of
primer and 2 coats of dull grey aluminum paint.
4. Rivets and other devices used for fixing sheet sign, plates to
their stiffeners or framework shall be compatible with the
materials being joined. Hollow rivets shall be blocked. They
shall be self-coloured or fitted with plastic caps to match the
colour of the front of the sign face where they are located.
5. Sign shall be located as instructed by the Engineer Incharge and
unless otherwise shown on the drawings, erected so that the
face is vertical and at an angle of 92º of the road cetreline. Where
lanes divide or are small radius curves, the contractor shall orientate
sign faces to avoid specular reflection and glare.
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903.2.3 Metal Posts
Metal posts shall be fabricated from structural steel conforming to the

Specifications of ASTM A 283 Grade D or HR-1, HR-2 of Pakistan
Steel Mills to the length and section shown in the drawings or as
All posts shall be thoroughly cleaned, free from grease, scale and rust,
and shall be given one coat of rust inhibitive priming paint and two
coats of specified paint.
903-2.4 Nuts and Bolts
Nuts, bolts, washers and other metal parts shall be hot-dip galvanized
after fabrication in accordance with the requirements of AASHTO M
111.
903-2.5 Concrete Foundation Blocks
The concrete for the foundation blocks shall be in accordance with

Section 701 and shall of the type B and size shown on the drawings.
903-3.1 Excavation and Backfilling
Holes shall be excavated to the required depth of the bottom of the

concrete foundation as shown on the drawings.
Backfilling shall be carried out by using the surplus excavated material

if approved by the Engineer Incharge and shall be compacted in layers
not exceeding 15 cm (6 inch) in depth.
Surplus excavated material shall be disposed of by the Contractor as

903-3.2 Erection of Posts
The posts shall be erected vertically in position inside the formwork of

the foundation block prior to the placing of the concrete and shall be
adequately supported by bracing to prevent movement of the post
during the setting process of the concrete. The posts shall be located at
the positions shown on the drawings.
903-3.3 Sign Panel Installation
Sign panels shall be installed by the Contractor in accordance with the

details shown on the drawings. Any chipping or bending of the sign
panels shall be considered as sufficient cause to require replacement of
the panels at the Contractor’s expense.
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The exposed portion of the fastening hardware on the face of the sign
shall be painted with enamels matching the background color.
All newly erected traffic road signs shall be covered with sacking or
other material until their uncovering is ordered by the Engineer
Incharge.
903-4 MEASUREMENT
The quantities of traffic road signs to be paid for shall be measured

under the following categories:-
Category 1 Warning, Prohibitory, Priority & Mandatory Signs.
Warning signs, prohibitory signs, priority and

mandatory signs shall be measured by the number
erected and accepted, including necessary posts.
The category 1 sings are subdivided into two classes

a. Advance warning/caution signs.
b. Mandatory/regulatory signs.
Category 2 Directions, Advance Direction & Confirmatory Signs
Direction signs, advance direction signs and

confirmatory signs shall be measured by the number of
signs erected and accepted, including necessary posts.
Category 3 These signs shall be rectangular in shape and

constructed with one, two, or three no. posts or as
shown on the drawings. Dimension may vary according
to the requirements, however total area of sign shall be
as under.
Category 3a = One Square meter.

Category 3b = Two Square meter.
Category 3c = As shown on drawings.
903-4.1 Installation of Safety Devices:
Safety devices comprising of road posts, delineators of various types,

fixed/ portable safety barriers and hazard markers e.g. Vergemaster,
Flexmaster Chevroflex, Bigmax, Edgemaster and passing place post
and other etc., shall be installed in accordance with the techniques and
methods laid down in the manufacturer’s manual or guide and in
conformity to the line and level and locations shown on the drawings
or as directed by the Engineer Incharge to ensure maximum visibility
and safety, even in adverse weather conditions. These shall be
constructed strictly with the specifications and full assistance by the
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manufacturer for installation with precision. These safety devices shall

be used as delineators at sharp curves of highways verges, high
embankments, culverts, bridges, as a visual and physical deterrent for a
prohibiting car parking on grass verges and protecting kerb-side areas
on public and private roads.
Sign faces
a) Design
All sign faces shall be of the type, colour, and size as shown in the
plans. Size and spacing of letters shall be as under:
1. The Urdu writing shall be in ‘Persian” character.

2. The Urdu and English writing shall be about the same in
length, width and spacing.
3. English letters are to be in italics except the first letter of
the word, which is to be in capital.
4. Height of Capital letters. 21
cm
5. Height of italics letters. 17
cm
6. Stroke Width and Width of border. 3.5
cm
7. Space between Words and borders. (at least). 5
cm
8. Space between Words. 5
cm
9. Space one line will occupy. 4
cm
10. Space between digits of numerals. 4
cm
11. Height of numerals same as capital letters. 23
cm
12. Space between lines (at least) 5
cm
13. Size of letter for km Height. K-
23 cm, m-8 cm
14. Width of letters for km including spacing. K-8
cm, m-9.6 cm
15. Width of dividing line. 2.0
cm
16. The size and spacing for Urdu letter and Words will
generally conform to the dimensions shown above for English
letters.
17. The spelling of place names in Urdu and in English shall be
as written in the Survey of Pakistan, maps.
b) Shop Drawings
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The contractor shall submit to the Engineer Incharge for approval,

three (3) copies of drawings for all special sign faces and all sign faces
bearing messages, showing the design and/or arrangement and spacing
of both the Urdu and English sign messages. Official town names and
their spelling shall be as provided by the Engineer Incharge. Size and
style of lettering shall be as shown on the plans or as otherwise
903-5 RATE
The quantities measured as determined above shall be paid for at the
contract unit price for the pay items listed below, and as shown in the
Bill of Quantities which price and payment shall be full compensation
for furnishing all labour, materials, tools, equipment, and
transportation, and for excavation, concreting, backfilling and erection
of posts, installation of sign panels and all incidental costs necessary to
complete the work as prescribed in this Section.
903-6 PAYMENT
Item No.903-6.1 Traffic Road Signs Category 1(a) Each

Item No.903-6.2 Traffic Road Signs Category 1(b) Each
Item No.903-6.3 Traffic Road Signs Category 2 Each
Item No. 903-6.4 Traffic Road Signs Category 3 (a) Each
Item No. 903-6.5 Traffic Road Signs Category 3 (b) Each
Item No. 903-6.6 Traffic Road Signs Category 3 (c) Sq. meter
or Sq. ft.
***************
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SECTION 904
PAVEMENT MARKING
904.1 DESCRIPTION
This work shall consist of furnishing non reflective or reflective

chlorinated rubber based or thermoplastic paint material or retro-
reflective preformed pavement marking (tape) whichever is called for
in the Special Provisions and shown in the Bill of Quantities, for
sampling and packing, for the preparation of the surface and for the
application of the paint to the pavement surface all in accordance with
these Specifications.
The paint shall be applied in conformance to the size, shape and

location of the markings as shown in the Drawings.
904.2 CHLORINATED RUBBER PAINT
904.2.1 Material Requirements
A standard and acceptable quality of Chlorinated Rubber based paint

shall be used. The paint shall be ready for application and shall be of a
smooth quality. The paint shall be homogeneous, well dispersed to a
smooth consistency and shall not cake, liver thicken, curdle, gel settle
badly or show any objectionable properties after period of storage not
to exceed six (6) months.
Composition
a) White Traffic Paint
i) Pigment Titanium Dioxide Rutile and extenders

100%
ii) Vehicle Modified Chlorinated Rubber

Plasticized and Resin Blend 52±4%
Solvents 45±4%
Additives i.e. Flow leveling, adhesion
Improving agents, anti-oxidants,
Siccatives etc. 1-3%
iii) Paint Composition Pigments 55±4% by Wt.

Vehicle, Solvent
and Additives 45±5% by Wt.
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b) White Traffic Paint
i) Pigment Chrome Yellow and

Extenders 100% by weight
ii) Vehicle Same as for white traffic paint
iii) Paint Composition Pigments 55±4% by weight

Vehicle, Solvent and
Additives 45±5% by weight
c) Black Traffic Paint
i) Pigment Chrome Black and

Extenders 100% by weight
ii) Vehicle Same as for white traffic paint
iii) Paint Composition Pigments 55±4% by weight

Vehicle 45±5% by weight
The volatile material shall be such character that has a minimum

solvent action of asphalt, and such that the resins and non-volatile
components will be entirely dissolved in the volatile material, and will
not precipitate from the solution on standing. The non-volatile material
shall be of such quality that it will not darken or become yellow when
a thin section is exposed to the sunlight.
Other pavement marking paint may be submitted by the Contractor as

an alternative to the above, for the approval of the Engineer Incharge.
904.2.1.1 Ballotini for Reflective Road Paint
The grading of ballotini dispersed in the paint shall be as follows:-
Sieve Sizes Percentage Retained
No. 12 0
No. 20 30
No. 30 50
No. 50 80
No. 80 100
Glass beads shall conform to AASHTO Designation M-247. At least

ninety (90) percent glass beads shall be transparent, reasonable
spherical and free from flaws.
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The proportion of ballotini to paint shall be not less than five hundred
(500) grams per liter of paint.
904.2.2 Photometric Requirements for Reflective Road Paint
Other reflective road paints may be considered for use by Engineer

Incharge provided they have minimum brightness values at two tenth
(0.2) degree and half (0.5) degree divergence expressed as candle
power per meter per square meter of surface coating as follows:
Colour
White Yellow
Divergence Angle (Degree) 0.2 0.5 0.2 0.5

Incidence Angles 4 (Degree) 237 118 129 75
Incidence Angles 40 (Degree) 75 43 43 32
904.2.3 Construction Requirements
Traffic marking shall be applied with approved equipment capable of

applying the paint at specified width and at the specified rate of
application. In no case shall the contractor proceed with the work until
the equipment, method of application and rate of application as
established by a test section have been approved by the Engineer
Incharge.
The paining of lane markers and traffic strips shall include the cleaning
of the pavement surfaces, the application, protection and drying of the
paint coatings, the protection pedestrians, vehicular or other traffic on
the pavements, the protection of all parts of the road, structures or
appurtenances against disfigurement by spatters, splashes or smirches
of paint or of paint materials, and the supplying of all tools, labour and
traffic paint necessary for the entire work.
The paint shall not be applied during rain, wet weather, when the air is
misty, or when, in the opinion of the Engineer Incharge, conditions are
otherwise unfavourable for the work. Paint shall not be applied upon
damp pavement surfaces, or upto pavements which have absorbed heat
sufficient to cause the paint to blister and produce a porous paint film.
The application of paint shall preferably be carried out by purpose-

made machine but where brushes are used only round or oval brushed
not exceeding 10 cm in width will be permitted. The paint, when
applied, shall be so applied as to produce a uniform, even coating in
close contact with the surface being painted.
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Traffic paint shall be applied to the pavement at a rate of one (1) litre
to tow and half (2.5) square meters or les. Contractor shall provide
adequate arrangements that applied paint is not disfigured by moving
traffic, till its complete drying and sticking to road surface.
904.3 Hot-Applied Thermoplastic Road Paints
904.3.1 Material Requirements
904.3.1.1 Aggregate
The aggregate shall consist of light coloured silica sand, calcite, quarts,
calcined flint, or other material approved by the Engineer Incharge.
904.3.1.2 Pigment and extender
a) White Material
The pigment shall be titanium dioxide complying with the

requirements of Type A (anatase) or Type R (rutile) of BS 1851
b) Yellow Material
Sufficient suitable yellow pigment shall be substituted for all or part of

the titanium dioxide to comply with the other requirements of this
specification.
c) All Materials
The extender shall normally be whiting (i.e. calcium carbonate

prepared from natural chalk) complying with the requirements of BS
1795. The manufacturer may substitute lithopone complying with the
requirement of BS 296 for any or all of the whiting.
d) Binder
The binder shall consist of synthetic hydrocarbon resin, or, with the
approval of the Engineer Incharge, gun or wood resin, plasticized with
mineral oil.
e) Composition of mixture
The proportions of the constituents of the mixed material as found on

analysis shall comply with the requirements of Table 1.
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TABLE 1
PROPORTIONS OF CONSTITUENTS OF MIXTURE
Constituent Percentage by mass of total mixture

Minimum Maximum
Binder (resin and 18 22
oil)
Pigment 6* -
Pigment and 18 22
extender
Ballotini 20 -
Aggregate
Pigment 78 82
Extender and
ballotini
* For titanium dioxide only. No minimum is specified for yellow

material.
Where specified, 10% in the case of material to which surface ballotini

is to be applied by pressure application.
The grading of the combined aggregate, pigment, extender and
ballotini (where specified) as found on analysis shall comply with the
requirements of table 2.
TABLE 2
GRADING OF COMBINED AGGREGATE, PIGMENT,
EXTENDER AND BALLOTINI
Sieve Percentage by mass passing Sprayed

2.80 mm 100
600 um 75-95
904.3.2 Sampling and Testing
904.3.2.1 Sampling
For the purpose of carrying out the testing, it is essential that adequate
and representative samples be taken in the manner prescribed in
specification BS 3262 at following stages.
a) At the manufacturer’s plant.

b) After it has been re-melted by the road application contractor.
904.3.3.2 Testing
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The samples shall be prepared and tested in accordance with BS

Specification 3262 (1976) appendix A to H. The test results shall
conform the following properties.
 Softening Point
The softening pint measured in accordance with appendix c shall

not be less than 65 centigrade.
 Colour and Luminance
a) White Material
The luminance factor of white material as delivered by the

manufacturer shall be measured in accordance with appendix D
and shall not be less than 70 whereas the luminance factor of
material obtained from an applicator or melter on site after re-
melting measured in accordance with appendix D shall not be
less than 65.
b) Yellow Material
The colour of yellow material shall be approximately BS 381C

Colour No. 355, Lemon. The luminance factor of yellow
material as delivered by the manufacturer shall be not less than
60 whereas the luminance factor of material obtained from an
applicator or melter on site after re-melting measured in
accordance with appendix D shall be less than 55.
 Heat Stability
a) White Material
When tested in accordance with appendix E, the luminance

factor of white material as measured in accordance with
appendix D shall be not less than 65.
b) Yellow Material
When tested in accordance with appendix E, the luminance

factor of yellow material as measured in accordance with
appendix D shall be not less that 55.
 Flow Resistance
In testing the flow resistance, a cone made and tested in

accordance with appendix F, shall not slump by more than
25%.
 Skid Resistance
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When tested in accordance with appendix G, the skid resistance of

a newly laid marking prepared under the stated conditions shall be
not less than 45.
904.3.3 Manufacturing, Packing and Storing of Paint
904.3.3.1 Manufacturing
The paint shall be produced in a plant owned and operated by the

manufacturer following a process which has been used by the
manufacturer for at least five (5) years to produce paint. The
equipment for mixing and grinding shall be clean, modern, and in good
condition.
904.3.3.2 Packing
 The material shall be supplied in sealed containers which do not

contaminate the contents and which protect them from
contamination.
 Each container shall be clearly and indelibly marked with the

manufacturer’s name, Batch number, date of manufacture,
reflectorisation (if applicable), colour, chemical type of binder and
maximum safe heating temperature.
904.3.3.3 Storing
The material shall be stored in accordance with the manufacturer’s

instructions and any material that is in damaged containers of which
the seal has been broken, shall not be used.
904.3.4 Certification
The Contractor shall furnish a certificate from manufacturer that the

material he proposes to use has the required properties, stating the
maximum and minimum proportions and grading of the constituents,
the acid value of the binder, the setting time, the maximum safe
heating temperature, the temperature range of the apparatus and the
proposed method of laying.
904.3.5 Application of Material to the Road
a) Preparation of site
The thermoplastic paint shall only be applied to surfaces, which are

clean and dry, immediately before the application of paint, the surface
shall be cleaned with mechanical broom, compressed air or other
approved means to remove surplus asphalt, oils, mud, dust and other
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loose or adhered material. The material shall not be applied if the road
surface is at a temperature of less than 5 centigrade.
b) Preparation of material on site
The material shall be melted in accordance with the manufacturer’s

instructions in a heather fitted with a mechanical stirrer to give a
smooth consistency to the thermoplastic material and such that local
overheating will be avoided. The temperature of the mass shall be
within the range specified by the manufacturer, and shall on no account
be allowed to exceed the maximum temperature stated by the
manufacturer. The molten material shall be used as expeditiously as
possible, and for thermoplastic material, which has natural resin
binders or is otherwise sensitive to prolonged heating, the material
shall not be maintained in a molten condition for more that 4 hours.
 After transfer to the laying apparatus, the material shall be

maintained within the temperature range specified by the
manufacturer and stirred to maintain the right consistency for
laying.
 On concrete carriageway, a tack coat compatible with the marking

material shall be applied in accordance with the manufacturer’s
instruction prior to the application of thermoplastic material
c) Laying
Carriageway centre lines, lanes and edge lines shall be laid to a regular
alignment by self-propelled machine. Other marking may be laid by
hand, hand propelled machine or self propelled machine as approved
by the Engineer Incharge. The surface produced shall be uniform in
texture and thickness and appreciably free from blisters and streaks.
d) Reflectorization by surface application
When surface application of ballotini is required, additional ballotini

(400 g/m to 500 g/m from the machine) shall be applied by pressure
concurrently with the laying of the line with sufficient velocity to
ensure retention in the surface of the line. The ballotini so sprayed
shall give uniform cover and immediate reflectivity over the whole
surface of the marking.
Ballotini dispensed on the surface of the markings shall conform to the

following grading:
Sieve Percentage by mass passing
1.7 mm 100
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Draft 2004
600 μ 80-100
425 μ 45-100
300 μ 10-45
212 μ 0-25
75 μ 0-5
Not less than 90% by mass of the ballotini, shall be of transparent

glass, spherical in shape and not more then ten (10) percent shall be
ovate in shape or have other flaws. The ballotini shall be made of soda
glass.
e) Thickness
Unless otherwise approved by the Engineer Incharge, the material shall

be laid to the following thickness.
a) Sprayed lines other than yellow. Not less than 1.5mm.

b) Sprayed yellow edge lines not less than 0.8mm.
The minimum thicknesses specified are exclusive of surface applied

ballotini. The method of thickness measurement shall be in accordance
with appendix H of BS 3262 (1976).
904.3.6 Trial Section
In no case shall the contractor proceed with the work until the
equipment, method of application and rate of application conforming
the required thickness (as established by a test section) have been
904.4 RETRO-REFLECTIVE PREFORMED PAVEMENT

MARKINGS
904.4.1 Materials Requirements
The performed markings shall consist of white or yellow films with

pigments selected to conform to standard highway colours. Ceramic
and glass beads shall be incorporated to provide immediate and
continuing retro-reflection. Ceramic skid particles shall be bonded to a
top urethane layer to provide a skid resistant surface.
The preformed markings shall be capable of being adhered to asphalt

cement concrete (ACC) or Portland Cement Concrete (PCC) by a pre-
coated pressure sensitive adhesive. A primer may be used to
precondition the pavement surface. The preformed marking film shall
mold itself to pavement contours by the actions of traffic. The
pavement marking film wearing courses during the paving operation in
accordance with the manufacturer’s instructions, approved by the
Engineer Incharge. Following proper application and tamping, the
markings shall be immediately ready for traffic. The bidder when
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bidding, shall identify proper solvents and/or primers (where

necessary) for proper application, and recommendation for application
that will assure effective product performance. The preformed
markings shall be suitable for use for one year after the date of receipt
when stored in accordance with the manufacturer’s recommendations.
The marking film shall be durable retro-reflective plisot polymer

pavement marking film for performed longitudinal markings subject to
low to medium traffic volumes and moderate wear conditions such as
repeated shear action form crossover or encroachment on
channelization lines.
The retro reflective pavement marking film shall consist of mixture of

high-quality pigmented polymeric materials, with a reflective layer of
ceramic and glass beads, and a layer of skid resistant ceramic particles
bonded to the top urethane wear surface. The film shall have a pre-
coated pressure sensitive adhesive. The edges of the preformed tape
shall be clear-cut and true.
904.4.2 Colour:
The daytime colour of the white film shall provide minimum initial
Luminance factor, Y, of 80, and shall conform to the following
chromaticity requirements: X=0.290, Y=0.315; X=0.491, Y=0.435;
X=0.512, Y=0.486; X=0.536, Y=0.463.
Measurements shall be made in accordance with ASTM E 1349, using

illuminant “C” and 0/45 (45/0) geometry. Calculations shall be in
accordance with ASTM E 308 for the 2-degree standard observer.
904.4.3 Reflectance.
The white and yellow films shall have the following initial minimum
reflectance values as measured in accordance with the testing
procedures of ASTM D 4061. The photometric quantity to be
measured shall be specific luminance (SL), and shall be expressed as
millicandals per square foot per foot-candle ((mcd. Ft-2). fc-1). The
metric equivalent shall be expressed as millicandals per square meter
per lux (mcd. m-2). lx-1)
White Yellow
Entrance Angle 86.00 86.5 degree 86.5 degree

degree
Observation Angle 1.0 degree 1.0 degree
Specified Luminance 300 175
SL[(mcd. ft-2) fc-1]
904.4.4 Skid Resistance
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The surface of the retro-reflective films shall provide an initial

minimum skid resistance value of 55 BPN as measured by the British
Portable Skid Tester in accordance with ASTM E 303.
904.4.5 Patchability
The pavement marking film shall be capable of use for patching worn
areas of the same type of film in accordance with the manufacturer’s
instructions.
904.4.6 Reflectance Retention
To have a good, effective performance life, the ceramic and glass beads
must be strongly bonded and not be easily removed by traffic wear.
The following test shall be employed to measure reflectively retention.
904.4.6.1 Taber Abraser Simulation Test
Using a Taber Abraser with an H-18 wheel and a 125 gram load, the
sample shall be inspected at 200 cycles, under a microscope, to
observe the extent and type of bead failure. No more than 15% of the
beads shall be lost due to popout and the predominant mode of failure
shall be “wear down” on the beads.
904.4.7 Beads
The size, equality and refractive index of the ceramic and glass beads
shall be such that the performance requirements for the marking shall
be met. The bead adhesion shall be such that beads are not easily
removed when the material surface is scratched.
904.4.8 Bead Retention
The film shall be ceramic and glass bead retention qualities such that
when a 2 in x 6 in. (5.08cm x 15.24cm) sample is bent over a ½ in.
(1.27cm diameter-mandrel, with the 2 in. dimension perpendicular to
the mandrel axis, microscopic examination of the area on the mandrel
shall show no more than 10% of the beads with entrapment by the
binder of less than 40%.
904.4.9 Thickness
The film without adhesive, shall have a minimum thickness of 0.030 in

(0.76 mm).
904.4.10 Effective Performance Life
The film, when applied according to the recommendations of the

manufacturer, shall provide neat, durable marking that will not flow or
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distort due to temperature if the pavement surface remains stable. The

film shall be weather resistant and through normal traffic wear shall
show no fading, lifting or shrinkage which will significantly impair the
intended usage of the marking throughout it useful life shall show no
significant tearing, roll back or other signs of poor adhesion.
904.4.11 Installation
The markings shall be applied in accordance with the manufacturer’s

instructions.
904.5 CEMENTITIOUS MARKING COMPOUND
Cementitious marking compound shall be used for Concrete, Surface

Dressing and Bitumen to provide enhanced night and wet, weather
visibility. This compound will be applied at following locations:
 Kerbs-Pavements and car park areas.

 Roundabout-vertical and sloping faces.
 Traffic Islands- vertical edges and bull noses, etc.
 Traffic Dividers-black and white chevrons.
 Concrete wall and faces-on high speed intersections and traffic
merging.
904.5.1 Measurement
The quantity of non-reflective or reflective chlorinated rubber based or

thermoplastic pavement marking paint, shall be the no. of linear meters
of painted traffic line for the specified width as indicated in BOQ. The
retro-reflective preformed pavement markings (tape) shall be measured
in square meters. The arrows shall be measured in number.
The measurement shall be made of painted areas, completed and

accepted. No measurement shall be made of unauthorized areas. Paint
that is supplied in unauthorized areas shall be completely removed
from the surface of the road to the satisfaction of the Engineer Incharge
and at Contractor’s expense.
904.5.2 Payment

Contract unit price respectively for the pay items listed below, which
price and payment shall constitute full compensation for furnishing and
placing all materials including sampling, packing and testing at
approved laboratory. The cost shall also include the preparation of the
surface, and for all other costs necessary to complete the work as
prescribed in this item.
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904-5.2.1 Pavement Marking in non-reflective Per meter or per ft.

CR/TP paint for lines of 12cm width
CR/TP Paint for Lines of 15 cm width
CR/TP Paint for Lines of 20cm width.
904-5.2.4 Pavement Marking in non-reflective Each
CR/TP Paint for Lines of 4.0M arrows.
904-5.2.5 Pavement Marking in non-reflective Each
CR/TP Paint upto 6.0M arrows.
904-5.2.6 Pavement Marking in non-reflective Per Sq. meter
CR/TP Paint for various sign. or per Sq.ft.
904-5.2.7 Pavement Marking in reflective Per meter or per ft.
CR/TP Paint of 20cm width.
904-5.2.10 Pavement Marking in reflective Each
CR/TP Paint for 4.0M arrows.
904-5.2.11 Pavement Marking in reflective Each
CR/TP Paint upto 6.0M arrows.
904-5.2.12 Pavement Marking in reflective Per Sq. meter
CR/TP Paint for various sign. or per Sq.ft.
904-5.2.13 Pavement Marking by retro reflective Per Sq. meter
preformed pavement markings(Tape) or per Sq.ft.
**************
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SECTION 905
REFLECTORIZED PAVEMENT STUDS

905-1 DESCRIPTION
This item shall consist of furnishing and installing reflectorized

pavement studs into the traveled way in accordance with the
specifications and at the locations shown on the drawings or as
905-2.1 Reflectorized Studs shall be either the ‘Flush Surface’ type or ‘Raised
profile type having the following characteristics.
a. Flush Surface Type
The ‘Flush Surface’ reflector shall be the short base type having
a maximum base area of 18 cm x 14 cm (7 inch x 5/1/2 inch).
The base shall be formed in cast-iron with adequate webbing to

ensure a firm key to the road when installed.
The pad shall be nightly resilient and durable rubber reinforced

with canvas and shall have an anticipated life of at least 5
years. The pad shall be so designed to produce a self-whipping
action of the reflector when depressed.
The reflectors shall be made of impact and abrasion resisting

glass and shall be hermetically sealed into a copper socket.
b. Raised Profile Type
The ‘Raised Profile’ reflectors shall consist of an acrylic plastic

shell filled with an adherent epoxy compound molded from
methyl methacylate into the shape of a shallow frustum of a
pyramid having base dimension of approximately 10 cm x 10
cm (4” x 4”) and thickness not more than 2 cm (3/4 inch). The
shell contain one or two prismatic reflectors each inclined at an
angle of 30o to the horizontal and having an area not less than
20 sq. cm (3.1 sq. inch)
The reflectors shall attain the following standards for their photometric
and physical qualities:
i). Photometric Requirements
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The reflectors shall have the following minimum Specific

Intensity values (SI) expressed as candlepower per foot candle
of illumination at the reflector on a plane perpendicular to the
incident light.
Color Crystal Yellow Red

Divergence Angle 0.20 0.20 0.20
Incidence Angle S.I S.I. S.I.
0o 3.00 1.80 0.75
20o 1.20 0.72 0.30
The reflector for testing shall be located with the center of the
reflecting face at a distance of 1.5 m (5 feet) from a uniformly
bright light source having an effective diameter of 0.5
centimeter (3/16 inch). The width of the photocell shall be 1.27
cms (1/2 inch) and shall be shielded from stray light. The
distance from the centers of the light source and photocell shall
be 0.53 cms (1/4 inch). Failure of more than 4% of the
reflecting faces shall be cause for rejection of the lot.
ii) Strength Requirement
The reflectors shall support a vertical load of 1000 kg (2204

Lbs) when tested in the following manner.
A reflector shall be centered horizontally over the open end of a

vertically positioned hollow metal cylinder 75 mm (3 inch)
internal diameter, 25 mm (1 inch) high and wall thickness of 6
mm (1/4 inch). The load shall be applied to the top of the
reflector through a 6 mm (1/4 inch) diameter by 6 mm (1/4
inch) high metal plug centered on top of the reflector.
Failure shall constitute either breakage or significant

deformation of the marker at any load less than or equal to
1000 kg (2204 Lbs).
905-2.2 Adhesive
When ‘Raised Profile’ type of reflectors are used, a two-part adhesive
having the following ingredients shall be applied to the stud for
bonding to the pavement surface.
PACKAGE A Kg / Liter Lbs / gal
Epoxy Resin 0.94 8.63
Titanium Dioxide 0.07 .64
Colloidal Silica 0.05 .46
Talc 0.345 3.17
PACKAGE B
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Modified Asphaltic Amine Hardener 0.24 2.2

(Reichold 2611)
Modified Asphaltic Amine Hardener 0.472 4.333
(Reichold 2613)
Carbon Black 0.0022 0.0202
Colloidal Silica 0.04 0.367
Talc 0.650 5.97
Equal volumes of Package A & B should be mixed together until a

uniform color is obtained. No more than one (1.1 liter) quart of
adhesive shall be prepared at one time.
905-2.3 Cement Mortar
Cement mortar shall consist of 1 part Portland Cement to 3 parts of

sand.
905-3.1 Flush Surface Type
The stud shall be installed into the pavement in accordance with the
manufacturer’s instructions but shall also comply with the following
requirements.
Cavities in the pavement shall be clearly cut to the dimensions of the

pavement stud and shall allow a clearance of 1.0 cm (3/8 inch) around
the stud base. The longitudinal centerline axis of the cavity shall be the
same as that required for the pavement stud when laid to correct line
and direction.
The walls of the cavity shall be splayed back at an angle of

approximately 30o to the vertical to facilitate a ‘dove-tail’ joint after the
mortar has set.
The bottom of the cavity shall be leveled with asphalt concrete prior to
placing the stud base which shall be pounded into position with a
pounded Foot attached to a pneumatic drill.
The depth of the cavity shall be such that when the stud base and
reflectors have been installed the elevation of the floor of the lens
socket shall not be greater than 2.0 mm (0.08 inch) or less than 1.0 mm
(0.04 inch) above the pavement surface.
The stud shall be grouted into position with asphalt concrete containing
fine aggregate only or with a cement mortar as described under section
905-2.3 above when the studs are installed into a cement concrete
pavement.
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905-3.2 Raised Profile Type
The pavement studs shall be installed in accordance with the

manufacturer’s instructions or to the requirements of the Engineer
Incharge
9045-4 MEASUREMENTS AND UNIT RATE
The quantity of reflectorized pavement studs to be paid for shall be the

number of ‘Flushed Surface’ type or ‘Raised Profile’ type or reflectors
whichever is called for in the Special Provisions of Bill of Quantities
installed complete and accepted.
905-5 RATE
The quantities measured as described above shall be paid for at the

contract unit price respectively for the pay items listed below and
shown in the Bill of Quantities, which pavement shall constitute full
compensation for furnishing and placing all materials, excavating
cavities, preparation of surfaces, applying adhesive and mortar, for all
labor, equipment, tools and incidentals necessary to complete the item.
905-6 PAYMENT
Pay Item No. 905-6.1 Reflectorized Pavement Stud

(Flush Surface Type) Each
Pay Item No.905-6.2 Reflectorized Pavement Stud

(Raised Profile Type) Each
***************
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SECTION 906
FENCING
906-1 DESCRIPTION
The work shall consist of constructing concrete or steel post and

barbed wire fence and chain link fence in accordance with the details
and at the locations shown on the drawings or as directed by the
Engineer Incharge.
906-2.1 Barded Wire
Barbed wire shall conform to the requirements of ASTM A 121, Class

1. The barbed wire shall consist of 2 strands of 12.5 gage wire, twisted
with 2 points, 14 gage barbs spaced 10 cm (4 inch) apart.
906-2.2 Chain Link Fabric
Chain link fabric shall be fabricated from 10 gage galvanized wire

conforming to AASHTO M 181 and shall be of the type shown on the
drawings. Before ordering the chain link fabric the Contractor shall
submit a sample of the material to the Engineer Incharge for his
approval.
906-2.3 Concrete Posts
Concrete posts shall be made from Class C concrete in accordance

with Section 701. The posts shall be cast to a tapered section 3 m (10
feet) long or to the length shown on the drawings and shall have a
smooth surface finish.
906-2.4 Steel Posts
Steel posts shall be of the section and length as specified or as shown

on the drawings. The posts shall be of copper bearing steel and shall
conform to the requirements of AASHTO M 183 for the grade
specified.
906-2.5 Steel Reinforcement for Concrete Posts
Steel reinforcement for the concrete posts shall be deformed steel bars
conforming to the provisions of Section 831
906-2.6 Hardware for Steel Posts
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Nuts, bolts, washers and other associated hardware shall be galvanized

after fabrication as specified in ASTM 153.
906-2.7 Base Concrete for Posts
Concrete in the base for posts shall be of class D as specified under

Section 701 to the size shown on the drawings.
906-3.1 Erection of Posts
The posts shall be erected vertically in position, inside the formwork of

the foundation block prior to the placing of the concrete and shall be
adequately supported by bracing to prevent movement of the post
during the setting process of the concrete. The posts shall be erected to
the height and at the locations shown on the drawings or as directed by
906-3.2 Installation of Chain Link Fabric or Fabric of Barbed Wire.
The chain link fabric or barbed wire shall be set to line and elevation
and pulled out between each post before spot welding or other method
of fixing as carried out.
Where splicing of the fabric is necessary or at joints the lapping of the

chain link fabric shall be a minimum of 10 cm (4 inch) and shall occur
only at the concrete post.
No horizontal splicing will be permitted.
The fabric shall be fixed to the concrete posts as shown on the

drawings.
906-4 MEASUREMENT
The quantity to be paid for shall be the number of linear meters or feet
of fencing erected in place and accepted, measured between the centers
of the end posts
906-5 RATE

contract unit price for the pay items listed below and shown in the Bill
of Quantities which price and payment shall be full compensation for
furnishing placing, excavating, backfilling and erecting all posts for the
installation, fixing and welding of the fabric and wire and for all
materials, labor, equipment, tools and incidentals necessary to
complete the work.
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906-6 PAYMENT
Pay item No.906-6.1 Chain Link Fabric Fencing per meter (m)
or foot
Pay item No.906-6.2 Barbed Wire Fencing Per meter (m)

or foot
**************
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SECTION 911
BEARINGS
911-1 DESCRIPTION
This section covers the construction and installation of structural

bearings that consist of one or more of the following component types:
metal rocker and roller bearings, PTFE sliding bearings (flat and
curved), plain elastomeric pads, fiberglass reinforced elastomeric pads,
cotton duck reinforced pads, steel reinforced elastomeric bearings, pot
bearings, disc bearings, and bronze and copper alloy bearings (flat and
curved). At the discretion of the Engineer Incharge, other component
types may be used, but the construction, installation and testing
requirements must then be agreed by the Engineer Incharge before the
start of fabrication.
The section also covers ancillary items such as masonry, sole and load
distribution plates, bedding materials, anchor bolts, lubricants and
adhesives.
911.2 APPLICABLE DOCUMENTS
911.2.1 AASHTO Standards
The following AASHTO Standards are relevant to this section:
AASHTO M 102 Steel Forgings, Carbon and Alloy for General Use
(ASTM A 668)
AASHTO M 107 Bronze Castings for Bridges and Turntables (ASTM B 22)
AASHTO M 108 Rolled Copper-Alloy Bearing and Expansion Plates and

Sheets for Bridges and Other Industrial Uses
(ASTM B 100)
AASHTO M 164 High-Strength Bolts for Structural Steel Joints

(ASTM A 325)
AASHTO M 251 Specifications for Plain and Steel Laminated Bearings for
Bridges (ASTM D 4014)
AASHTO M 153 Heat-Treated Steel Structural Bolts 150 Ksi Minimum

Tensile Strength (ASTM A 490)
AASHTO M 270 Structural Steel for Bridges (ASTM A 709)
911.2.2 ASTM Standards
The following ASTM Standards are relevant to this section:
ASTM A 167 Specification for Stainless and Heat-Resisting Chromium-

Nickel Steel Plate Sheet, and Strip.
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ASTM A 240 Specification for Heat-Resisting Chromium-Nickel

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels.
ASTM A 307 Specification for Carbon Steel Externally Threaded

Standard Fasteners.
ASTM A 781 Standard Specification for Castings, Steel and Alloy,

Common Requirements, for General Industrial Use.
ASTM A 788 Specification for Steel Forgings, General Requirements.
ASTM A 802 Practice for Steel Castings, Textures and Discontinuities,

Evaluation and Specifying by Visual Examination.
ASTM B 22 Bronze Castings for Bridges and Turntables (AASHTO M

107).
ASTM B 29 Specification for Pig Lead.
ASTM B 36 Specification for Brass Plate, Sheet, Strip, and Rolled Bar.
ASTM B 100 Specification for Rolled Copper Alloy Bearing and

Expansion Plates for Bridge and Other Structural Uses
(AASHTO M 108).
ASTM B 103 Specification for Phosphor-Bronze Plate, Sheet, Strip and

Rolled Bar.
ASTM B 438 Specification for Sintered Bronze Bearings (Oil

Impregnated).
ASTM D 395 Test Methods for Rubber Property-Compression Set.
ASTM D 412 Test Methods for Rubber Property-Tension Set.
ASTM D 429 Test Methods for Rubber Property-Peel Set.
ASTM D 518 Test Methods for Rubber Deterioration-Surface Cracking.
ASTM D 573 Test Methods for Rubber-Deterioration in an Air Oven.
ASTM D 746 Test Methods for Brittleness Temperature of Plastics and

Elastomers by Impact.
ASTM D 792 Test Methods for Specific Gravity (Relative Density) and
Density of Plastics by Displacement.
ASTM D 903 Test Methods for Peel or Stripping Strength of Adhesive

Bonds.
ASTM D 1043 Stiffness Properties of Plastics as a Function of

Temperature by means of a Torsion Test.
ASTM D 1149 Test Methods for Rubber Deterioration-Surface Ozone

Cracking in a Chamber.
ASTM D 1777 Method of Measuring Thickness of Textile Materials.
ASTM D 2000 Classification System for Rubber Products in Automotive

Applications.
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ASTM D 2240 Test Methods for Rubber Property-Durometer Hardness.
ASTM D 2256 Test Methods for Breaking Load (Strength) and

Elongation of Yarn by the Single-Strand Method.
ASTM D 3293 Specification for PTFE Resin Molded Sheet.
ASTM D 4014 Specification for Plan and Steel-Laminated Elastomeric

Bearings for Bridges (AASHTO M 251).
ASTM D 4894 Specification for Polytetrafluoroethylene (PTFE) Granular

Molding and Ram Extrusion Materials.
ASTM D 4895 Specification for Polytetrafluoroethylene (PTFE) Resin

Produced from Dispersion.
911.3 GENERAL REQUIREMENTS
Bearings shall be constructed in accordance with the details shown on

the plans and specifications. When complete details are not provided,
bearings shall be furnished that conform to the limited details shown on
the plans and shall provide the performance characteristics specified.
911.4 MATERIALS
911.4.1 General
911.4.1.1 Steel
911.4.1.1.1 Rolled steel shall be of the type required on the plans and shall satisfy
the testing requirements of the standard to which it conforms. Unless
otherwise specified, it shall conform to AASHTO M 270 (ASTM A
709) Grade 36 and shall cause no adverse electrolytic or chemical
reaction with other components of the bearing. It shall be free of all
rust and mill scale.
911.4.1.1.2 Unless otherwise specified by the Engineer Incharge, steel laminates in
steel reinforced elastomeric bearings shall be made from rolled mild
steel conforming to M 270 Grade 36, Grade 50 (ASTM A 36, A 572),
or equivalent, and shall have a nominal thickness not less than 16 gage.
Holes in laminates, not specified on the plans but used for
manufacturing purposes, shall be permitted only with the written
911.4.1.1.3 Cast steel shall satisfy the requirements of ASTM A 802 and be free of
all blow-holes and impurities larger than 1/8 inch. The inside wall of
the pot in pot bearings and the contact surface of metal rocker or roller
bearings shall be free of blow-holes or impurities of any size.
911.4.1.1.4 Forged steel shall satisfy the requirements of ASTM A 788.
911.4.1.1.5 Unless otherwise specified by the Engineer Incharge, stainless steel
shall conform to ASTM A 167 or A 240 type 304, and have a
minimum thickness of 20 gage. Stainless steel in contact with PTFE
sheet shall be polished to a #8 mirror finish.
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911.4.1.1.6 Steel weld metal shall be chosen to be compatible with the parent
materials and the welding process used and shall be approved by the
Engineer Incharge. Stainless steel weld used for overlays shall be type
309L.
911.4.1.1.7 Bolts shall conform to AASHTO M 164 (ASTM A 325), AASHTO M
253 (ASTM A 490) or ASTM A 307 unless specified otherwise.
911.4.2 Special Material Requirements for Metal Rocker and Roller

Bearings
The steel at the contact surface of a metal bearing may be hardened

provided that, after hardening, it satisfies the strength and ductility
requirements of the contract plans and material specifications.
911.4.3 Special Material Requirements for PTFE Sliding Surface
911.4.3.1 PTFE
911.4.3.1.1 PTFE resin shall be 100% pure new material and shall comply with
ASTM D 4894 or D 4895. It shall satisfy the requirements of Table
911.4.3.1-1. No reclaimed material shall be used.
Finished PTFE sheet, strip and fabric shall be resistant to acids, alkalis,
and petroleum products, stable at temperatures from 360ºF to + 500ºF,
nonflammable, and nonabsorbing of water.
911.4.3.1.2 Filter material, when used in PTFE, shall be milled glass fiber, carbon
fiber or other approved fiber. The filler shall not react chemically with
the PTFE but shall adhere to it so that the two act compositely.
911.4.3.1.3 Finished PTFE sheet shall be made from virgin PTFE resin or virgin
PTFE resin uniformly blended with approved filler. The maximum
filler content shall be 15% for fiberglass and 25% for carbon fibers.
The maximum filler content for other materials shall be determined by
the Engineer Incharge. The PTFE sheet shall satisfy the requirements
of Table 911.4.3.1-1. Values for intermediate filler contents may be
obtained by interpolation.
911.4.3.1.4 Woven fabric PTFE shall be made from oriented multi-filament PTFE
fibers or from a mixture of PTFE fibers made from twisted, slit PTFE
tape and other fibers. It shall conform to the requirements of Table
911.4.3.1-1.
911.4.3.2 Adhesives
Adhesive used for bonding sheet PTFE shall be an epoxy material , as

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911.4.3.3 Lubricants
Lubricant, if used, shall consist of a combination of solids which does

not react chemically or electrolytically with the PTFE and its mating
surface and shall remain stable in the environmental conditions
expected at the bridge site.
911.4.3.4 Interlocked Bronze and Filled PTFE Structures
The phosphor bronze back plate shall conform to AASHTO M 108

(ASTM B 100) and the porous bronze layer shall conform to ASTM B
103.
911.4.4Special Material Requirements for Pot Bearings
911.4.4.1 The rotational element of the pot bearing shall be made from an
elastomeric compound, with a hardness of 50 + 10 on the Shore A
scale. It shall be made from all new material. The raw polymer on
which it is based shall be either polychloroprene (neoprene) or
polyisoprene (natural rubber). The compound shall satisfy the physical
property requirements for a 50 hardness material as specified in Table
911.4.5.1-1A or -1B.
911.4.4.2 The elastomer may be lubricated with a silicone grease which does not
react chemically with the elastomer and which does not alter its
properties within the range of environmental conditions expected at the
bridge site.
911.4.4.3 The sealing rings shall be made of brass conforming to ASTM B 36

(half hard) for rings of rectangular cross-section. The Engineer
Incharge may, at own discretion, approve other sealing ring materials
on the basis of test evidence which demonstrates adequate sealing
properties and durability of the material.
TABLE 911.4.3.1-1 Physical Properties of PTFE
Sheet with Sheet with

ASTM Sheet Woven
Physical Property 15% glass 25% carbon
Test Method (Unfilled) fabric
fibers fibers
Specific Gravity D 4894, D 4895, 2.16 + 0.03 2.20 + 0.03 2.10 + 0.03 _
or D 5977
Melting point(ºF) D 4894, D 4895, 623 + 2 621 + 18 621 + 18 _
or D 5977
Tensile Strength D 4894, D 4895, 28001 20002 13002 24,000
(psi) or D 5977
Elongation at D 4894, D 4895, 2001 1502 752 351
Break (%) or D 5977
1
Using Test Method ASTM D 2256
2
Using Test Method ASTM D 638
911.4.4 Special Material Requirements for Steel Reinforced
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Elastomeric Bearings and Elastomeric Pads
911.4.5.1 Elastomer
The raw elastomer shall be either virgin in neoprene (polychloroprene)

or virgin natural rubber (polyisoprene). The elastomer compound shall
be classified as being of low temperature grade 0, 2, 3, 4 or 5. The
grades are defined by the testing requirements in Table 911.4.5.1-1A
and 1B. A higher grade of elastomer may be substituted for a lower
one. In the absence of more specific information, bearings shall be
Grade 3, 60 durometer elastomer.
The elastomer compound shall meet the minimum requirements of

Table 911.4.5.1-1A and - 1B except as otherwise specified by the
Engineer Incharge. The nominal hardness of the compound shall lie
between 50 and 60 for reinforced bearings and between 50 and 70 for
plain pads. Test requirements may be interpolated for intermediate
hardness. If the material is specified by its shear modulus, its measured
shear modulus shall lie within 15% of the specified value. A consistent
value of hardness shall also be supplied for the purpose of defining
limits for the tests in Tables 911.4.5.1-1A and - 1B. If the hardness is
specified, the measured shear modulus must fall within the range of
Table 14.6.5.2.1 in Article 14.6.5.2 of Division I. When test specimens
are cut from the finished product, the physical properties shall be
permitted to vary from those specified in Tables 911.4.5.1 - 1A and -1B
by 10%. All material tests shall be carried out at 73º + 4ºF unless
otherwise noted. Shear modulus tests shall be carried out using the
apparatus and procedure described in annex A of ASTM D 4014,
amended where necessary by the requirements of Tables 911.4.5.1 - 1A
or - 1B.
911.4.5.2 Fabric Reinforcement
Fabric reinforcement shall be woven from 100% glass fibers of "E"

type yarn with continuous fibers. The minimum thread count in either
direction shall be 25 threads per inch. The fabric shall have either a
crowfoot or an 8 Harness Satin weave. Each ply of fabric shall have a
minimum breaking strength of 800 lb/in. of width in each thread
direction.
911.4.5.3 Bond
The vulcanized bond between fabric and reinforcement shall have a

minimum peel strength of 30 lb/in. Steel laminated bearings shall
develop a minimum peel strength of 40 lb/in. Peel strength tests shall
be performed by ASTM D 429 Method B.
911.4.6 Special Material Requirement for Bronze
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or Copper Alloy Sliding Surfaces
911.4.6.1 Bronze and Copper Alloys
911.4.6.1.1 Bronze
Bronze components shall conform to the requirements of AASHTO M

107 (ASTM B 22) alloy C90500, C91100 or C86300. Alloy C91100
shall be furnished unless otherwise specified. Components may be
cast, rolled or forged. Castings shall be free of blow-holes larger than
1/8 inch and contact surfaces shall be free of all blow-holes of any size.
911.4.6.1.2 Rolled Copper-Alloy
Rolled copper-alloy bearing and expansion plates shall conform to the

Specification for Rolled Copper-Alloy Bearing and Expansion Plates
and Sheets for Bridge and Other Structural Uses, AASHTO M 108
(ASTM B 100). Alloy No. C51000 or No. C51100 shall be furnished
unless otherwise specified.
911.4.6.2 Oil Impregnated Metal Power Sintered Material
Metal powdered sintered material shall conform to ASTM B 438,

Grade 1, Type II or Grade 2, Type I.
911.4.7 Special Material Requirements for Disc Bearings
911.4.7.1 Elastomeric Rotational Element
The rotational element of the disc bearing shall be made from an

elastomeric compound with a hardness which lies between 45 and 65
on the Shore D scale. The raw polymer on which it is based shall be
polyether urethane. The compound shall satisfy the physical property
requirements appropriate to the material's hardness in Table
911.4.7.1-1.
911.4.8 Special Material Requirements for Guides
911.4.8.1 Low-Friction Material
The sliding interface shall be made from a material which is approved

by the Engineer Incharge and which will provide a friction coefficient
no greater than the one used in the design.
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TABLE 911.4.5.1-1A Material Tests - Polychloroprene
PHYSICAL PROPERTIES
D 2240 Hardness (Shore A Durometer) 50 + 5 60 + 5 70 + 5
D 412 Tensile Strength, Minimum psi 2,250 2,250 2,250
Ultimate Elongation, Minimum % 400 350 300
HEAT RESISTANCE
D 573 Change in Durometer Hardness,
70 Hours Maximum Points 15 15 15
at 212ºF
Change in Tensile Strength, Maximum % -15 -15 -15
Change in Ultimate Elongation, Maximum -40 -40 -40
%
COMPRESSION SET
D 395 22 Hours @ 212ºF, Maximum % 35 35 35
Method B
OZONE
D 1149 100 pphm ozone in air by volume, 20% No No No
strain 100ºF Cracks Cracks Cracks
+ 2ºF
100 hours mounting procedure D518,
Procedure A
LOW TEMPERATURE BRITTLENESS
D 746 Grades 0 & 2 - No Test Required 35 35 35
Procedure B
No No No
Grade 3 Brittleness at - 40ºF
Failure Failure Failure
No No No
No No No
INSTANTANEOUS THERMAL STIFFENING
D 1043 Grades 0 & 2 - Tested @ - 25ºF Stiffness at test temperature shall not
exceed 4 times the stiffness measured
at 73ºF
Grade 3 - Tested @ - 40ºF Stiffness at test temperature shall not
at 73ºF
Grade 4 - Tested @ - 50ºF
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Draft 2004

Quad Shear Test Grade 0 - No Test Required Stiffness at test time and temperature
As described in
Annex A of Grade 2 - 7 days @ 0ºF shall not exceed 4 times the stiffness
ASTM D 4014 Grade 3 - 14 days @ - 15ºF measured 73ºF with no time delay.
Grade 4 - 21 days @ - 35ºF The stiffness shall be measured with a
Grade 5 - 28 days @ - 35ºF quad shear test rig in an enclosed
freezer unit. The test specimens shall
be taken from a randomly selected
bearing. A + 25% strain cycle shall be
used, and a complete cycle of strain
shall be applied with a period of 100
seconds. The first 3/4 cycle of strain
shall be discarded and the stiffness
shall be determined by the slope of
the force deflection curve for the next
1/2 cycle of loading.
TABLE 911.4.5.1-1B Material Tests - polyisoprene
PHYSICAL PROPERTIES
D 2240 Hardness (Shore A Durometer) 50 + 5 60 + 5 70 + 5
D 412 Tensile Strength, Minimum psi 2,250 2,250 2,250
Ultimate Elongation, Minimum % 450 400 300
HEAT RESISTANCE
D 573 Change in Durometer Hardness,
70 Hours Maximum Points 10 10 10
at 158ºF
Change in Tensile Strength, Maximum % -25 -25 -25
Change in Ultimate Elongation, Maximum -25 -25 -25
%
COMPRESSION SET
D 395 22 Hours @ 158ºF, Maximum % 25 25 25
Method B
OZONE
D 1149 100 pphm ozone in air by volume, 20% No No No
strain 100ºF Cracks Cracks Cracks
+ 2ºF
48 hours mounting procedure D518,
Procedure A
LOW TEMPERATURE BRITTLENESS
D 746 Grades 0 & 2 - No Test Required
Procedure B
No No No
No No No
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No No No
D 1043 Grades 0 & 2 - Tested @ - 25ºF Stiffness at test temperature shall not
at 73ºF
Quad Shear Test Grade 0 - No Test Required Stiffness at test time and temperature
as described in
annex A of Grade 2 - 7 days @ 0ºF shall not exceed 4 times the stiffness
ASTM D 4014 Grade 3 - 14 days @ - 15ºF measured 73ºF with no time delay.
Grade 4 - 21 days @ - 35ºF The stiffness shall be measured with a
Grade 5 - 28 days @ - 35ºF quad shear test rig in an enclosed
freezer unit. The test specimens shall
be taken from a randomly selected
bearing. A + 25% strain cycle shall be
used, and a complete cycle of strain
shall be applied with a period of 100
seconds. The first 3/4 cycle of strain
shall be discarded and the stiffness
shall be determined by the slope of
the force deflection curve for the next
1/2 cycle of loading.
TABLE 911.4.7.1 Physical Properties of

Polyether Urethane
ASTM
Test
Physical Property Method Requirements
Hardness, Durometer 'D' D 2240 45 45 65
Minimum Tensile Stress (psi) D 412
at 100% elongation 1500 1900 2300
at 200% elongation 2800 3400 4000
Tensile Strength (psi) D 412 4000 5000 6000
Elongation at break (%) D 412 350 285 220
Maximum Compression Set D 395 40 40 40
(22 hrs @ 158ºF, %)
911.4.8.2 Adhesive
Any adhesive used to attach the sliding interface material shall be

recommended for that purpose by the manufacturer of the sliding
material and approved by the Engineer Incharge.
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911.4.9 Special Requirements for Bedding Material
911.4.9.1 Fabric-Reinforced Elastomeric Bedding Pads
Performed fabric pads used as bedding shall be composed of multiple

layers of 8-ounce cotton duck impregnated and bonded with high
quality natural rubber or of equivalent and equally suitable materials
compressed into resilient pads of uniform thickness. The number of
plies shall be such as to produce the specified thickness, after
compression and vulcanizing. The finished pads shall withstand
compression stress perpendicular to the plane of the laminations of not
less than 10,000 pounds per square inch without detrimental reduction
in thickness or extrusion.
911.4.9.2 Sheet Lead
Sheet lead used as bedding shall be common desilverized lead

conforming to ASTM B 29. The sheets shall be of uniform thickness
and shall be free from cracks, seams, silvers, scale, and other defects.
Unless otherwise specified, lead sheet thickness shall be 1/8 inch +
0.03 inch.
911.4.9.3 Grout and Mortar
Grout and mortar used for filling under masonry plates shall conform
to the relevant specification for these items.
911.5 FABRICATION
911.5.1 General
911.5.1.1 Bearings shall be accurately machined to the dimensions and

tolerances shown on the contract plans and shall be free from flaws.
911.5.1.2 All fabrication from steel plate shall comply with Section 831,
911.5.1.3 If a masonry plate is used, the bearing shall be attached to it by a

method that permits transfer of all the specified loads, but also allows
replacement of the bearing. Recessing is recommended.
911.5.1.4 Unless specified otherwise, the dimensional tolerances and surface

finishes of the bearing shall satisfy the requirements of Table
911.5.1.5-1.
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911.5.2 Special Fabrication Requirements for Metal

Rocker and Roller Bearings
911.5.2.1 Steel
Rocker bearings may be made by casting, forging or fabricating from

plate. Roller bearings more than 9 inches in diameter shall be forged
and annealed. Smaller roller bearings may either be forged and
annealed or be made from cold-finished carbon steel shafting.
In roller bearings more than 9 inches in diameter, a hole not less than 2
inches a diameter shall be bored full length along the axis after the
forging has cooled to a temperature below the critical range and before
annealing. It shall be done under conditions which prevent damage by
cooling too rapidly.
911.5.2.2 Lubricant
Lubrication shall be applied to all gear mechanisms and to all other

components of roller bearings for which it is required. The type of
lubricant shall be as specified on the contract plans, and shall be
applied in accordance with the manufacturer's recommendations.
TABLE 911.5.1.5-1
Fabrication Tolerances and Surface Finish Requirements
Thickness Flatness or Surface
Tolerance Dimension Out-of-round finish (µ-in)
Item tolerance tolerance (rms.)
Metal Rocker & Roller Bearings
Single Roller: diameter - -0.063", + -0.001", + 63
0.063" 0.001"
Nested Roller: diameter - -0.002", + -0.001", + 63
0.002" 0.001"
Rockers: diameter - -0.125", + -0.001", + 125
0.125" 0.001"
Pins: diameter - -0.005", + -0.002", + 32
0.000" 0.002"
Bushings: diameter - -0.000", + -0.002", + 32
0.005" 0.002"
Pot Bearings
Overall dimensions -0.000", + -0.000", + - -
0.250" 0.125"
Pot depth (inside) - -0.000", + - -
0.025"
Pot wall: thickness & -0.000", + -0.003", + -0.001", + 32
ave. I.D. 0.125" 0.003" 0.001"
Pot base: top & bottom surfaces -0.000", + - Class C 63
0.025"
Piston: rim -0.000", + -0.003", + -0.001", + 32
0.063" 0.003" 0.001"
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Piston: top and bottom surfaces -0.000", + - Class C 63

0.025"
Elastomeric disk -0.000", + -0.063", + - -
(unstressed) 0.150" 0.000"
Disk Bearings
0.250" 0.125"
Shear-restricting element - -0.000", + Class A 32
0.005"
Other machined parts -0.000", + -0.000", + Class B 63
0.063" 0.063"
Urethane disk -0.000", + -0.000", + Class B 63
0.063" 0.125"
Flat PTFE Sliding Bearings
PTFE -0.000", + -0.000", + Class A -
0.063" 0.030"
Stainless Steel -0.000", + -0.000", + Class A # 8 mirror
0.063" 0.025"
Flat Bronze and Copper Alloy Sliding Bearings
Sliding surfaces -0.000", + -0.000", + Class A 32
0.125" 0.125"
Curved PTFE Sliding Bearings
Convex radius - -0.010", + -0.002", + # 8 mirror
0.000" 0.002"
Concave radius - -0.000", + -0.002", + 125
0.010" 0.002"
Steel-reinforced Elastomeric Bearings
0.250" 0.250"
Internal rubber layers -0.125", + - - -
0.125"
& +0.20*
design
Cover -0.000", + - - -
0.125"
Parallelism: top & bot. surfaces +0.005 radius - - -
Parallelism: sides - +0.020 radius - -
Elastomeric Pads
0.125" 0.250"
Guides
Contact surface - -0.000", + Class A 32
0.125"
Distance between guides - -0.000", + - -
0.030"
Parallelism of guides - +0.005 radius - -
Load Plates
Overall dimensions -0.063", + -0.250", + Class A 125
0.063" 0.250"
Bevel slope +0.002 radius - - -
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Notes: Fitness: Class A = 0.001 x nominal dimension

Class B = 0.002 x nominal dimension
Class C = 0.005 x nominal dimension
'only for surface in contact with the bearing
911.5.3 Special Fabrication Requirements for PTFE

Sliding Bearings
911.5.3.1 Fabrication of PTFE
Each PTFE element shown on the plans as a single piece shall be so

fabricated and supplied.
911.5.3.2 Attachment of PTFE
911.5.3.2.1 Flat Sheet PTFE
All flat sheet PTFE attached to a metal backing plate shall be attached
by recessing into the backing plate for one half of the PTFE thickness
and bonding. PTFE attached to other materials, such as elastomers,
shall be attached by a method approved by the Engineer Incharge.
The PTFE shall be factory-bonded, using an adhesive that is approved

by the Engineer Incharge, in accordance with the instructions of the
adhesive’s manufacturer. Prior to bonding, the surface shall be etched
by an approved manufacturer using the sodium naphthalene or sodium
ammonia process. When the backing plate is metal, the bonding shall
be conducted under a uniform pressure greater than 100 psi.
The peel strength of the bond shall be not less than 20 lb/n, tested in
accordance with ASTM D 429 Method B. The finished surface of the
PTFE shall be smooth, free from bubbles and shall conform to the
tolerances shown in Table 911.5.1.5-1. Filled PTFE sheets shall be
polished after bonding.
911.5.3.2.2 Curved Sheet PTFE
Curved sheet PTFE, such as used in spherical bearings, shall be

attached by recessing for one half of the PTFE thickness. The
dimensions of the PTFE element shall be selected so that it fits tightly
in the recess even when the bearing is subjected to its lowest design
temperature.
911.5.3.2.3 Woven PTFE Fabric
Fabric made from woven PTFE fibers shall be bonded or mechanically

fastened to a rigid substrate in such a way that the fabric can carry a
compressive stress of 10,000 psi without cold flow. The attachment of
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the fabric to the substrate shall be capable of withstanding, without

delamination, a shear force equal to (0.1 + µ) P at the same time as the
normal load P, where µ is the design coefficient of friction between the
PTFE and its mating surface and P is the design load acting
perpendicularly to the interface.
911.5.3.3 Stainless Steel Mating Surface
Each stainless steel element shown on the plans as a single piece shall
be so supplied. Each sheet shall be attached to its backing material by
seal welding around the entire perimeter so as to prevent entry of
moisture between the stainless steel and the backing material. Welds
shall conform to the American Welding Society requirements for
stainless steel. After welding, the stainless steel sheet shall be flat, free
from wrinkles and in continuous contact with its backing plate.
911.5.3.4 Lubrication
Lubrication shall be applied to the entire PTFE surface if specified by

the Engineer Incharge. If the PTFE is dimpled, enough lubricant shall
be used to fill all the dimples.
911.5.4 Special Fabrication Requirements for

Curved Sliding Bearings
All mating parts of any bearing shall be furnished by the manufacturer.
Sheet PTFE shall be attached to the metal backing surface by recessing

in accordance with Article 911.5.3.2.2.
Unless otherwise specified by the Engineer Incharge, the PTFE shall

be bonded to its metal backing surface using an adhesive that is
recommended by the manufacturer and approved by the Engineer
Incharge. While the adhesive sets, the PTFE shall be compressed
between the two mating curved metal surfaces under a pressure of at
least 100 psi.
911.5.5 Special Fabrication Requirements for

Pot Bearings
911.5.5.1 Pot
The pot shall be made by forging, casting, fabrication by welding or

machining from a single piece of plate. In pots made by welding a ring
to base plate, the weld shall be a full penetration butt weld.
The piston shall be machined from a single piece of steel. The outside
diameter of the piston shall be no more than 0.030 inches less than the
inside diameter of the pot at the level of the interface between the
piston and elastomeric rotational element. The sides of the piston shall
be beveled to facilitate rotation.
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If guides are used, they may be attached to the piston by welding or

bolting.
911.5.5.2 Sealing Rings
The sealing rings shall be recessed into the elastomeric disk and shall
fit snugly against the pot wall. Rings of rectangular cross section shall
be installed with their gaps equally spaced around the circumstance.
The gap between the ring and the wall shall nowhere exceed 0.01
inches. The gap between the cut ends of the ring shall not exceed 0.05
inches.
911.5.5.3 Elastomeric Rotational Element
The elastomeric pad shall have the same nominal diameter as the pot.
It may be individually molded or cut from sheet. It may be made of no
more than three separate layers, of which none may have a nominal
thickness of less than ½ inch. The sealing ring recess depth shall be the
same as the total ring thickness if rectangular rings are used.
911.5.6 Special Fabrication Requirements for Steel

Reinforced Elastomeric Bearings and
Elastomeric Pads
911.5.6.1 Requirements for All Elastomeric

Bearings
Bearings and pads which are designed to act as a single unit with a
given shape factor shall be manufactured as a single unit.
Flash tolerance, finish, and appearance shall meet the requirements of

the latest edition of the Rubber Handbook as published by the Rubber
Manufacturers Association, Inc., RMA F3 and T.063 for molded
bearings and RMA F2 for extruded bearings.
911.5.6.2 Steel Laminated Elastomeric Bearings
Bearing with steel laminates shall be cast as a unit in a mold and shall
be bonded and vulcanized under heat and pressure. The mold finish
shall conform to standard shop practice. The internal steel laminates
shall be sandblasted and cleaned of all surface coatings, rust, mill scale
and dirt before bonding, and shall be free of sharp edges and burrs.
External load plates (sole plates) shall be protected from rusting by the
manufacturer, and preferably should be hot bonded to the bearing
during vulcanization.
911.5.6.3 Fabric Reinforced Elastomeric Pads
Fabric-reinforced elastomeric pads may be vulcanized in large sheets

and cut to size. Cutting shall be performed in such a way as to avoid
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heating the materials and shall produce a smooth finish with no

separation of the fabric from the elastomer. Fabric reinforcement shall
be at least single ply for the top and bottom reinforcement layers and
double ply for internal reinforcement layers. Fabric shall be free of
folds and ripples and shall be parallel to the top and bottom surfaces.
911.5.6.4 Plain Elastomeric Pads
Plain pads may be molded, extruded, or vulcanized in large sheets and

cut to size. Cutting shall not heat the material, and shall produce a
smooth finish.
911.5.7 Special Fabrication Requirements for Bronze

And Copper Alloy Bearings
911.5.7.1 Bronze Sliding Surfaces
Bronze plates shall be cast according to details shown on the plans.

Unless detailed otherwise, sliding surfaces shall be machined parallel
to the direction of movement and polished.
911.5.7.2 Copper Alloy Plates
Copper alloy plates shall be furnished according to details shown on

the plans. Rolled plates need not be finished provided they have a
plane, true and smooth surface.
911.5.8 Special Fabrication Requirements for Disc Bearings
911.5.8.1 Steel Housing
The steel housing of the disc bearing shall be made by machining from
a single piece of plate or by fabrication by welding.
The shear restriction mechanism shall be connected to the bearing plate

by mechanical fastening, welding or other means approved by the
Engineer Incharge.
911.5.9 Special Fabrication Requirements for Guides
911.5.9.1 Guide bars shall be attached to the body of the bearing by a method
which minimizes distortion and allows the flatness tolerances on all
parts of the bearing to be met after attachment. The sliding surfaces of
the guide system shall be flat and parallel.
911.5.9.2 Bolts or threaded fasteners used to attach the guide bars to their
supporting plates shall have an embedded thread length adequate to
develop their required strength.
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911.5.9.3 If low friction material is used at the contact interface, it shall be

attached to its backing piece by two or more of the following methods
simultaneously: bonding, recessing and mechanical attachment with
countersunk fasteners.
If the material is bonded, it shall first be etched by the method

recommended by the manufacturer of the material or the bonding
agent. Recessing shall be one half of the material thickness. Fasteners
shall be countersunk to a depth which ensures that they will not touch
the mating material after allowing for wear.
911.5.10 Special Requirements for Load Plates
Load plates shall be made from a single steel plate or they may be built
up from several steel laminates, each oriented in the plan perpendicular
to the direction of the load. Built up load plates shall be joined by
complete seal welding to prevent ingress of moisture. Such welds shall
also provide sufficient shear strength to resist the applied loads. The
load plates shall have no sharp corners or edges. Holes may be formed
by drilling, punching, or accurately controlled oxygen cutting. All
burrs shall be removed by grinding.
911.5.11 Special Requirements for Anchor Bolts
Anchor bolts shall be provided with anchorage details that permit

development of the full tension strength of the bolt. Hooks or end
plates are recommended.
911.6 CORROSION PROTECTION
After fabrication, steel surfaces exposed to the atmosphere, except

stainless steel surfaces, shall be cleaned and coated to protect against
corrosion in accordance with the contract plans and specifications.
Areas to be welded shall be free of all rust, moisture, and foreign

material at the time of welding. The required final cleaning and
911.7 TESTING AND ACCEPTANCE

911.7.1 General
911.7.1.1 Scope
Testing and acceptance criteria for bearings shall conform to the
minimum requirements laid out in this section. The Engineer Incharge
may require more stringent standard.
The tests shall be conducted in accordance with the requirements of
Article 911.7.2. The minimum frequency of testing for different
bearing types is set out in Article 911.7.4.
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When bearings are made from a number of components, each

component shall satisfy the testing requirements from the applicable
section.
The Engineer Incharge, or his or her assigned agents, shall be given

free access to inspect the manufacturer of the bearings at all times.
911.7.1.2 Definitions
Load Range - A load range is a range of load capacities in which the

highest, capacity is no more than 2.0 times as large as the lowest.
Lot – A lot is a group of no more than 25 bearings of the same type (e.g.
elastomeric or pot bearings, and fixed, guided or floating), in the same
load range.
Batch – A batch is a body of material in which the ingredients are uniformly

blended together at one time.
Sample – A sample is a piece of material or a complete bearing which is tested in

order to infer the properties of the batch of material or group of bearing
elements from which it is taken. A sample shall consist of at least one
bearing chosen randomly from each lot and material batch and shall
comprise at least 10% of the lot.
911.7.1.3 Test Pieces to be supplied to the Engineer Incharge
If required by the Engineer Incharge, the Manufacturer shall supply

material samples from the batches used in the bearings and two
finished bearings for inspection and testing at a site of the Engineer
Incharge’s choice.
911.7.2 Tests
The tests prescribed in Articles 911.7.2.2 – 911.7.2.9 shall be carried

out at the manufacturer’s expense. Unless otherwise agreed by the
Engineer, they shall be supervised by an independent testing agency.
911.7.2.1 Material Certification Tests
Material certification tests to determine the physical and chemical

properties of all materials shall be conducted in accordance with the
appropriate specification governing the material. The test certificates
shall be provided to the Engineer Incharge.
911.7.2.2 Material Friction Test (Sliding Surfaces Only)
The coefficient of friction between the two mating surfaces shall be

measured. Samples taken from the same batch of materials as those
used in the prototype bearings shall be used or the tests may, at the
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manufacturer’s option, be conducted on finished bearings. Only new

materials shall be used, and no material that has been previously tested
shall be used.
The surfaces shall first be thoroughly cleaned with a degreasing

solvent. No lubrication other than that specified for the prototype
bearings shall be used. The mating surfaces for the test pieces shall
have a common area no less than the smaller of the bearing area or 7
in2.
The test pieces shall be loaded in compression to a stress

corresponding to their maximum service dead plus live load, which
shall be held constant for 1 hour prior to and throughout the duration of
the sliding test. At least 100 cycles of sliding, each consisting of at
least + 1 inch of movement, shall then be applied at a temperature of
68ºF + 2ºF. The uniform sliding speed shall be 2.5 inches/minute.
The breakaway friction coefficient shall be computed for each

direction of each cycle, and its mean and standard deviation shall be
computed for the sixth through twelfth cycles. The initial static
breakaway coefficient of friction for the first cycle shall not exceed
twice the design coefficient of friction. The maximum coefficient of
friction for all subsequent cycles shall not exceed the design coefficient
of friction. Failure of a single sample shall result in rejection of the
entire lot.
Following the 100 cycles of testing, the breakaway coefficient of

friction shall be determined again and shall not exceed the initial value.
The bearing or specimen shall show no appreciable sign of wear, bond
failure or other defects.
911.7.2.3 Dimensional Check
The dimensions of the bearing shall be checked. Two types of

dimensions, standard and critical, shall be measured. For each
component type, the standard and critical dimensions are defined in the
appropriate Article 911.7.3. The values of the critical dimensions shall
be recorded and provided by the manufacturer to the Engineer
Incharge. Failure of a critical dimension to satisfy its tolerance shall
constitute absolute cause for rejection. Failure of a standard
measurement to satisfy its tolerance shall, at the discretion of the
Engineer Incharge, constitute cause for rejection.
Flatness shall be checked by placing a precision straightedge on the

surface to be checked and by inserting feeler gages between the two.
The straight-edge shall be placed at different orientations and the worst
condition shall be established. No more than three feeler gages may be
stacked on top of one another. The straight-edge shall be as long as the
largest dimension of the flat surface. Flatness shall satisfy the
requirements of Table 911.5.1.5 – 1.
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911.7.2.4 Clearance Test
In a clearance check the components of the bearing shall be moved

through their design displacements or rotations in order to verify that
the required clearances exist. If the test is conducted on a rotational
component which is not under simultaneous full vertical load,
allowance shall be made for the displacements which would be caused
by that load.
911.7.2.5 Short-term Compression Proof Load Test
The bearing shall be loaded in compression to 150% of its rated service

load. If a rotational element exists, a tapered plate shall be introduced
in the load train so that the bearing sustains the load at the maximum
simultaneous design rotation. The load shall be held for 5 minutes,
removed, then reapplied for a second period of 5 minutes. The bearing
shall be examined visually while under the second loading. Any
defects shall constitute cause for rejection. If the load drops below the
required value during either application, the test shall be restarted from
the beginning.
911.7.2.6Long-term Compression Proof Load Test
The test shall be conducted in the same way as the short-term proof
load test except that the second load shall be maintained for 15 hours.
If the load drops below 90% of its target value during this time, the
load shall be increased to the target value and the test duration shall be
increased by the time for which the load was below the required value.
911.7.2.7 Bearing Friction Test (for sliding surfaces only)
The purpose of the Bearing Friction Test is to verify that the friction
values achieved in the material friction tests are adequate predictors of
the friction in the finished bearing.
No lubrication shall be applied except that used for the whole lot of
bearings. The bearing shall be loaded in compression with 100% of the
full service dead plus live load, which shall be held constant for one
hour prior to and throughout the duration of the sliding test. At least 12
cycles of sliding, each consisting of the smaller of the design
displacement and + 1 inch of movement, shall then be applied. The
average sliding speed shall be 2.5 inches/minute. When the test is
applied to curved sliding bearings, the design rotation shall be used in
place of the displacement.
In flat sliding bearings, the breakaway friction coefficient shall be

computed for each direction of each cycle, and its mean and standard
deviation shall be computed for the sixth through twelfth cycles.
Neither the friction coefficient for the first movement nor the mean
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plus two standard deviations for the sixth through twelfth cycles shall
exceed the value used in design, and the mean value for the sixth
through the twelfth cycles shall not exceed two third of the value used
in design.
In curved sliding surfaces, the moment corresponding to the design

rotation shall be established at each peak movement (positive and
negative) during the first and last six full cycles of testing. The
corresponding load eccentricity shall be calculated by dividing the
moment by the total compressive load acting. The eccentricity shall be
small enough that the allowable stresses on the PTFE used in design
are not violated.
911.7.2.8 Long-term Deterioration Test
The purpose of the test is to verify the long-term resistance of the

materials to creep, wear and deterioration. The test shall be conducted
on samples of the materials used in the bearings, or, at the option of the
manufacturer, it may be conducted on a pair of bearings, placed back-
to-back. The samples shall have an area not less than 7 in 2. The test
piece shall first be loaded in compression to a stress corresponding to
100% of the maximum dead plus live service load. Flat sliding systems
shall then be displaced through at least 1000 cycles with an amplitude
of at least + 1 inch (2 inches peak to peak). Curved sliding systems and
rotational systems that depend on deformation of an elastomeric
element shall be subjected to displacements corresponding to 5000
cycles of rotation at + the design amplitude. The sliding may take place
at up to 10 inches/minute, except when readings are taken of the
coefficient of friction, when the sliding speed shall be 2.5
inches/minute. The following shall be cause for rejection of the
bearing:
(1) Damage visible to the naked eye on disassembly of the bearing,

such as excessive wear, cracks or splits in the material.
(2) A coefficient of friction which exceeds two thirds the value

used in design.
911.7.2.9 Bearing Horizontal Force Capacity

(Fixed or Guided Bearing Only)
The purpose of the test is to verify that the bearing is stable and that
the guide or restraint system has adequate strength under the most
severe combination of horizontal and vertical loads.
One or more loading combinations, consisting of a horizontal and

vertical service load which could exist simultaneously in the structure,
shall be selected. The vertical load shall be applied first, at 1.0 times its
nominal value. The horizontal load shall be applied in stages, up to 1.5
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times its nominal value. Failure or excessive deflection of any of the

components shall be cause for rejection.
911.7.3 Performance Criteria
If one bearing of the sample fails, all the bearings of that lot shall be
rejected, unless the manufacturer elects to test each bearing of the lot at
own expense. In lieu of this procedure, the Engineer Incharge may
require every bearing of the lot to be tested.
911.7.4 Special Testing Requirements
911.7.4.1 Special Test Requirements for Rocker and Roller Bearings
Material certification tests shall be performed to establish the material

properties of the steel.
911.7.4.2 Special Test Requirements for PTFE Sliding Bearings
Inspection of the competed bearings or representative samples of

bearings with PTFE surfaces in the manufacturer’s plant may be
required by the Engineer Incharge. Inspectors, if appointed, shall be
allowed free access to the necessary parts of the manufacturer’s plant
and test facility. When testing is performed by the manufacturer, copies
of the test results shall be submitted to the Engineer Incharge.
The manufacturer is required to perform material tests on the matches

used in the sliding surface in accordance with Article 911.7.2.2. A
minimum of one test must be performed for each lot of bearings.
If requested by the Engineer Incharge and available test facilities

permit, complete bearings shall be tested for complete bearing friction
as defined in Article 911.7.2.7. If the test facility does not permit
testing complete bearings, at the direction of the Engineer Incharge,
extra bearings may be manufactured by the Contractor and samples of
at least 100-ips capacity at normal working stresses prepared by
sectioning the bearings. As soon as all bearings have been
manufactured for a given project, notification shall be given to the
Engineer Incharge who will select the prescribed test bearings at
random from the lot. Manufacturer’s certification of the steel,
elastomeric pads, preformed fabric pads, PTFE, and other materials
used in the construction of the bearings shall be furnished along with
notification of fabrication completion.
911.7.4.3 Special Test Requirements for Curved Sliding Bearings
Curved PTFE sliding surfaces shall satisfy all of the test requirements
specified for PTFE sliding surfaces in Article 911.7.4.2, except that,
when the prototype bearing is too large to test, a test bearing may be
especially manufactured using materials and fabrication methods that
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are identical to those used for the prototype, in lieu of sectioning a

bearing.
Critical dimensions shall include the difference between the average

radii of the two elements and the variation of the actual curved surface
from the average one. The Engineer Incharge may require verification
of these critical dimensions through a dimensional check as described
in Article 911.7.2.3.
911.7.4.4 Special Test Requirements for Pot Bearings
911.7.4.4.1 Material Certification Tests
The manufacturer shall select, at random, samples for material

certification tests as defined in Article 911.7.2.1. The tests shall be
performed, and certifications shall be delivered to the Engineer
Incharge.
Certification shall be provided for all elastomeric elements. Their

material properties shall satisfy the requirements of the design
documents and the tests described in Article 911.7.4.5. Additional tests
may be required by the Engineer Incharge.
911.7.4.4.2 Testing by the Engineer Incharge
When quality assurance testing is called for by the special provisions,

the manufacturer shall furnish to the Engineer Incharge the required
number of complete bearings and component samples to perform
quality assurance testing. At least one elastomeric element shall be
tested per lot of bearings. All exterior surfaces of sampled production
bearings shall be smooth and free from irregularities or protrusions that
might interfere with testing procedures.
For quality assurance testing, the Engineer Incharge may select at

random the required sample bearing(s) and the material samples from
completed lots of bearings or from stock.
A minimum of 30 days shall be allowed for inspection, sampling, and

quality assurance testing of production bearings and component
materials.
911.7.4.4.3 Bearing Tests
Critical dimensions shall include the clearance between the piston and
pot, and shall be verified by the Clearance Test described in Article
911.7.2.4.
A Long-term Deterioration Test as described in Article 911.7.2.8 shall
be performed on one bearing of each lot of pot bearings. The test shall
be performed at the maximum design rotation combined with
maximum dead plus live load. If size limitations prevent testing of the
full size bearing, a special bearing with the same sealing rings, the
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same rotational capacity and no less than 200 kips compressive load
capacity may be tested in its place.
A Long-term Compression Proof Load Test as described in Article

911.7.2.6 may be required by the Engineer Incharge.
911.7.4.5 Test Requirements for Elastomeric Bearings

911.7.4.5.1 Scope
Materials for elastomeric bearings and the finished bearings

themselves shall be subjected to the tests described in this section.
Material tests shall be in accordance with the appropriate Table
911.4.5.1-1A or Table 911.4.5.1-1B.
911.7.4.5.2 Frequency of Testing
The ambient temperature tests on the elastomeric described in Article

911.7.4.5.3 shall be conducted for the materials used in each lot of
bearings. In lieu of performing a shear modulus test for each batch of
material, the manufacturer may elect to provide certificates from tests
performed on identical formulations within the preceding year, unless
otherwise specified by the Engineer Incharge. Test certificates from the
supplier shall be provided for each lot of reinforcement.
The three low temperature tests on the elastomeric described in Article

911.7.4.5.4 shall be conducted on the material used in each lot of
bearings for grades 3, 4, and 5 material and the instantaneous thermal
stiffening test shall be conducted on material of grades 0 and 2. Low
temperature brittleness and crystallization tests are not required for
grades 0 and 2 materials, unless especially requested by the Engineer
Incharge.
For grade 3 material, in lieu of the low temperature crystallization test,

the manufacturer may choose to provide certificates from low-
temperature crystallization tests performed on identical material within
the last year, unless otherwise specified by the Engineer Incharge.
Every finished bearing shall be visually inspected in accordance with

Article 911.7.4.5.5.
Every steel reinforced bearing shall be subjected to the short-term load

test described in Article 911.7.4.5.6.
From each lot of bearings either designed by the provisions of Article

14.6.5 of Division 1 of this specification or made from grade 4 or
grade 5 elastomer, a random sample shall be subjected to the long-term
load test described in Article 911.7.2.7 and 911.7.4.5.7. The sample
shall consist of at least one bearing chosen randomly from each size
and material batch and shall comprise at least 10% of the lot. If one
bearing of the sample fails, all the bearings of that lot shall be rejected,
unless the manufacturer elects to test each bearing of the lot at own
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expense. In lieu of this procedure, the Engineer Incharge may require

every bearing of the lot to be tested.
The Engineer Incharge may require shear stiffness tests on material

from a random sample of the finished bearings in accordance with
Article 911.7.4.5.8.
911.7.4.5.3 Ambient Temperature Tests on the Elastomer
The elastomer used shall at least satisfy the limits prescribed in the
appropriate Table 911.4.5.1-1A or 1B for durometer hardness, tensile
strength, ultimate elongation, heat resistance, compression set, and
ozone resistance. The bond to the reinforcement, if any, shall also
satisfy Article 911.4.5.3. The shear modulus of the material shall be
tested at 73ºF using the apparatus and procedure described in Annex A
of ASTM D 4014, amended where necessary by the requirements of
Table 911.4.5.1 – 1A or – 1B. It shall fall within 15% of the specified
value, or within the range of its hardness given in Article 14.6.5.2 of
Division I if no shear modulus is specified.
911.7.4.5.4 Low Temperature Tests on the Elastomer
The tests shall be performed in accordance with the requirements of

Table 911.4.5.1 – 1A and – 1B and the compound shall satisfy all limits
for its grade. The testing frequency shall be in accordance with Article
911.7.4.5.2.
911.7.4.5.5 Visual Inspection of the Finished Bearing
Each finished bearing shall be inspected for compliance with

dimensional tolerances and for overall quality of manufacturer. In steel
reinforced bearings, the edges of the steel shall be protected
everywhere from corrosion.
911.7.4.5.6 Short-Duration Compression Tests on Bearings
Each finished bearing shall be subjected to a short-term compression

test as described in Article 911.7.2.5. If the bugling pattern suggests
laminate parallelism or a layer thickness that is outside the specified
tolerances, or poor laminate bond, the bearing shall be rejected. If there
are three or more separate surface cracks that are greater than 0.08
inches wide and 0.08 inches deep, the bearing shall be rejected.
911.7.4.5.7 Long-Duration Compression Tests on Bearings
The bearing shall be subject to a long-term compression test as

described in Article 911.7.2.6. The bearing shall be examined visually
at the end of the test while it is still under load. If the bulging pattern
suggests laminate parallelism or a layer thickness that is outside the
specified tolerances, or poor laminate bond, the bearing shall be
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rejected. If there are three or more separate surface cracks that are
greater than 0.08 inches wide and 0.08 inches deep, the bearing shall
be rejected.
911.7.4.5.8 Shear Modulus Tests on Materials from Bearings
The shear modulus of the material in the finished bearing shall be

evaluated by testing a specimen cut from it using the apparatus and
procedure described in Annex A of ASTM D 1014, amended where
necessary by the requirements of Table 911.4.5.1 -1A or 1B, or, at the
discretion of the Engineer Incharge, a comparable nondestructive
stiffness test may be conducted on a pair of finished bearings. The
shear modulus shall fall within 15% of the specified value. If the test is
conducted on finished bearings, the material shear modulus shall be
computed from the measured shear stiffness of the bearings, taking due
account of the influence on shear stiffness of bearing geometry and
compressive load.
911.7.4.7 Test Requirements for Bronze and Copper Alloy Bearings
Material certification tests for the bronze or copper shall be performed

to verify the properties of the metal.
Bearing friction tests as defined in Article 911.7.2.7 or material friction

tests as defined in Article 911.7.2.2 may be required by the Engineer
Incharge.
911.7.4.8 Test Requirements for Disc Bearings
911.7.4.8.1 Material Certification Tests
The manufacturer shall select, at random, samples for material

certification tests as defined in Article 911.7.2.1. The tests shall be
performed, and certifications shall be delivered to the Engineer
Incharge.
Certification shall be provided for all polyether urethane elements.

Their material properties shall satisfy the requirements of the design
documents and the tests described in Article 911.4.8.1. Additional tests
may be required by the Engineer Incharge.
911.7.4.8.2 Testing by the Engineer Incharge
When quality assurance testing is called for by the special provisions,

the manufacturer shall furnish to the Engineer Incharge the required
number of complete bearings and component samples to perform
quality assurance testing. At least one set of material property tests in
accordance with Article 911.4.8.1 shall be conducted per lot of
bearings. All exterior surfaces of sampled production bearings shall be
smooth and free from irregularities or protrusions that might interfere
with testing procedures.
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For quality assurance testing, the Engineer Incharge may select at

random the required sample bearing(s) and the material samples from
completed lots of bearings.
A minimum of 30 days shall be allowed for inspection, sampling, and

quality assurance testing of production bearings and component
materials.
911.7.4.8.3 Bearing Tests
Critical dimensions shall include the clearance between the upper and
lower parts of the steel housing, and shall be verified by the Clearance
Test described in Article 911.7.2.4.
A Long-term Deterioration Test as described in Article 911.7.2.8 shall

be performed on one disc bearing of each lot. The test shall be
performed at the maximum design rotation combined with a maximum
dead plus live load. If size limitations prevent testing of the full size
bearing, a special bearing with the same rotational capacity and no less
than 200 kips compressive load capacity may be tested in its place.
A Long-term Compression Proof Load Test as described in Article

911.7.2.6 may be required by the Engineer Incharge.
911.7.5 Cost of Transporting
The Contractor shall assume the cost of transporting all samples from
the place of manufacturer to the test site and back, or if applicable, to
the project site.
911.7.6Use of Tested Bearings in the Structure
Bearing which have been satisfactorily tested in accordance with the

requirements of this section may be used in the structure provided that
they are equipped with new deformable elements, sliding elements and
seals, as required by the Engineer Incharge.
911.8 PACKING, SHIPPING AND STORING
For transportation and storage, bearings shall be packaged in a way

that prevents relative movement of their components and damage by
handling, weather, dust, or other normal hazards. They shall be stored
only in a clean, protected environment. When installed, bearings shall
be clean and free from all foreign substances.
Bearings shall not be opened or dismantled at the site except under the
direct supervision of, or with the written approval of, the manufacturer
or its assigned agents.
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911.9 INSTALLATION
911.9.1 General Installation Requirements
Bearings shall be installed by qualified personnel at the locations

shown on the plans. Bearings shall be set to the dimensions and offsets
prescribed by the manufacturer, the Engineer Incharge, and the plans
and shall be adjusted as necessary to take into account the temperature
and future movements of the bridge due to temperature changes,
release of false work, shortening due to prestressing and other bridge
movements.
Each bridge bearing shall be located within + 1/8 inch of its correct
position in the horizontal plane and oriented to within an angular
tolerance of 0.02 radians. Guided Bearings shall also satisfy the
requirements of Article 911.9.2.3. All bearings except those which are
placed in opposing pairs shall be set horizontal to within an angular
tolerance of 0.005 radians, and must have full and even contact with
load plates, where these exist. The super-structure supported by the
bearing shall be set on it so that, under full dead load, its slope lies
within an angular tolerance of 0.005 radians of the design value. Any
departure from this tolerance shall be corrected by means of a tapered
plate or by other means approved by the Engineer Incharge. If shim
stacks are needed to level the bearing they shall be removed after
grouting and before the weight of the super-structure acts on the
bearing.
Metallic bearing assemblies not embedded in the concrete shall be

bedded on the concrete with a filler or fabric material conforming to
Article 911.4.10.
Bearings seated directly on steel work required the supporting surface

to be machined so as to provide a level and planer surface upon which
the bearing is placed.
Bearings or masonry plates that rest on a steel support may be installed
directly on it, provided that it is flat to within a tolerance of 0.002
times the nominal dimension, and is sufficiently rigid that it will not
deform under the specified loads to exceed that flatness tolerance.
911.9.2 Special Installation Requirement
911.9.2.1 Installation of Rocker and Roller Bearings
Just before placing roller bearings, the Contactor shall coat all contact
surfaces thoroughly with oil and graphite.
911.9.2.2 Installation of Elastomeric Bearings
Elastomeric bearings without external load plates may be placed

directly on a concrete or steel surface provided that it is flat to within
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an tolerance of 0.005 of the nominal dimension for steel reinforced

bearings and 0.01 of the nominal dimension for others. Bearings shall
be placed on surfaces that are horizontal to within 0.01 radians. Any
lack of parallelism between the top of the bearing and the underside of
the girder that exceeds 0.01 radians shall be corrected by grouting or as
otherwise directed by the Engineer Incharge.
Exterior places of the bearing shall not be welded unless at least 1.5
inches of steel exists between the weld and the elastomer. In no case
shall the elastomer or the bond be subjected to temperatures higher
than 400ºF.
911.9.2.3 Installation of Guideways and Restraints
Guided bearings and bearings which rotate about only one axis shall be
oriented in the direction specified on the contract plans to within an
angular tolerance of 0.005 radians.
911.9.2.4 Installation of Anchorages
Load plates shall be set level to within an angular tolerance of 0.005

radians and shall have a uniform bearing over their whole area. When
plates are to be embedded in concrete, provision shall be made to keep
the plates in the correct position while the concrete is being placed.
A bedding layer may be used to achieve level, uniform bearing. This

may consist of grout or a ductile metal such as a thin lead sheet. The
bedding material shall be able to support the specified vertical and
horizontal loads without undergoing displacements or deformations
detrimental to the bearing or structure.
Anchor bolts embedded in concrete shall either be cast into the

concrete or shall be grouted into drill holes.
911.10 DOCUMENTATION
911.10.1 Working Drawings
The manufacturer shall submit to the Engineer Incharge shop drawings

and design calculations which are sufficiently detailed to permit proper
review of the bearing. The drawings shall show all details of the
bearings and of the materials proposed for use and must be approved
by the Engineer Incharge before fabrication of the bearings is begun.
Such approval shall not relieve the Contractor of any responsibility
under the contract for the successful completion of the work. The
drawings shall include, but not be limited to the following information:
(1) Plan, elevations and sections including all nominal dimensions

and material designations.
(2) Vertical and horizontal load capacities, horizontal movement
capacities and rotation capacities about two horizontal and one
vertical axes.
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(3) Design calculations for all items.

(4) Material designations and specifications.
(5) A schedule of bearing offsets, if any are required.
(6) Shop painting or coating requirements.
(7) Any special installation requirements.
911.10.2 Marking
Each bearing shall be marked in indelible ink or flexible paint. The

marking shall consist of the location, orientation, order number, lot
number, bearing identification number, and elastomer type and grade
number. Unless otherwise specified in the contract documents, the
marking shall be on a face, which is visible after erection of the bridge.
911.10.3 Certification
The manufacturer shall supply certification data for all materials used.
This shall consist of at least test reports for the bearing performance
tests and for any forgings, castings or hardened material, mill
certificates for the bearing as a whole and for any anchor bolts, dowels
or other accessories.
The manufacturer shall also supply a separate sheet showing the

materials, critical dimensions and clearances for each bearing other
than elastomeric pads. The precise information to be supplied shall be
agreed between the Engineer Incharge and the manufacturer prior to
starting production.
911.11 MEASUREMENT
Bearing devices will be measured either by the pound as determined

from scale weights or by a unit basis for each type of bearing assembly
listed in the schedule of bid items. Scale weights are not required when
calculated weights are shown on the plans in which case the weights
shown on the plan will be used as the basis of payment.
911.12 PAYMENT
Bearing devices will be paid for at the contract price per pound or per
unit. Such payment shall include full compensation for furnishing all
labor, materials, tools, equipment and incidentals, and for doing all the
work involved in furnishing, testing and installing said bearing
devices, complete in place, as shown on the plans, and as specified in
these Specifications and the special provisions, and as directed by the
Engineer Incharge.
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SECTION 921
BRIDGE DECK JOINT SEALS
921-1 GENERAL
This work shall consist of the furnishing and installing of joint sealing
systems in bridge decks of the types used where significant movements are
expected across the joint. These include compression seal joints consisting
of preformed elastomeric material compressed and installed in specially
prepared joints and joint seal assemblies consisting of assemblies of metal
and elastomeric materials installed in recesses in the deck surface.
Joint seals described in the plans or the specifications as poured joint seals
shall conform to the requirement of section, “Expansion and contraction
Joints.”
The type and dimensions for bridge deck joint at each location shall be as
shown on the plans or ordered by the Engineer Incharge.
All joints shall prevent the intrusion of material and water through the joint
system.
921-2 MATERIALS
Bridge deck joint seal materials and assemblies shall conform to the
following specifications:
Preformed elastomeric joint seals of multiple web design shall conform to

AASHTO M 220 (ASTM D 2628).
Lubricant – adhesive for use with preformed elastomeric seals shall

conform to ASTM D 4070.
Deck joint seal assemblies shall be of an approved type for each size
required and shall conform to the specifications provided by the
manufacturer at the time of approval.
Steel and fabricated steel components shall conform to the requirements of

Section, “831 of standard specification for road and bridges construction.
921.3MANUFACTURE AND FABRICATION
921.3.1 Compression Seal Joints
Preformed elastomeric joint seals shall not be field spliced except when
specifically permitted by the Engineer Incharge.
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921.3.2 Joint Seal Assemblies
Expansion joint assemblies shall be fabricated and delivered to Bridge

site completely assembled, unless otherwise shown on the plans or
specified in the special provision.
921.4INSTALLATION
921.4.1 General
All joint materials and assemblies, when stored at the job site shall be
protected from damage and assemblies shall be supported so as to
maintain their true shape and alignment. Deck joint seals shall be
constructed and installed to provide a smooth ride. Bridge deck joints
shall be covered over by protective material after installation until final
cleanup of the bridge deck.
After installation and prior to final acceptance, deck joint seals shall be
tested in the presence of the Engineer Incharge for leakage of water
through the joint. Any leakage of the joint seal will be cause for
rejection.
921.4.2 Compression Seal Joints
Joints in the roadway area of bridge decks which are to be sealed with
compression seals shall be cast to a narrower width than required for
the preformed material. Such joints in kerbs and sidewalks may be cast
to full width. Prior to installation of compression seals in joints whose
width is narrower than needed, a groove of proper width and depth to
receive the preformed material shall be saw cut along the top of the
joint.
When making saw cuts into the bridge deck, spalling shall be
minimized. Both sides of a groove shall be cut simultaneously to the
proper depth and alignment as shown on the plans. The alignment of
the saw shall be controlled at all times by a rigid guide. The width of
the groove will depend on the temperature and age of the concrete and
shall be as directed by the Engineer Incharge. Lip of saw cut should be
bevelled to avoid later breakage. After saw cutting, any spalls, popouts
or cracks shall be repaired prior to installation of the lubricant sealant.
Saw cuts are not required where armor plates are used.
At the time of installation the joint shall be clean and dry and free from
spalls and irregularities which might impair a proper joint seal.
Concrete or metal surfaces shall be clean, free of rust, laitance, oils,
dirt, dust, or other deleterious materials. Pre-molded elastomeric
compression joint seals shall be installed without damage to the seal by
suitable hand methods or machine tools. The lubricant-adhesive shall
be applied to both faces of the joint prior to installation and in
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accordance with the manufacturer’s instructions. The preformed

elastomeric seal shall be compressed to the thickness specified on the
plans or as approved by he Engineer Incharge for the rated opening and
ambient temperature at the time of installation. Loose fitting or open
points between the seal and the deck will not be permitted.
921.4.3 Joint Seal Assemblies
Expansion joint seal assemblies shall be constructed to provide

absolute freedom of movement through a range consistent with that as
shown on the design plans.
921.5MEASUREMENT
Deck joint seals will be measured by the linear foot of acceptable joint
seal completely installed.
921.6RATES AND PAYMENT
Payment of linear feet of joint seal as measured, for each type of seal
for which separate payment is provided, shall include full
compensation for the cost of labor, equipment and materials to furnish
and install the deck joint seal.
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SECTION 931
RAIN WATER OUTLETS FOR BRIDGE DECK SLAB.
931.1 DESCRIPTION
The work specified in this section consists of furnishing galvanized mild steel
pipes of specified length indicated and placing the same in correct position n
bridge deck slab, all in accordance with the lines, dimensions and notes shown
on the drawings.
931.2 MATERIALS
The rain water outlet pipes are to be galvanized mild steel pipes. The
galvanized surfaces are to be entirely coated with zinc of a minimum weight
of 0.38 Kg/m2 (1.25 ounces per square foot) of surface area. The finished
surface shall be perfectly smooth and uniform with the coating firmly adhering
to the pipe.
The galvanized mild steel pipe of the specified size shall be provided at the
location s shown on the drawings or as directed by the Engineer-Incharge.
Placing of the pipe shall be done at the time of concreting. Leaving space and
providing the pipe at a later stage shall not be allowed. Pipes placed as rain
water outlets shall be saved from concrete, mortar or any other material to
enter inside. Outer surface of the pipe however, shall have proper bond with
concrete which shall be ensured by cleaning the surface of the pipes before
placing in position.
931.4 MEASUREMENT
Rain water outlets when fixed in accordance with these specifications shall be
measured in numbers of outlets actually fixed in place and accepted. The unit
of measurement shall be one number.
931.5 RATE
The unit rate shall be full compensation for furnishing, shaping and fixing rain
water outlets all according to the requirements of this section.
931.6 PAYMENT
Pay Item No.931-6.1 Rain Water Outlets Each
**************
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SECTION 941
KILOMETER STONES AND RIGHT OF

WAY MARKERS
941.1 DESCRIPTION
The work covered in this Section consists of furnishing and placing

pre-cast reinforced cement concrete kilometer stones and right of way
markers of the specified size and shape and set in specified base
concrete including painting marking and lettering the same as indicated
on the drawings or as directed by the Engineer Incharge.
941-2 TYPES OF KILOMETER STONES
941-2.1 Ordinary Kilometer Stones
These shall be required at the interval of one kilometer on Provincial

Highways and Major District Roads except that at 5 th repeating interval
the kilometer stones of the type given under Section 941-2.2 shall be
required. The dimensions of the ordinary kilometer stones, their
reinforcement details and the dimensions of base concrete have been
given in plate 1.
941-2.2 5th Kilometer Stones
These shall be required at the interval of 5 kilometers on Provincial

Highways and Major District Roads. The dimensions of the 5 th
kilometer stones, there reinforcement details and the dimensions of
base concrete have been given in plate 3.
941-2.3 Kilometer Stones for District and Farm to Market Roads.
These shall be required at each kilometer of the District and Farm to

Market Roads.. Their dimensions, reinforcement details and
dimensions of base concrete have been given in plate 3.
941.3 MATERIALS
The concrete kilometer stones or right of way markers shall be

furnished by the contractor, which shall be made of nominally
reinforced type C concrete as specified in Section 701. The painting
marking and lettering shall be as specified on the drawings. Base
concrete shall be of type E as specified in Section 701
Reinforcing bars shall conform to section 821.
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941-4 CONSTRUCTION METHODS
The concrete kilometer stones or right of way markers shall be pre-cast

in approved moulds and on approved platforms. These shall then be
cured and stacked in sheds till removed for installation at site. These
shall be set in a concrete base of type E concrete, as shown on the
drawings. These shall then be painted with two coats of approved
white paint and written with 3 coats of approved black paint.
Thereafter, the Contractor shall be responsible for their maintenance
until the final acceptance of the contract, keeping them in their proper
locations and condition at all times.
941-5 SCRIPT AND SEQUENCE OF INSCRIPTION
i). Ordinary kilometer stones (vide Plate 1) shall be inscribed in

Urdu and indicate alternatively the name and distance to the
next important (i.e. intermediate) town or the terminal/starting
station as the case may be .Fifth kilometer stones, on the other
hand, shall be inscribed only in Roman and show the name and
distance of the terminal/starting station as well as of the
intermediate town.
ii). The place names shall be inscribed in different scripts in the

following sequence, only one script being used on any one
kilometer stone.
Km. No Script for Place Names Place to be shown.

0 Roman Terminal/Starting Station
and next Important Town.
1 Urdu (Script) Next Important Town
2 Urdu Terminal/Starting Station
3 Urdu Next Important Town
4 Urdu Terminal/Starting Station
5 Roman Terminal/Starting Station
and next Important Town
6 Urdu Next Important Town and
so on, repeated in the
same order.
iii). On kilometer stones fixed on other District Roads and Farm to

Market Roads, inscription in Roman script is not necessary,
unless the road leads to a place of tourist or archaeological
interest or there are other good reasons.
iv). In every case, the numerals on kilometer stones shall be

inscribed in the international form of numerals. Urdu numerals
shall not be used.
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v). Distance will be in whole numbers. Fraction less than 0.5 will
be ignored and fraction of 0.5 and above will be counted one
whole number.
vi). The kilometer stones will be numbered from zero to the end of
the road in a continuous arithmetical numbering.
vii). On each kilometer stone, its number shall be inscribed on the

side of the stone facing the carriageway (see Plates 1,2 and 3).
In case of thin R.C.C. kilometer stones the digits may be
inscribed one below the other starting from the top. Thus 426
will be shown as:
941-6 PLACEMENT
i). Normally kilometer stones shall be located on left hand side of

the road as one proceeds from the station from which the
kilometer count starts. On divided roads having a central
median, kilometer stones should be provided at the left on both
sides of the road i.e. independently for each direction of travel.
ii). Kilometer stones shall be fixed at right angles to the center line
of the carriageway. On embankments, these shall be located on
the edge of the roadway beyond the shoulders, if necessary on
specially erected platforms. On cut sections, these shall be
fixed clear of the shoulders as well as the side drains.
iii). In case of a physical constraint, such as a bridge, a kilometer

stone will be fixed out-side the physical constraint. The overall
distance will not, however, change
941-7 MEASUREMENT
The quantities to be paid for under this Section shall be the number of
kilometer stones or right of way markers constructed, completed and
accepted. The unit of measurement shall be by the number.
941-8 RATE
The quantities determined as provided above, shall be paid for at the

contract unit price each for kilometer stones or right of way markers
complete including painting, markings and lettering. Such prices and
payments shall be full compensation for all the work specified in this
Section.
941-9 PAYMENT
Pay Item No.941-9.1 Ordinary kilometer stone

On Provincial Highways &
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Major District Roads

Complete. Each.
Pay Item No.941-9.2 5th kilometer stone

On Provincial Highways &
Major District Roads
Complete. Each
Pay Item No.941-9.3 Kilometer stone for

District &Farm to Market
Roads complete Each
Pay Item No.941-9.4 Right of way Markers

Complete. Each
*****************
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CHAPTER 1000
ROADWAY CONSTRUCTION
MATERIALS
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SECTION 1001
PORTLAND CEMENT
1001-1 DESCRIPTION
These specifications give requirements for the composition, sampling

and testing of ordinary and other types of Portland cements normally in
use with the Department, and as manufactured according to ASTM,
BSS or Pakistan Standard (PS).
1001-2 TYPES OF CEMENT
According to A.S.T.M. C 150
Type I. For use when the special properties specified for

any other type are not required.
Type IA Air-entraining cement for the same uses as Type

– I, where air-entrainment is desired.
Type II For general use, mo especially when moderate

sulphate resistance or moderate heat of
hydration is desired.
Type IIA Air-entraining cement for the same uses as

Type – II, where air-entrainment is desired.
Type III For use when high early strength is desired.
Type IIIA Air-entraining cement for the same uses as

Type – III, where air-entrainment is desired.
Type IV For use when a low heat of hydration is desired.
Type V For use when high sulphate resistance is desired.
1001-3 BASIS OF PURCHASE
The purchaser shall specify the desired type or types of Portland

cement. When no type is specified, the requirements of Type 1
(ASTM C-150) or ordinary cement (B.S..12 or BS-202) shall govern.
1001-4 DEFINITION
Portland cement is the product obtained by pulverizing clinker

consisting essentially of hydraulic calcium silicates to which, no
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additions have been made subsequent to calcinations other than water

and /or untreated sodium sulphate except that addition of other non
deleterious materials may be added at the option of the manufacturer in
an amount not to exceed 0.1 percent.
1001-5 QUALITY REQUIREMENTS
Portland cement of the types shown in section 1001-2 shall conform to

the chemical and physical requirements given in Table 1 & 2
respectively of ASTM Designation C-150, BS 12 or PS 232 (latest
issue) whichever is applicable.
1001-6 PACKING AND MARKING
When the cement is delivered in packages, the name and brand of the
manufacturer and the type shall be plainly identified thereon, except
that, in the case of type I cement, the type need not be identified. When
the cement is delivered in bulk this information shall be contained in
the shipping advices accompanying the shipment. A bag shall contain
net 50 kg (112 Lbs) of cement. All packages shall be in good condition
at the time of inspection.
1001-7 STORAGE
1001-7.1 Storage Godowns
The cement shall be stored in such a manner as to permit easy access

for proper inspection and identification of each shipment and in a
suitable water proof building that will protect the cement from
dampness and minimize warehouse set. Cement bags shall be stacked
on a damp-proof floor or on timber platform raised at least 30 cms (12
inches) from the ground with air space below. There shall be similar air
space between the stack and walls and roof of the building. The
maximum height of stack shall not exceed twelve bags. If the stack is
to be more than eight (8) bags high, these shall be arranged in header
and stretcher fashion. The bags in stacks shall be placed together.
Cement in earlier stacks shall be used first.
1001-7.2 Temporary Storage at Site
Very often bags of cement have to be stored on the works site in the
open, for use on work for one or more days. In such cases the bags
must be laid on a dry platform made of wooden planks resting on a
brick masonry, concrete or dry sand or aggregate platform about (30
cm) 12 inches above the ground.
The number of bags should be kept to a minimum preferably just

sufficient for the day’s consumption.
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Care should be taken to see that every point in the pile is well covered
by tarpaulins and protect against the moisture in the air. The tarpaulins
must overlap each other properly. This method of temporary storage
should not be adopted in wet weather.
1001-8 INSPECTION
Every facility shall be provided to the purchaser for careful sampling

and inspection either at the factory or at site of the work, as may be
specified by the purchaser. The following periods from time of
sampling shall be allowed for completion of testing.
1 day test 6 days

3 day test 8 days
7 day test 12 days
28 day test 33 days
1001-9 REJECTION
1001-9.1 The cement may be rejected if it fails, to meet any of the requirements
of these specifications.
1001-9.2 Cement remaining in bulk storage at the factory, prior to shipment, for
a period greater than six months after completion of the tests may be
re-tested and may be rejected if it fails to conform to any of the
requirements of these specifications.
1001-9.3 Packages varying more than 5 percent from the specified weight may
be rejected, and if the average weight of packages in any shipment, as
shown by weighing 50 packages taken at random is less than that
specified, the entire shipment may be rejected.
1001-9.4 Cement failing to meet the relevant test for soundness may be accepted
if it passes a retest, using a new sample, at any time within 28 days
thereafter. The provisional acceptance of the cement at the factory shall
not deprive the purchaser of the right to reject on a retest of soundness
at the time of delivery of the cement to the purchaser.
1001-10 METHOD OF SAMPLING AND TESTING.
The sampling and testing of Portland cement shall be in accordance

with the following related standards of ASTM, BSS, and PS.
i) ASTM Standards
Sampling Hydraulic Cement C 183

Test for compressive strength of hydraulic cement
Mortars C 109
Chemical Analysis of Hydraulic cement. C 114
Test for fineness of Portland cement. C 115
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Draft 2004
Test for autoclave expansion of Portland cement C 151

Test for Heat of hydration. C 186
Test for time of setting by Vicat needle C 191
Test for calcium sulphate in hydrated Portland cement
mortar C 265
Test for early stiffening of Portland cement. C 451
Test for potential expansion of Portland cement mortars
Exposed to sulphate. C 452
ii). British Standards and Pakistan Standards.
Sampling
The sample for testing shall be taken by the purchaser

according to the procedure laid down in clause 10 of B.S-12
within one week of delivery of the cement, stored in a dry and
clean airtight container and test within four weeks of delivery.
The samples taken as described above shall be tested for the

following properties as per test procedures specified by B.S-12
or PS-232.
i- Fineness
ii- Chemical Composition.
iii- Strength
iv- Setting time
v- Soundness
The test results for the above properties shall conform to the
following requirements specified by BS-12 or PS-232 which-
ever is applicable.
i) Fineness
Ordinary Portland
Cement Specific Area not less than
2250 sq.cm/gm.
Rapid-hardening
Portland Cement. Specific Area not less than
3250 sq.cm/gm.
ii) Chemical Composition
Lime saturation factor Not greater than 1.02 and

not less than 0.66.
Insoluble Residue. Not more than 1.5 percent by

mass
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Magnesium Not more than 4.0 percent by

mass
Alumina-iron Ratio Not more than 0.66 percent by

mass
Loss on ignition. Not more than 3.0 percent by

mass
iii) Strength
Compressive Strength (average of 3 mortar Cubes)

Ordinary Portland Cement.
a) When tested according to BS 4550-1978
3 days Not less than 3600 Lbs/sq. in

(25 N/mm2)

(47N/mm2)
Not less than 9700 Lbs/sq. in

(67 N/mm2)
b) When tested according to AASHTO M 8580

(12.4 N/mm2)

(19.3 N/mm2)
Rapid Hardening Cement
a) When tested according to BS 4550

(25 N/mm2)

(52 N/mm2)
b) When tested according to AASHTO M 8580

(12.4 N/mm2)

(24.1 N/mm2)
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iv) Setting Time
Initial setting Time Not less than 45 minutes.

Final setting Time Not more than 10 hours.
v) Soundness
By Le Chatelier Method Expansion not more than

10 mm (0.4 in)
By Autoclave Method Expansion not more than 0.5 %
1001-11 MEASUREMENT
Cement shall be measured by weight. The unit of measurement shall be

one metric ton (Tonne).
1001-12 RATE
The unit rate for supply of cement, at site of work shall be full
compensation for cost of cement, octroi charges, unloading from
wagons/trucks, transportation to site of work, and its storage in
godowns.
1001-13 PAYMENT
Payment for supply of cement, when specifically called for in bid

schedule shall be made as under:-
Item No.1001-13.1 Supply of Portland cement

of Specified Quality Per metric ton
*****************
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SECTION 1011
BITUMINOUS BINDERS
1011-1 DESCRIPTION
The work covered under this Section consists of supplying bituminous

binders of designated grades, in accordance with these specifications
and at location designated by the Engineer Incharge.
1011-2 TYPES OF BITUMINOUS BINDERS
For the purposes of these specifications, the following types of

bituminous binder shall be considered.
(i) Bitumen (Penetration grade / straight run)

(ii) Cut Backs
(iii) Emulsions
1011-2.1 Bitumen
Penetration grade bitumen shall be obtained from crudes by either

vacuum distillation or semi blowing or two stage blowing, or fluxing
and solvent extraction methods.
The supply order for bitumen shall be designated by its penetration at

25oC (77oF). The grades of bitumen are usually designated by
penetration limits such as 200/300, 120/150, 80/100, 60/70 etc. Grade
specifically required shall be designated.
1011-2.2 Cut Backs
Cut backs shall consist of penetration grade bitumen’s mixed with a

volatile solvent or flux which shall be either white spirit or Naphtha, or
a type of Kerosene or type of gas oil.
Bitumen when mixed with naphtha or white spirit, produces rapid

curing cutbacks, when mixed with a type of kerosene, produces
medium curing cutbacks and when mixed with a type of gas oil,
produces slow curing cutbacks.
Grades of cutbacks are designated by the kinematics viscosity

measured at a standard temperature of 60o C (140o F). Each grade is
named by the lower limit of the viscosity and the upper limit for the
grade is twice that of lower limit. These results in the grades being
know as RC, MC, SC, 800, RC, MC, SC 3000 etc.
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1011-3.1 Standard Requirements
Standard requirements for penetration grade bitumens, cutbacks

emulsions conform to the specifications given in Table 1011-1 to 1011-
4 of this Section.
1011-4 Application Temperatures for Various Bituminous Binders
Various bituminous binders for applications shall be heated to

temperatures shown in Table 1011-5
1011-5 SUPPLY OF BITUMEN
The agency supplying bituminous binders to the Department shall do

so either in tank trucks or in waterproof drums, as called for in the Bid
schedule. The drums shall be standard 35/36 Imp. Gallons or as
specified by the Department made of 24 SW gauge or thicker M.S.
sheet as specified and properly welded to make it waterproof. The tank
trucks shall be fully insulated. They shall be inspected prior to loading
and if necessary they shall be drained and cleared.
1011-6 METHODS OF SAMPLING AND TESTING.
Latest revision of standard methods of AASHTO shall apply as under:-
1. Penetration Grade Bitumen
a. Sampling T 40
b. Penetration T 49
c. Flash point (C.O.C) T 48
d. Ductility. T 51
e. Solubility Trichloroethylene T 44
f. Thin Film oven test. T 179
g. Softening Point (Ring and Ball) T 53
h. Foaming Temperature. M-20
2. Cut backs Bitumens
a. Sampling T 40
b. Kinematic viscosity. T 201
c. Water content. T 55
d. Distillation T 78
e. Penetration. T 49
f. Saybolt furol viscosity T 72
g. Ductility. T 51
h. Solubility T 44
i. Flash Point T 79
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3. Emulsions (Emulsified bitumen)
a. Sampling T 40
b. Testing T 59
1011-7 MEASUREMENT
Bitumen binders shall be measured by weight or by volume as

specified. When measured by weight, the unit of measurement shall be
one metric ton (Tonne) or one-binder pounds. When measured by
volume, the unit of measurement shall be an imperial Gallon or U.S.
Gallon or liter.
1011-8 RATE
The unit rate for supply of bituminous binder at site of work shall be
full compensation for cost of material, octroi charges, unloading from
wagons/trucks, transportation to site of work & its storage in godowns.
1011-9 PAYMENT
Payment for supply of bituminous binder or tar, when specifically

called for in bid schedule shall be made under:-
Pay Item Supply of bituminous Metric ton (Tonne) or

No.1011-9.1 binder of specified one hundred pounds
quality and grade (100 lbs) when
measured by weight.
Pay Item Supply of bituminous Imp gallon or U.S.
No.1011-9.2 binder of specified gallon or litre when
quality and grade measured by volume at
16oC (60 F)
****************
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TABLE 1011-1
REQUIREMENTS FOR PENETRATION GRADE BITUMENS
(AASHTO M –20)
PENETRATION GRADE
40-50 60-70 80-100 120-150 200-300

Min.
Max. Min. Max. Min. Max. Min. Max. Min. Max.
1. Penetration at 250C (77oF)100g, 5 Sec. 40 40 60 70 80 100 120 150 200 300
2. Flash point, Cleveland Open Cup (F0) 450 - 450 - 450 - 425 - 350 -
3 Ductility at 250 C(770 F) 5 cm. Per min, cm 100 - 100 - 100 - 100 - - -
4 Solubility in Trichloroethylene percent. 99 - 99 - 99 - 99 - 99 -

Thin-film oven test, 1/8 in. (3.2mm), 1630 C(3250 F) 5 hour.
5 - 0.8 - 0.8 - 1.0 - 1.3 - 1.5
Loss on heating percent.
6 Penetration of residue, percent of original 58 - 54 - 50 - 46 - 40 -
7 Ductility of residue at 250C(770F)5 cm. per min, cm. - - 50 - 75 - 100 - 100 -
Properties:
The asphalt cement shall be homogenous, free from water and shall not foam when heated to 1750C (3470F).
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TABLE 1011-2
REQUIREMENTS FOR RAPID-CURING CUTBACKS
(AASHTO M –81)
S.No. RC-70 RC-250 RC-800 RC-3000

Min Max Min Max Min. Max Min Max
1. Kinematics Viscosity at 600C (1400F)(see note) centistokes 70 140 250 500 800 1600 3000 6000
2. Flash point (tag. Open cup) degree C(F) - - 27(80) - 27(80) - 27(80) -
3 Water percent. - 0.2 - 0.2 - 0.2 - 0.2
4 Distillation test
Distillate, percentage by volume of total distillate to 3600C (6800F)
To 1900C (3740F) 10 - - - - - - -
To 2250C(4370F) 50 - 35 - 15 - - -
0 0
To 260 C (500 F) 70 - 60 - 45 - 25 -
0 0
To 315 C (600 F) 85 - 80 - 75 - 70 -
5 Residue from distillation to 3600C (6800F) volume percentage of 55 - 65 - 75 - 80 -
sample by difference.
6 Test on residue from distillation
Penetration, 100g, 5 sec. at 250C(770F) 80 120 80 120 80 120 80 120
0 0
Ductility, 5 Cm/min. at 25 C(77 F) cm 100 - 100 - 100 - 100 -
Solubility in Trichloroethylene percent 99 - 99 - 99 - 99 -
Note:- As an alternate say bolt-Furol Viscosities may be specified as follows:-

Grade RC-70 Furol Viscosity at 500C (1220F) 60 to 120 Sec.
0
Grade RC-250 Furol Viscosity at 60 C (1400F) 125 to 250 Sec.
Grade RC-800 Furol Viscosity At 82.20C (1800F) 100 to 200 Sec.
Grade RC-3000 Furol Viscosity At 82.20C (1800F) 300 to 600 Sec.
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TABLE 1011-3
REQUIREMENTS FOR MEDIUM-CURING CUTBACKS
(AASHTO M –82)
S.No. MC-30 MC-70 MC-250 MC-800 MC-3000

Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
1. Kinematics Viscosity at 600C (1400F)(see note) 30 60 70 140 250 500 800 1600 3000 6000
centistokes
2. Flash point (tag. Open cup) degree C(F) 38(100) - 38 - 66 - 66 - 66 -
(100) (150) (150) (150)
3 Water percent. - 0.2 - 0.2 - 0.2 - 0.2 - 0.2
4 Distillation test
Distillate, percentage by volume of total distillate to
3600C (6800F)
To 2250C (4370F) - 25 - 20 - 10 - - - -
To 2600C (5000F) 40 70 20 60 15 55 - 35 - 15
To 3150C (6000F) 75 93 65 90 60 87 45 80 15 75
5 Residue from distillation to 3600C (6800F) volume 50 - 55 - 67 - 75 - 80 -
percentage of sample by difference
6 Test on residue from distillation
Penetration, 100g, 5 sec. at 250C(770F) 120 50 120 250 120 250 120 250 120 250
Ductility, 5 Cm/min. cm (see note 2) 100 - 100 - 100 - 100 - 100 -
Solubility in Trichloroethylene percent 99 - 99 - 99 - 99 - 99 -
Note 1:- As an alternate say bolt-Furol Viscosities may be specified as follows:-

Grade MC-30 Furol Viscosity at 250C (770F) 75 to 150 Sec.
0
Grade MC-70 Furol Viscosity at 50 C (1220F) 60 to 120 Sec.
0 0
Grade MC-250 Furol Viscosity at 60 C (140 F) 125 to 250 Sec.
Grade MC-800 Furol Viscosity At 82.20C (1800F) 100 to 200 Sec.
0 0
Grade MC-3000 Furol Viscosity At 82.2 C (180 F) 300 to 600 Sec
Note 2. If penetration of residue is more than 200 and its ductility at 250C 770F) is less than 100 cm, the material will be
acceptable if its ductility at 15.50C (600F) is more than 100 cm.
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TABLE 1011-4
REQUIREMENTS FOR EMULSIFIED BITUMEN
(ASTM-D-977),(AASHTO-M-140)
TYPE RAPID-SETTING SLOW-SETTING.

Grade RS-1 RS-2 SS-1 SS-1h
Min Max Min Max Min Max Min Max
Tests on Emulsions
Viscosity, Saybolt Furol at 20 100 - - 20 100 20 100

250C(770F) Sec
Viscosity, Saybolt Furol at - - 75 400 - - - -

500C(1220F) Sec
Settlement a 5 days, percent % - 5 - 5 - 5 - 5
Storage Stability test, 1 day - 1 - 1 - 1 - 1
Demulsibility,b 60 - 60 - - - - -
35 ml, 0.02 Ncacl2 percent
Cement mixing test percent - - - - - 2 - 2
Sieve test percent - 0.10 - 0.10 - 0.10 - 0.10
Residue from distillation test- 55 - 63 - 57 - 57 -

%
Tests on residue from

distillation test.
Penetration 250C (770F) 100g 100 200 100 200 100 200 40 90
5.sec
Ductility, 250C (770F), 5 40 - 40 - 40 - 40 -

cm/min.cm
Solubility in Trichloroethlene 97.5 - 97.5 - 97.5 - 97.5 -

percent..
Suggested uses Surface Surface Plant or road mixture with

treatment treatment and graded and fine
penetration penetration aggregates a substantial
macadam macadam quantity of which passes a
and tack sieve No.200 (0.075 mm);
coat slurry seal treatment.
a. Storage stability test may be used instead of 5-days settlement test.

b. The demulsibility test shall be made within 30 days from date of shipment.
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TABLE NO.1011-5
APPLICATION TEMPERATURES FOR BITUMEN’S,

CUTBACKS, EMULSIONS
MIXING TEMPERATURE IN SPRAYING TEMPERATURE

GRADE ASPHALT PLANT FOR SURFACE
TREATMENT
0 0 0 0
C F C F
Penetration Bitumen
Grade 200-300 130+ 265+ 115-150 235-305
Grade 120-150 130+ 270+ 120-155 245-310
Grade 80-100 140+ 280+ 120-165 250-325
Grade 60-70 145+ 295+ 130-170 265-325
Grade 40-50 150+ 300+ 130-175 270-350
Cutback MC-30 30+ 86+ - -
MC/RC-70 50+ 122+ - -
MC/RC-250 75+ 167+ - -
MC/RC-800 95+ 203+ - -
MC/RC-3000 110+ 230+ - -
All Emulsions. 20-70 68-160 10-70 50-160
RT-I to RT-2
RT-1 to RT-2 16-52 60-125 - -
RT-3 27-66 80-150 - -
RT-4 27-66 80-150 27-66 80-150
RT-6 27-66 80-150 27-66 80-150
RT-7 to RT-9 66-107 150-225 66-107 150-225
RT-10 79-121 175-250 - -
RT-11 to RT-12 - - 79-121 175-250
NOTE:
1- Owing to the inflammable nature of the solvent in RC type cutbacks the

application temperatures of these grades should be kept to the lower end of the
ranges quoted.
2. The temperature range given for each grade is necessary rather wide because
local climatic conditions and the type and conditions of the equipment affects
the optimum spraying temperature.
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SECTION 1031
COARSE AGGREGATE FOR CEMENT CONCRETE
1031-1 DESCRIPTION
The work covered in this Section consists of supplying coarse

aggregate which shall consist of crushed stone, crushed brick, crushed
or un-crushed gravel or crushed, air cooled blast furnace slag or
crushed concrete or a combination thereof conforming to the
requirements of this specification.
1031-2 SOURCE
Coarse aggregate shall be obtained from an approved source.
1031-3 GRADING
All coarse aggregate shall be uniformly graded from coarse to fine

within the limits specified in Table 1031-1.
1031-4 QUALITY
Unless otherwise specified elsewhere the coarse aggregate shall

conform to the following requirements.
i. Percentage wear by
Los Angeles Abrasion test
At 500 Revolutions(AASHTO-T-96) Not more than
40%
ii. Soundness of Aggregate

By use of Sodium sulphate
(AASHTO-T-104)
Max. Percentage loss on 5 cycles. Not more than 12
iii. Flakiness Index (BS 812). Not more than 35

iv. Sampling aggregates. T-2
v. Sieve analysis. T-27
vi. Amount of material passing the No.200
sieve. T-11
vii. Organic impurities. T-21
viii. Mortar Strength. T-71
ix) Sodium sulphate soundness. T-104
x. Friable particles. T-112
xi. Abrasion loss. T-96
xii. Specific Gravity. T-84
xiii) Absorption. T-85
xiv. Production of Plastic Fines. T-210
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xv. Fineness Modulus. T-27

xvi. Sand Equivalent. T-17
xvii. Potential Reactivity of Carbonate Rock
For Concrete Aggregate
(Rock Cylinder Method) ASTM C 586
xviii. Potential Alkali Reactivity of Cement

Aggregate Combinations
(Mortar-Bar Method) ASTM C 227
xix. Potential Reactivity of Aggregates

(Chemical Methods) ASTM C 289
xx. Petrographic analysis. ASTM C 259
1031-5 IMPURITIES
The deleterious matter in any coarse aggregate shall not exceed the
following.
i). Clay Lumps 0.25% Max

ii). Material Passing No.200 Sieve 1.0% “
iii). Soft fragments & shale 5.0% “
iv). Friable Particles 1.0% “
1031-6 STOCKPILING AGGREGATE
The stockpile sites, as directed by the Engineer Incharge shall be

prepared by clearing, burning of all trees, stumps, bush and debris as
provided in section 301. The floor for each stockpile shall be
comparatively uniform in cross section. The completed stockpiles shall
be neat and regular in form and shall be made to occupy the smallest
feasible areas. Height of the pile or their average depth shall not be
more than 1.8m (6.0 ft). The side slopes shall not be flatter than 1½: 1.
To avoid segregation of the various sizes in each stockpile, the

aggregate shall be deposited in uniform layer or lifts not exceeding 30
cm(1foot) in thickness. The aggregate shall be placed in each lift by
trucks or other types of hauling units. Stockpiling from a conveyor belt
will not be permitted. The piles shall be so located and so constructed
that no intermingling of grading will occur.
1031-7 MEASUREMENT
Coarse aggregate shall be measured in bulk. The unit of measurement

shall be one cubic meter (m3) or 100 cubic feet (100 cft).
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1031-8 RATE
The unit rate shall be full compensation for furnishing coarse aggregate
in well graded and clear state as per above specification at site of work,
including loading, transportation, unloading, and stacking at site of
work to be defined in the bid schedule.
1031-9 PAYMENT
Pay Item No.1031-9.1 Coarse Aggregate

of Specified Gradation
for Cement Concrete. Per cu m(m3)
or per 100
Cu.ft.
***************
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SECTION 1032
FINE AGGREGATE FOR CEMENT CONCRETE
1032-1 DESCRIPTION
The work covered under this Section consists of furnishing and placing
aggregates for Portland Cement Concrete in stockpiles in accordance
with these specifications at the location shown on the drawings or in
the bid schedule.
1032.2.1 Fine aggregate shall consist of natural sand or manufactured sand or

combinations thereof, having hard, strong durable particles, and shall
conform to the requirements of these specifications. Sand equivalent
(AASHTO-T-176) of the material shall be more than 75.
1032.2.2 Fine aggregate from different sources of supply shall not be mixed or
stored in the same pile nor used alternately in the same class of
construction or mix, without permission from the Engineer Incharge
1032.3 DELETERIOUS SUBSTANCES
The amount of deleterious substance shall not exceed the following

limits:-
Maximum Permissible
Description Limit
Percent (By Weight)
Clay lumps 1.00
Coal and ignite 1.00
Material Passing the No.200 Sieve
a) In concrete subject to surface 3.00
abrasion (not more than)
b) All other classes of concrete (not 5.00

more than)
1032-4 SOUNDNESS
1032-4.1 When the fine aggregate is subjected to five alternation of the sodium
sulphate/Magnesium sulphate test, the weighted loss shall not exceed
10 percent by weight.
1032-4.2 The requirements for soundness given in 1032-4.1 above may be

waived off in the case of aggregate for use in structure or portions of
structures not exposed to weathering.
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1032-5 ORGANIC IMPURITIES
All fine aggregate shall be free from injurious amounts of organic

impurities. Aggregate subjected to the calorimetric test for organic
impurities and producing a color darker than the standard shall be
rejected unless they pass the mortar strength test as specified in section
1032-6. Should the aggregate show a darker color than that of samples
originally approved for the work, its use shall be withheld until tests
have been made to determine whether the increased color is indicative
of an injurious amount of deleterious substances.
1032.6 MORTAR MAKING PROPERTIES
When subjected to the test for mortar-making properties, the fine

aggregate shall develop a compressive strength at the age of 3 days
when using ASTM Type III cement or at 7 days when using ASTM
type I or II cement, of not less than 90 percent of the strength
developed by a mortar prepared in the same manner with the same
cement and graded sand having a fineness modulus of 2.40 + 0.10.The
cement used shall be as specified in Section 1001.
1032-7 GRADING
1032-7.1 Fine aggregate shall be well graded, coarse to fine and when tested by
means of laboratory sieves shall conform to the grading requirements
of Table 1032-1
Table 1032-1
Gradation Requirements for Fine Aggregate
DESCRIPTION PERCENT
Passing a 9.5 mm (3/8”) Sieve 100 100 100
Passing a 4.75 mm (No.4) Sieve 95-100 90-100 90-100
1032-7.2 Fine aggregate failing to pass the minimum requirement for material
passing the No.50 and /or No.100 sieve may be used provided a
satisfactory inorganic fine material is added to correct for the
deficiency in grading.
1032-7.3 At the option of the Engineer Incharge when the fine aggregate is to be
used in the construction of concrete pavements for bases, the specified
minimum amount passing the 37.5 mm (No.50 sieve may be reduced
to 5 percent and the specified minimum amount passing the 0.15 mm
(No.100) sieve may be reduced to 0 percent.
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1032-8 UNIFORMITY OF GRADING
The grading requirements given in Section 1032-7.1 represent the

extreme limits, which shall determine suitability for use from all
sources of supply. The gradation from any one source shall be
reasonably uniform and not subject to the extreme percentages of
gradation specified above. For the purpose of determining the degree
of uniformity, a fineness modulus determination shall be made upon
representative samples, submitted by the Contractor, from such sources
as he proposes to use. Fine aggregate from any one source having a
variation in fineness modulus of the representative sample submitted
by the Contractor may be rejected.
Fineness Modulus of Fine Aggregate shall range from 1.8 to 3.7 unless
1032-9 METHODS OF SAMPLING AND TESTING OF AGGREGATE
Samples of fine and coarse aggregate to be used shall be selected by

the Engineer Incharge. It shall be the responsibility of the Contractor to
designate the source or sources of aggregate and to obtain the
necessary samples and submit them for testing at least thirty (30) days
before actual concreting operations are to begin.
Samples of aggregates shall be obtained and tested in accordance with

the following standard AASHTO methods:-
Sampling AASHTO T-2

Clay lumps AASHTO T-112
Light Weight Pieces in Aggregates AASHTO T-113
Amount of Material passing a No.200 Sieve AASHTO T-11
Organic Impurities. AASHTO T-21
Mortar Making Properties. AASHTO T-71
Sieve Analysis AASHTO T-27
Soundness (Sodium Sulphate) AASHTO T-104
Sand Equivalent. AASHTO T-176
Potential Reactivity. ASTM C- 586
Potential Alkali. ASTM C- 227
Potential Reactivity. ASTM C- 289
1032-10 STOCKPILING OF AGGREGATES

prepared by clearing, burning of all trees, stumps, bush and debris as
provided in Section 301. The floor for each stockpile shall be
comparatively uniform in cross section. The complete stockpiles shall
feasible areas. The height of the piles or their average depths shall not
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be more than 1.8 m (6 ft) unless otherwise directed by the Engineer

Incharge. The side slopes shall not be flatter than 1½: 1.

aggregate shall be deposited in uniform layer or lifts not exceeding 30
cm(1 foot) in thickness. The aggregates shall be placed in each lift by
trucks or other types of hauling units. Stockpiling from a conveyor belt
will not be permitted. The piles shall be so located and so constructed
that no intermingling of grading shall occur.
1032-11 MEASUREMENT
The quantity of aggregate of specified grades stockpiled shall be

measured by volume. The unit of measurement shall be one m 3 or 100
cft.
1032-12 RATE
The unit rate per unit of measurement shall be full compensation for
furnishing and stockpiling all aggregates including all labour,
equipment, tools and incidentals necessary to complete the work
prescribed in this Section.
1032-13 PAYMENT
Pay Item No.1032-13.1 Fine aggregate of

specified gradation
for Portland Cement
Concrete per Cu. m or
Per 100 cft.
****************
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SECTION 1033
MORTAR SAND
1033-1 DESCRIPTION
The work covered under this Section consists of furnishing and placing
in stockpiles mortar sand for use in cement mortar/Portland cement
concrete in accordance with these specifications.
Mortar sand shall consist of hard, strong, durable uncoated mineral or

rock particles, free from injurious amounts of organic or other
deleterious substances.
1033-3 ORGANIC IMPURITIES
Mortar sand when subjected to the calorimetric test for organic

impurities and producing a color darker than the standard color shall be
rejected unless the sand complies with the mortar strength test
specified in Section 1033-4.
1033-4 MORTAR STRENGTH
When subjected to the test for mortar making properties, the fine
aggregate shall develop a compressive strength at the age of 3 days
when using type III cement or at 7 days when using type I or II cement
of not less than 90 percent of the strength developed by a mortar
prepared in the same manner with the same cement and graded sand
having a fineness modulus of 2.40 + 0.10. Type I, II and III cement are
prescribed in the Standard Specifications for Portland Cement Section
1001.
1033-5 GRADING
Mortar sand shall be uniformly graded from fine to coarse as per limits
given in table1033-1.
Table No.1033-1
Sieve Size Passing Percentage

General Plaster
Purpose
4.75 mm (No.4) 100 100
2.36 mm (No.8) 90-100 90-100
0.30 mm (No. 50) 5-70 5.40
0.15 mm (No.100) 0-15 0-10
0.075 mm (No.200) 0-5 0-10
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1033-6 METHODS OF SAMPLING AND TESTING
Sampling and testing of sand for mortar shall be in accordance with the
following standard methods.
Sampling AASHTO T2
Organic Impurities AASHTO T 21
Mortar Marking Properties AASHTO T 71
Sieve Analysis AASHTO T 27
Material Passing No.200 Sieve AASHTO T 11
Sand Equivalent AASHTO T 176
Reactive Aggregates AASHTO M-6
1033-7 STOCKPILING

prepared by cleaning, burning of all tress stumps, brush and debris as
provided in Section 301. The floor for each stockpile shall be
comparatively uniform in cross section. The completed stockpiles shall
feasible areas. The height of the piles or their average depth shall not
be more than 1.8m (6 ft) unless otherwise directed by the Engineer
Incharge. The side slopes shall not be flatter than 1½: 1.

aggregate shall be deposited in uniform layer or lifts not exceeding I
foot in thickness. The aggregate shall be placed in each lift by trucks or
other types of hauling units. Stockpiling from a conveyor belt will not
be permitted. The piles shall be so located and so constructed that no
intermingling of grading will occur.
1033-8 MEASUREMENT
Mortar sand shall be measured by volume. The unit of measurement

shall be one cubic meter (m3) or 100 cubic feet (ft3).
1033-9 RATE
The unit rate shall be full compensation for furnishing mortar sand in a
clean state as per specification mentioned above including its loading,
transportation to site of work, unloading for storage etc. complete.
1033-10 PAYMENT
Payment Item No.1033-10.1 Mortar Sand per cubic meter (m3) or

Per 100 cubic feet
***************
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SECTION 1034
MINERAL FILLER
1034-1 COMPOSITION
Mineral filler shall consist of hydrated lime, rock dust, Portland

cement, or any other inert mineral matter from approved sources. The
mineral filler shall be thoroughly dry and free from lumps consisting of
aggregations of fine particles. Ground phosphate will not be allowed as
mineral filler.
1034-2 GRADATION
The mineral filler shall meet the gradation requirements given in Table
No.1034-1
Table No.1034-1
U.S. Sieve Size Percent Passing

No.30 (600 mm) 100
No. 80 (180 mm) 95-100
No. 200 (75 mm) 70-100
1034-3 PLASTICITY INDEX
The mineral filler shall have a Plasticity Index not exceeding 3%.
1034-4 MEASUREMENT
Mineral filler shall be measured by volume, the unit of measurement

shall be one cubic meter (m3) or 100 Cubic feet.
1034-5 RATE
The unit rate shall be full compensation for furnishing mineral filler as
per specifications mentioned above, including its loading
transportation to site of work, unloading to storage etc, complete.
1034.6 PAYMENT
Pay Item No.1034-6.1 Mineral Filler per Cu. m (m3)

Or per 100 Cu. ft.
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***************
SECTION 1041
CLAY BRICKS AND CLAY TILES
1041-1 DESCRIPTION
The work under this section consists of supplying and stacking at

construction site first class bricks or first class tiles according to the
following specifications.
1041-2 SOURCE
The bricks or tiles shall be supplied from the approved brick kiln.
1041-3 CLAY FOR BRICKS OR TILES
1041.3.1 Clay shall be obtained from good earth containing 20-30% fine sand.
1041-3.2 Clay shall not contain more than 0.5% soluble salts, more than 0.2%
sulphate, and more than 4% organic contents. It shall not contain any
gravel, coarse sand, kankar, roots of grass and plants.
1041-3.3 Preparation
Clay before use shall be dug up and left to weather for a week. It shall
be thoroughly watered, turned over for at least 48 hours and tempered
until free from lumps and it is stiff. Any stone found shall be picked
out. The tempering shall be done in a pug mill, or by treading. When
ready for moulding the clay shall be of such consistency (plasticity
index of 7-10% for so as to hand moulding) which gives a
homogeneous brick or tile.
1041-4 MOULDING
Hand or machine moulding shall be carried out in suitable iron moulds

having a size, which shall give the required size of the brick or tile
after burning. All brick or tiles shall be sand moulded.
1041-5 FROGGING
Each brick shall have a frog 6 mm (1/4”) deep on the upper face and,
trademarks in it as approved by the Engineer Incharge.
There shall be no frog in the clay tile.
1041-6 TEST REQUIREMENTS
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The size of he bricks shall be as specified. The standard size is 228 mm

x 114 mm x 76 mm (9” x 4½” x 3”). They shall be well burnt without
being vitrified. They shall be of uniform color, regular in shape and
size, with sharp and square corners and parallel faces. They must be
homogeneous in texture and emit a clear ringing sound when struck.
They shall be free from flows and cracks. They shall not absorb more
than 1/6 the of their weight of water after being soaked for 24 hours, in
accordance with BS 1257 and shall show no signs of efflorescence on
drying. Compressive strength shall not be less than 140 kg/cm 2 (2000
lbs. Per square inch).
Tiles shall conform to above requirements in quality. The size shall be
(i). 300 mm x 150 mm x 50 mm (12” x 6” x 2”)
(ii). 300 mm x 150 mm x 31 mm (12” x 6” x 1¼”)
(iii). 225 mm x 113 mm x 39 mm (9” x 4½” x 1½”)
(iv). 225 mm x 113 mm x 50 mm (9” x 4½” x 2”)
or as specially specified.
1041-7 STACKING
The bricks shall be sorted and arranged in stacks of one or two

thousands as specified. Each stack unit shall be 10 course high and two
bricks thick. At least 1 m (three feet) space between the stacks shall be
left for inspection.
1041-8 SAMPLING
The bricks or tiles required for carrying out the tests laid down in these
specifications shall be taken by one of the methods given below:
1041-8.1 Sampling Bricks or Tiles in Motion
Samples in this way shall be taken when the bricks or tiles are being
loaded or unloaded. Samples shall be taken at random from each of a
number of convenient portions of the consignment or batch.
1041-8.2 Sampling Bricks or Tiles from a Stack.
Samples shall be taken at random from a stack. The number of bricks

required for the tests shall be taken from across the top of the stack, the
sides accessible and from the interior of the stack by opening the
trench from the top. Whichever method is employed a sample of 50
bricks or tiles shall be taken at random from every consignment of
50,000 bricks/tiles or part thereof.
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The samples thus taken shall be stored in a dry place not in contact
with the ground until the tests are made.
The bricks for tests shall be taken at random from the sample.
1041-9 MEASUREMENT
Measurement of bricks or tiles shall be in numbers. The unit of

measurement shall be one thousand. If more than 10% bricks in the
stacks do not conform to the specification, the whole consignment will
be rejected but if it is less than 10% the batch may be accepted but
below specification bricks rejected.
1041-10 RATE
The unit rate shall be full compensation for supply of bricks/tiles

including loading, transportation to site of work, unloading and
stacking including all incidentals etc. complete.
1041-11 PAYMENT
Pay item No.1041-11.1 Supply of Bricks of

approved quality & Size. Per 1000 Nos.
Pay item No.1041-11.2 Supply of Tiles of

approved quality & Size. Per 1000 Nos.
*****************
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SECTION 1046
STONE FOR MASONRY
1046-1 DESCRIPTION
The work covered under this Section consists of supplying and

stacking stone for stone masonry from an approved source. This shall
be quarried according to an approved method.
1046-2 SOURCE
Stone shall be obtained from nearest approved quarry. If the same

quarry has stone of varying nature in different section sections, then
stone from the approved section only shall be quarried and supplied.
1046-3 QUALITY
Stone shall be hard, tough, compact, durable, having uniform colour

and free from faults and cleavage. It shall be of a kind that previous
use has been proven to be satisfactory for the specified purpose.
Stone for Ashlars masonry shall be free of seams, laminations, and

minerals, which, by weathering would cause discoloration or
deterioration.
1046-4 SIZE AND SHAPE
Each stone shall be free from depressions and projections that might
weaken it or prevent it from being properly bedded, and shall be of
such shape as will meet both architecturally and structurally the
requirements for the class of masonry specified.
In general stones shall have thickness of not less than 125 mm (5”)
width of not less than 1½” times their respective thickness, with
minimum width of 300 mm (12”), and lengths of not less than 1½”
time their respective widths. Where headers are required their lengths
shall be not less than the width of the widest adjacent stretches plus
300 mm (12 inches).
At least 50 percent of the total volume of the masonry shall be of stone

having a volume of at least 0.03 Cu.m. (1 Cu. ft.).
1046-5 DRESSING AND CUTTING
The stone shall be dressed to remove any thin or weak portions. All
visible edges shall be free from chipping. Face Stones shall be dressed
to provide bed and joint lines with a maximum variation from true
lines as follows:
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(1) Random Rubble Masonry 38 mm (1½”)
(2) Course Rubble Masonry 6 mm (1/4”)
(3) Ashlars Masonry 1.5 mm (1/16”)
1046-6 BED SURFACES
Bed Surfaces of face stones shall be normal to the faces of the stone for
about 75 mm (3”) and this point may depart from normal not be exceed
25 mm (1”) in 300 mm (12 inches) for ashlar masonry and 50 mm (2”)
in 300 mm (12’), for all other classes.
1046-7 JOINT SURFACES
In all classes except ashlar masonry, the joint surfaces for face stones
shall form an angle with the bed surface of not less than 45 degrees.
In ashlar masonry, the joint surface shall be normal to the bed surfaces.
They shall also be normal to the exposed faces of the stone for at least
50 mm (2”), from which point they may depart from normal not be
exceed 25 mm (1”) in 300 mm (12”).
The corners at the meeting of the bed and joint lines shall not be
rounded in excess of 38 mm (1½”) in case of Random Rubble
Masonry. Course Rubble Masonry & Ashlar Masonry shall have no
rounding.
1046-8 BEDDING
Rubble stone shall be evenly bedded and shall be quarried in as large

blocks as will permit of being handled.
1046-9 STACKING
Stacking shall be done on even ground and closely packed. The length
and breadth shall be in multiples of 10 and height may vary from 60
cm (2”) to 1 meter and 50 cm.(5”).
1046-10 MEASUREMENT
Stone shall be measured by volume; the unit of measurement shall be

one hundred cubic meter or one hundred cubic feet.
1046-11 RATE
The unit rate shall be full compensation for furnished stone for a
particular class of masonry conforming to the stone specifications and
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stacking at site of work including quarrying, dressing, loading,

transportation and unloading etc. complete in all respects
1046-12 PAYMENT
Pay Item No.1046-12.1 Stone for Random Per cu. meter

Rubble Masonry or per 100
Cu.ft.
Pay Item No.1046-12.2 Stone for Course Per cu. meter
Rubble Masonry or per 100
Cu.ft.
Pay Item No.1046-12.3 Stone for Ashlar Per cu. meter
Masonry or per 100
Cu.ft.
******************
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SECTION 1051
WATER
1051-1 DESCRIPTION
This work shall consist of furnishing and applying to any of the civil
engineering work concerned with highway construction of Highway
maintenance project in accordance with these specifications.
1051-2 SOURCE
Water shall be obtained from an approved source.
1051-3 QUALITY
The water for curing, for washing aggregates and for mixing shall be
subject to the approval of the Engineer Incharge. It shall be free from
oil and shall contain not more than one thousand (1.000) parts per
million of chlorides nor more than one thousand three hundreds
(1,300) parts per million of sulfates (SO 4). In no case shall the water
contain an amount of impurities that will cause a change in the setting
time of Portland cement of neither more than twenty five (25) percent
nor a reduction in the compressive strength of mortar at fourteen (14)
days of more than five (5) percent when compared to the result
obtained with distilled water.
In non-reinforced concrete work, the water for curing, for washing

aggregates, and for mixing shall be free from oil and shall not contain
more than two thousands (2,000) parts per million of chlorides nor
more than one thousand five hundreds (1,500) parts per million of
sulfates as SO4.
In addition to the above requirements, water for curing concrete shall

not contain any impurities in a sufficient amount to cause discoloration
of the concrete or produce etching of the surface.
When required by the Engineer Incharge, the quality of the mixing

water shall be determined by the Standard Method of Test for Quality
of Water to be used in concrete, AASHTO Methods of Sampling and
Testing, Designation: T-26.
1051-4 STORAGE
Water shall be stored in water tight tanks or containers so as to be

adequately protected from the admixture of dust and other foreign
matter.
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1051-5 MEASUREMENT
Water shall be measured in bulk. The unit of measurement shall be

1000 liters.
1051-6 RATE
The unit rate shall be full compensation for supplying and application
of water and its transportation and storage etc. complete including all
incidentals.
1051-7 PAYMENT
Pay Item No.1051-7.1 Water per 1000 liters.
******************
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SECTION 1052
ADMIXTURES FOR CONCRETE
1052-1 DESCRIPTION
This Section covers specification for materials proposed to be used as

air-entraining and chemical admixtures to be added to concrete
mixtures in the field.
1052-2 DEFINITION
1052-2.1 Air Entraining Admixtures
For the purpose of these specifications an air-entraining admixture is

defined as a material that is used as an ingredient of concrete, added to
the batch immediately before or during its mixing, for the purpose of
entraining air.
1052-2.2 Chemical Admixture
Type. A Water reducing admixture
An admixture that reduces the quantity of mixing water

required producing concrete of a given consistency.
Type. B Retarding admixture
An admixture that retards the setting of concrete.
Type. C Accelerating admixture
An admixture that accelerates the setting and early

strength development of concrete.
Type. D Water reducing and retarding admixture

required to produce concrete of a given consistency and
retards the setting of concrete.
Type. E Water reducing and accelerating admixture

required to produce concrete of a given consistency and
accelerates the setting and early strength development
of concrete.
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Type. F Water reducing admixture high range

required to produce concrete of a given consistency by
12% or greater.
Type. G Water reducing high range and retarding

admixture

required to produce concrete of a given consistency by
12% or greater and retards the setting of concrete.
1052-3 GENERAL REQUIREMENTS FOR AIR ENTRAINING

ADMIXTURES
The air-entraining admixture shall conform to the following

requirements.
1052-3.1 Bleeding
The percentage of bleeding by concrete containing the admixture under

test shall not exceed 65 percent of the bleeding of similar concrete
without the admixture.
1052-3.2 Compressive Strength
The compressive strength of concrete containing the admixture under

test shall be not less than 85 percent of that of similar concrete without
the admixture at all test ages.
1052-3.3 Flexural Strength.
The flexural strength of concrete containing the admixture under test

shall be not less 85 percent of that for similar concrete without the
admixture at all test ages.
1052-3.4 Resistance to Freezing and Thawing
The relative durability factor of concrete containing the admixture

under test shall be not less than 80.
1052-3.5 Bond Strength
The bond strength of concrete containing the admixture under test shall
be not less than 85 percent of that of similar concrete without the
admixture at the age of 28 days.
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1052-3.6 Volume Change
The volume change on drying of concrete containing the admixture

under test, expressed as a percentage change in length, shall be not
more than 0.10 greater than that of similar concrete without the
admixture at ages of 28 days, 6 months, and one year.
1052-4 GENERAL REQUIREMENTS FOR CHEMICAL ADMIXTURES
1052-4.1 Concrete in which each of the seven types of admixture shown as

above are used shall conform to the respective requirements
prescribed in table 1.
1052-4.2 At the request of the purchaser, the manufacturer shall state in writing
that the admixture supplied for use in the work is identical in all
essential respects, including concentration to the admixture tested
under this specification.
1052-4.3 At the request of the purchaser, when the admixture is to be used in pre
stressed concrete, the manufacturer shall state in writing the chloride
content of the admixture and whether or not chloride has been added
during its manufacture.
1052-5 METHOD OF TESTING
1052-5.1 Air Entraining Admixtures
The properties enumerated above shall be determined in accordance

with the Standard Method of Testing Air Entraining Admixtures for
Concrete (AASHTO Designation T 157). It is recommended that,
whenever practicable, tests be made in accordance with Section 2(d) of
Methods T 157 using the cement proposed for specific work.
1052-5.2 Chemical Admixtures
The above properties of chemical admixtures shall be determined in

accordance with the standard test Methods outlined under AASHTO
Designation M 194-82” Standard Specification for Chemical
Admixture for concrete.
1052-6 MEASUREMENT
Measurement for Admixture for Concrete shall be by weight. The unit

of measurement shall be kilogram or Lbs.
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1052-7 RATE
The unit rate shall be full compensation for furnishing and supplying
of concrete admixture according to the specifications at site of work or
at store specified by the Engineer Incharge.
1952-8 PAYMENT
Pay item No.1052-8.1 Air Entraining Admixture

for Concrete. Per Kg or Lbs.
Pay item No.1052-8.2 Chemical Admixture

for Concrete. Per Kg or Lbs.
****************
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TABLE 1052-1
PHYSICAL REQUIREMENTS FOR CHEMICAL ADMIXTURES FOR CONCRETE
(AASHTO M-194)
TYPE A WATER TYPE B TYPE C TYPE D TYPE E WATER TYPE F WATER TYPE G
REDUCING RETARDING ACCELERAT WATER REDUCING & REDUCING HIGH WATER
ING REDUCING & ACCELERATING RANGE REDUCING
RETARDING HIGH
RANGE &
RETARDING
WATER CONTENTS MAX % OF 95 - - 95 95 88 88
CONTROL TIME OF SETTING.
INITIAL: AT LEAST - 1:00 LATER 1:00 EARLIER 1:00 LATER 1:00 EARLIER - 1:00 LATER
NOT MORE THAN 1:00 EARLIER 3:30 LATER 3:30 EARLIER 3:30 LATER 3:30 EARLIER 1:00 EARLIER NOR 3;30 LATER
NOR 1:30 LATER 1:30 LATER
FINAL; AT LEAST - - 1:00 EARLIER - 1:00 EARLIER - -
NOT MORE THAN 1:00 EARLIER 3:30 LATER - 3:30 LATER - 1:00 EARLIER NOR 3:30 LATER
NOR 1:30 LATER 1; 30 LATER
COMPRESSIVE STRENGTH MIN %
CONTROL A
1 Day - - - - - 140 125
3 Days 110 90 125 110 125 125 125
7 Days 110 90 100 110 110 115 115
28 Days 110 90 100 110 110 110 110
6 Months 100 90 90 100 100 100 100
1 Year 100 90 90 100 100 100 100
FLEXURAL STRENGTH MIN %
CONTROL B
3 Days 100 90 110 100 110 110 110
7 Days 100 90 100 100 100 100 100
28 Days 100 90 90 100 100 100 100
LENGTH CHANGE MAX.
SHRINKAGE(ALTERNATIVE
REQUIREMENTS)C
PERCENT OF CONTROL 135 135 135 135 135 135 135
INCREASE OVER CONTROL 0.010 0.010 0.010 0.010 0.010 0.010 0.010
RELATIVE DURABILITY FACTOR, MIN 80 80 80 80 80 80 80
D
A The values in the table include allowance for normal variation in test results. The object of the 90% compressive strength requirement for a Type-B admixture is to require
a level of performance comparable to that of the reference concrete.
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Draft 2004
SECTION 1061
HIGH TENSILE STEEL
1061-1 DESCRIPTION
The work specified in this Section consists of supplying high tensile

steel for pre stressed construction.
High tensile steel wire shall comply with B. S. 2691, “Steel for pre
stressed concrete Part 1 Plain Hard Drawing Steel Wire” and shall be
pre straightened and stress relieved. High tensile steel wire shall be
stabilized and have a relaxation loss at 20oC not exceeding 2 % at 1000
hours from an initial load of 70% of the minimum guaranteed breaking
load of the material.
1061-3 TEST CERTIFICATE
High tensile steel wire shall be the product of an approved

manufacturer. Each coil of wire shall be accompanied by the
manufacturer’s test certificate giving the batch reference number or
mark, the date of manufacture, the wire diameter, the tensile strength,
the 0.1 percent proof stress and the stress diagram.
1061-4 WIRE COILS
The wire shall be supplied in coils not less than 180 cm (six feet) in
diameter and weighing not more than 225 kg (500 lbs). The coils shall
be protected against damage through corrosion by wrapping in jute
covered tarred paper or other impervious medium. Wire, which has
been pitted, splashed by weld metal or surface damaged in any way,
shall not be used.
1061-5 PROOF STRESS
The 0.1 percent proof stress as determined by slow loading and

measured by a precision extensometer shall be not less than 12600
kg/cm2 (80 ton per square inch) and the ultimate tensile stress shall be
within the limits of 16500 and 17300 kg/cm2 (105 and 110 tons per
square inch)
1061-6 TENSILE TESTS
The tests for ultimate tensile strength and proof stress shall be carried
out in accordance with B.S. 18. Tensile testing of metals. Tests to
determine compliance with the proof stress requirements shall not be
made until 48 hours after the wire has been drawn.
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Draft 2004
The ultimate elongation of the wire shall be at least 4% of its initial

length in a gauge length of ten times the wire diameter.
1061-7 COLD BEND TESTS
The cold bend test for the wire shall be in accordance with B.S.2691:
Part 1: Steel for pre stressed concrete. The number of tests and retests
shall be as stated therein.
1061-8 MEASUREMENT
Measurement for high tensile steel shall be by weight. The unit of

measurement shall be one hundred kilogram.
1061-9 RATE
The unit rate shall be full compensation for furnishing and supplying
high tensile steel wire according to these specifications at site of work
or store.
1061.10 PAYMENT
Pay Item No.1061-10.1 High Tensile Steel Wire

Per hundred
Kilogram.
****************
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Draft 2004
SECTION 1081
PAINTS
(OTHER THAN ROAD MARKING)
1081-1 DESCRIPTION
The work covered in this Section consists of supplying paint of

prescribed quality from an approved source for structural steel,
guardrails, kilometer stones, right-of-way markers, traffic signs and
any other structure or surfaces required to be painted, all as specified.
It shall be packed in strong containers plainly marked with the weight
per liter, the volume of the paint contents in litters, the colour, lot batch
and exact types of paint. The name and address of manufacturer and
date of manufacture should also be marked on the container. Any
container not so marked shall not be accepted for use.
No paint shall be used after one year of its manufacture.
1081-2 QUALITY
The paint shall be thoroughly ground to a condition that stirring readily

produces a smooth uniform mixture of such a consistency that it works
well under the brush and satisfies the following requirements.
1081-2.1 Paint shall become surface dry in not more than 24 hours when tested,
according to method discussed subsequently.
1081-2.2 The paint after complete removal of any surface skin, shall be well
mixed by shaking and / or stirring. Two coats of the mixed paint shall
then be applied by brushing on to a smooth, clean, non absorbent
surface. The first coat shall be allowed to dry thoroughly before the
application of the second one. The agreed sample shall be treated in the
same way and at the same time, and the two surfaces after drying for
48 hours shall match in colour, opacity and finish.
1081-2.3 The change of the colour of the paint film, when exposed to the direct
exposure of bright summer sunlight for 100 hours shall not be greater
than that of a film of an agreed sample tested in the same manner and
at the same time.
1081-2.4 The paint shall not contain more than 0.5 percent of water
1081.2.5 The flash point shall not be below 90oF or 32.3oC.
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Draft 2004
1081-3 METHOD OF TESTING
1081-3.1 General
Normally the paint manufacturers certificate regarding the

specifications of the paints and enamels shall be accepted as enough
evidence to ensure conformity with these specifications. The Engineer
Incharge may, however, at his discretion take a sample and test
according to the following tests.
Any paint or enamel which, although inspected and approved at the

point of manufacture, hardens in the containers so that it cannot be
readily broken up with the paddle to a smooth, uniform painting
consistency, will be rejected. Any paint or enamel too thick for proper
brush application, though otherwise according to specifications will be
rejected
1081-3.2 Tests
1081-3.2.1 Drying Time
The mixed paint shall be brushed out on a clean non absorbent surface,
say a piece of glass 150 mm x 150 mm (6” x 6”), and exposed in a
vertical position in a well ventilated room at 35 o C to 40 o C (95 o F to
104 o F) The painted surface is illuminated by a diffused day light for at
least six hours during the dry period. The paint when tested in the
above manner should not become” surface dry “ in less than 8 hours
and should become “Hard Dry” in not more than 24 hours. Paint is
“surface dry “ when clean, dry silver sprinkled on to the surface of the
paint and allowed to remain for about one minute, can be removed
with a camel-hair brush without injury to the paint film. Plant is “hard
dry” when a second coat of paint could be satisfactorily applied over it.
1081-3.2.2 Colour, Opacity, Finish and Consistency
The paint film, prepared as mentioned in 1081-3.2.1 should after

drying for 48 hours match in colour, opacity and finish (i.e. glass,
smoothness of surface, freedom from runs and specters etc) a film
prepared in the same way at the same time from an agreed sample.
1081-3.2.3 Fastness of Colour to Exposure
Direct exposure (i.e. gloss not intervening ) to bright summer sunlight

for 100 hours is usually a sufficiently good test for fastness of colour to
exposure. In the absence of such sunlight the paint film may be
exposed to standard lamp for 80 hours.
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Draft 2004
The change of colour of the direct plaint film, when tested as described
above should not be greater than that of a film of an agreed sample
tested in the same way at the same time.
1081.3 TEST STANDARDS
Various raw materials required for manufacture of paint shall be tested

according to AASHTO/ASTM standards.
1081-5 COMPOSITION AND PHYSICAL PROPERTIES
The composition of paints and other physical properties shall depend

upon the requirements of the job and shall be as specified by the
Engineer Incharge.
1081-6 MEASUREMENTS
Paint shall be measured in bulk. The unit of measurement shall be one

liter
1081-7 RATE
The unit shall be full compensation for supply of paint, conforming to

the specifications, to be supplied at the site of work as defined in the
bid schedule.
1081-8 PAYMENT
Pay Item No.1081-8.1 Paint of Specified Quality Per liter.
***************
- 412 -
Draft 2004
CHAPTER 1100
MISCELLANEOUS
- 413 -
Draft 2004
SECTION 1101
STANDARD BID SCHEDULE FORM
Sr. Pay Item Quantity in Unit of (To be Filled by the Bidder) Amount
No. Units Measurement Tendered Unit Rates
Number Description In Figures In Words
CHAPTER 200 CONSTRUCTION EQUIPMENT AND LABORATORY
1. 211-8.1 Maintenance of traffic Lump sum
CHAPTER 300 SITE CLEARANCE
2. 301-6.1 Clearing and Grubbing 100 m2 or 100 Sft
3. 302-4.2.1 Removal of trees, 150-300mm Each

(from 6 to 12 inch) girth
4. 302-4.2.2 Removal of trees, 301-600mm Each

(>12 upto 24 inch) girth
5. 302-4.2.3 Removal of trees, 601mm or over Each

(> 24 inch) girth
6. 303-3.2.1 Stripping. m3 or 100 Cft
7. 311-6.1 Removal of Existing Structure Lump sum
CHAPTER 400 EARTHWORK AND RELATED OPERATIONS
8. 401-3.2.1 Breaking of Existing Road Pavement Structure m3 or Cft
9. 401-3.2.2 Scarification of Existing Road Pavement m2 or Sft
10. 402-6.1 Structural Excavation in Common Material m3 or 100 Cft
11. 402-6.2 Structural Excavation in Common Material Below m3 or 100 Cft
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Draft 2004
SECTION 1101
water level
12. 402-6.3 Structural Excavation in Rock Material m3 or 100 Cft
13. 402-6.4 Structural Excavation in Rock Material below water m3 or 100 Cft
Level
14. 402-6.5 Granular Backfill m3 or 100 Cft
15. 402-6.6 Common Backfill m3 or 100 Cft
16. 403-8.1 Excavate Unsuitable Common Material m3 or 100 Cft
17. 403-8.2 Excavate Unsuitable Rock Material m3 or 100 Cft
18. 403-8.3 Excavate Surplus Common Material m3 or 100 Cft
19. 403-8.4 Excavate Surplus Rock Material m3 or 100 Cft
20. 409-3.2.1 Subgrade preparation in Earth Cut. m2 or 100 Sft
21. 409-3.2.2 Subgrade preparation in Existing Road

i) Without any fill m2 or 100 Sft
ii) With fill less than 30 cm. m2 or 100 Sft
22. 410-4.2.1 Improved Subgrade m3 or 100 Cft
23. 411-6.1 Formation of Embankment from Roadway m3 or 1000 Cft

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Draft 2004
SECTION 1101
24. 411-6.2 Formation of Embankment from Roadway m3 or 1000 Cft

25. 411-6.3 Formation of Embankment from Borrow m3 or 1000 Cft

26. 411-6.4 Formation of Embankment from Borrow m3 or 1000 Cft

27. 411-6.5 Formation of Embankment from Structural m3 or 1000 Cft

28. 411-6.6 Formation of Embankment from Structural m3 or 1000 Cft

CHAPTER 500 SUB-BASE AND BASE
29. 501-8.1 Gravel Sub Base Course of the specified thickness. m3 or 100 Cft
30. 501-8.2 Crushed stone aggregate Sub-base course of the m3 or 100 Cft
specified thickness
31. 501-8.3 Crushed brick Sub Base Course of the specified m3 or 100 Cft
thickness.
32. 515-7.2.1 Providing and Placing of Geotextile, m2 or Sft

Type ________
33. 521-6.1 Brick Sub Base course of the specified thickness m3 or 100 Cft
34. 521-6.2 Brick pavement of the specified thickness m3 or 100 Cft
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Draft 2004
SECTION 1101
35. 541-6.1 Crushed brick drainage layer of the Specified m3 or 100 Cft
thickness
36. 541-6.2 Crushed stone aggregate drainage layer of the m3 or 100 Cft
Specified thickness
37. 541-6.3 Gravel drainage layer of the Specified thickness m3 or 100 Cft
38. 541-6.4 Coarse sand drainage layer of the Specified m3 or 100 Cft
thickness
39. 551-A-6.1 Crushed stone water bound macadam base course of m3 or 100 Cft
the specified thickness
40. 551-B-6.1 Aggregate Base Course of the specified thickness m3 or 100 Cft
41. 552-6.1 Brick Edging m. or 100 Lft
CHAPTER 600 BITUMINOUS BASE AND SURFACING
42. 601-7.1 Bituminous Prime Coats at Specified rate of m2 or 100 Sft

Application.
43. 611-6.1 Bituminous Tack Coat at specified rate of applic. m2 or 100 Sft
44. 621-7.1 Plant mixed bituminous base course of specified m3 or 100 Cft
requirement
45. 621-7.2 Plant mixed bituminous base course of specified m2 or 100 Sft
thickness
- 417 -
Draft 2004
SECTION 1101
46. 631-7.1 Triple Surface Treatment using the specified m2 or 100 Sft
quantities of Bitumen and Aggregate
47. 631-7.2 Surface Dressing (Re-surfacing) using the specified m2 or 100 Sft
quantities of Bitumen and Aggregate
48. 631-7.3 Supplying aggregate of specified Sizes for triple m3 or 100 Cft
surface treatment.
49. 631-7.4 Supplying aggregate of specified Sizes for m3 or 100 Cft

resurfacing
50. 651-7.1 Plant mixed bituminous surface course of specified m3or 100 Cft
requirements
51. 651-7.2 Plant mixed bituminous surface Course of specified m2 or 100 Sft
thickness
52. 652-5.2.1 Recycling of Asphalt Concrete (0-60 mm thick) m3or 100 Cft
53. 652-5.2.2 Bitumen Binder Grade (40-50, 60-70, 80-100) Ton
54. 652-5.2.3 Wearing Course Asphalt Ton
CHAPTER 700 CEMENT CONCRETE
55. 701-18.1 Cement Concrete Class “A1” m3or Cft
- 418 -
Draft 2004
SECTION 1101
58. 701-18.4 Cement Concrete Class “B” m3or Cft
59. 701-18.5 Cement Concrete Class “C” m3or Cft
60. 701-18.6 Cement Concrete Class “D1” m3or Cft
63. 701-18.9 Cement Concrete Class “Y” m3or Cft
64. 701-18.10 Cement Concrete Class “Lean Concrete” m3or Cft
65. 711-13.1 Plain Cement Concrete Pavement m3or Cft
66. 711-13.2 Reinforced Cement Concrete Pavement m3or Cft
67. 711-13.3 Concrete Lug Anchors m or Lft
68. 721-6.1 Plum Concrete consisting 40% plum and 60% Lean m3or Cft
Concrete
CHAPTER 800 HIGHWAY STRUCTURES
69. 801-19.1 1st class brick work in cement mortar as Specified m3or 100 Cft
70. 801-19.2 Coping in specified cement mortar m or Lft
71. 801-19.3 Brick work in Arches m3or 100 Cft
- 419 -
Draft 2004
SECTION 1101
72. 801-19.4 Cut bricks 1000 Nos.
73. 801-19.5 Striking Joints m2 or 100 Sft
74. 802-29.1 Ashlar Masonry m3or 100 Cft
75. 802-29.2 Course Rubble masonry m3or 100 Cft
76. 802-29.3 Random Rubble Masonry m3or 100 Cft
77. 802-29.4 Dry Rubble Masonry m3or 100 Cft
78. 802-29.5 Cornices, String Courses. m or Lft
79. 802-29.6 Copings m3or 100 Cft
80. 802-29.7 Stone Masonry in arches. m3or 100 Cft
81. 803-5.1 Steel Wire mesh For Gabions Kg or Lbs
82. 803-5.2 Rock Fill in Gabions m3or Cft
83. 811-8.1 Pre-stressed Beam of Specified Size m3 or Cft
84. 811-8.2 Pre-stressed diaphragm of Specified Size m3 or Cft
85. 811-8.3 Pre-stressed Slab of Specified thickness m3 or Cft
86. 811-8.4 Lifting, Transporting And placing beam diaphragms m3 or Cft

or slabs etc.
- 420 -
Draft 2004
SECTION 1101
87. 821-14.1 Furnishing and placing Plain reinforcing Steel bars % Kg
88. 821-14.2 Furnishing and placing Deformed reinforcing bars % Kg
89. 831-17.1 Steel Structures. % Kg

Structural steel portions of other structures
Wrought iron.
Castings and forging.
90. 831-17.2 Rivets, nuts & bolts including washers used in the Kg
structures as fasteners.
91. 841-10.1 Structural steel work for Cutting edge % Kg
92. 841-10.2 Cement concrete Type “C” for Well Curb, plugging m3 or Cft
of well Steining or Transom Slab
93. 841-10.3 (a) Furnishing and placing Deformed Reinforcing Steel % Kg

Bars for Well Curbs, Steining and Transom Slab.
94. 841-10.3 (b) Furnishing and placing intermediate grade % Kg

Deformed Reinforcing Bars for Well Curbs and
Transom Slab.
95. 841-10.3 (c) Furnishing and placing Mild Steel Reinforcing bars % Kg
for Ring Beams and well steining.
96. 841-10.4 (a) Dry sinking of Wells in ordinary Soil m3 or 100 Cft
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Draft 2004
SECTION 1101
97. 841-10.4 (b) Dry sinking of Wells in hard Soil m3 or 100 Cft
98. 841-10.4 (c) Dry sinking of Wells in hard strata such as Shingle, m3 or 100 Cft
Gravel etc.
99. 841-10.4 (d) Wet sinking of Wells in ordinary Soil m3 or 100 Cft
100. 841-10.4 (e) Wet sinking of Wells in Cohesive Soil (C > 5) m3 or 100 Cft
101. 841-10.4 (f) Wet sinking of Wells in hard strata such as Shingle, m3 or 100 Cft
Gravel etc.
102. 841-10.5 Sand filling in Well holes m3 or 100 Cft
103. 851-5.2.1 Drilled / Bored Piles of the specified diameter. Lm or Lft
104. 851-5.2.2 Steel reinforcement for drilled / bored piles % Kg
105. 851-5.2.3 Bell footings constructed to the specified or m3 or yd3 or 100 Cft
authorized dimensions.
106. 851-5.2.4 Test piles of the specified diameter. Lm or Lft
107. 851-5.2.5 Test bells for the diameter and shape specified or m3 or yd3 or 100 Cft
authorized and approved
108. 851-5.2.6 Exploration holes for soil samples or rock cores. Lm or Lft
109. 851-5.2.7 Permanent casing. Lm or Lft
110. 851-5.2.8 Load tests (including load test report). Each
- 422 -
Draft 2004
SECTION 1101
111. 852-5.2.1 Piles, Furnished Lm or Lft
112. 852-5.2.2 Piles, Driven Each
113. 852-5.2.3 Test Piles, Furnished Lm or Lft
114. 852-5.2.4 Test Piles, Driven Each
115. 852-5.2.5 Pile Load Test (Static) Each
116. 852-5.2.6 Pile Load Test (Dynamic) Each
117. 852-5.2.7 Splices Each
118. 852-5.2.8 Pile Shoes Each
119. 852-5.2.9 Pile Lugs Each
120. 861-6.1 Regular Excavation (Guide Banks) m3 or 1000 Cft
121. 861-6.2 Making Embankment (Guide Banks) m3 or 1000 Cft
122. 861-6.3 Stone roughly hand packed in apron m3 or 100 Cft
123. 861-6.4 Stone for top layer of aprons tightly hand packed. m3 or 100 Cft
124. 861-6.5 Filter /Bedding under stone pitching on slope. m3 or 100 Cft
125. 861-6.6 Stone pitching roughly hand packed on slope. m3 or 100 Cft
126. 861-6.7 Stone pitching tightly hand Packed on slope. m3 or 100 Cft
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Draft 2004
SECTION 1101
127. 861-6.8 Turfing m2 or 100 Sft
128. 872-10.1 Cement Plaster in 1:6 cement/sand mortar m2 or 100 Sft
129. 872-10.2 Cement Plaster in 1:3 cement/sand mortar m2 or 100 Sft
130. 872-10.3 Deep cut or Struck Cement Pointing m2 or 100 Sft
131. 872-10.4 Flush Cement Pointing. m2 or 100 Sft
132. 891-6.1 AASHTO M 86 Diameter 150 mm (6”) Non- Lm or Lft

reinforced Concrete pipe Culvert




137. 891-6.6 AASHTO M 170 Diameter 460 mm (18”) Lm or Lft


- 424 -
Draft 2004
SECTION 1101





144. 891-6.13 AASHTO M 36M Corrugated Steel Circular Pipe Lm or Lft

Diameter ____mm ( __in.)
145. 891-6.14 AASHTO M 190M Bituminous Coated Corrugated Lm or Lft

Steel Circular Pipe Diameter ____mm ( __ in.)
146. 891-6.15 AASHTO M 246M Polymer Coated Steel Circular Lm or Lft

Pipe Diameter ____mm ( __in.)
147. 892-6.1 Granular Materials in Bed to Concrete Pipe Culvert m3 or 100 Cft
148. 892-6.2 Concrete Type “B” in Bed to Concrete Pipe Culvert m3 or 100 Cft
149. 893-4.1 Perforated Concrete Pipe for Under drain, 150mm Lm or Lft
Ø
- 425 -
Draft 2004
SECTION 1101
Ø
Ø
152. 893-4.4 Porous Concrete Pipe for Under drain, 150 mm Ø Lm or Lft
153. 893-4.5 Porous Concrete Pipe for Under drain, 200 mm Ø Lm or Lft
154. 893-4.6 Granular Backfill to Concrete Pipe under drain. m3 or 100 Cft
155. 895-6.1 Concrete manhole 1 m to 2 m 3.28 ft to 6.56 ft) Each

deep
156. 895-6.2 Concrete manhole more than 2 m and up to 3 m Each

(6.56 ft up to 9.84 ft) deep
157. 896-5.1 Excavation (catch basins, and drop inlets) m3 or 1000 Cft
158. 896-5.2 Masonry (catch basins, and drop inlets) m3 or 1000 Cft
159. 896-5.3 Concrete (catch basins, and drop inlets) m3 or 100 Cft
160. 896-5.4 Steel Reinforcement (catch basins, and drop inlets) % Kg
161. 896-5.5 Steel Frames, Grates (catch basins, and drop inlets) Kg
162. 897-3.8.1 Hand-placed Riprap m3 or 100 Cft
163. 897-3.8.2 Grouted Riprap m3 or 100 Cft
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Draft 2004
SECTION 1101
164. 897-3.8.3 Precast concrete slope paving m2 or 100 Sft
165. 897-3.8.4 Filter blanket of approved filter material and m2 or 100 Sft
specified thickness
166. 898-6.1 Cast-in-situ Cement Concrete Kerb Lm or Lft
167. 898-6.2 Cast-in-situ Cement Concrete Gutter Lm or Lft
168. 898-6.3 Pre-cast Concrete Kerb Lm or Lft
169. 898-6.4 Pre-cast Concrete Gutter Lm or Lft
170. 898-6.5 Compacted Bed Course m3 or 100 Cft
171. 899-6.1 Cement Concrete sidewalk m2 or Sft
CHAPTER 900 INCIDENTAL CONSTRUCTION
172. 901-6.1 Metal Guardrail Lm or Lft
173. 901-6.2 Guardrail end or Buffer Sections Each
174. 901-6.3 Concrete Post for Guardrail Each
175. 901-6.4 Steel Post for Guardrail Each
176. 902-5.1 Cement Concrete Beam Guardrail Lm or Lft
177. 902-5.2 Cement Concrete Post for Guardrail Each
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Draft 2004
SECTION 1101
178. 903-6.1 Traffic Road Signs Category 1(a) Each
179. 903-6.2 Traffic Road Signs Category 1(b) Each
180. 903-6.3 Traffic Road Signs Category 2 Each
181. 903-6.4 Traffic Road Signs Category 3 (a) Each
182. 903-6.5 Traffic Road Signs Category 3 (b) Each
183. 903-6.6 Traffic Road Signs Category 3 (c) m2 or Sft
184. 904-5.2.1 Pavement Marking in non-reflective CR/TP paint Lm or Lft

for lines of 12cm width
185. 904-5.2.2 Pavement Marking in non-reflective CR/TP Paint Lm or Lft

for Lines of 15 cm width
186. 904-5.2.3 Pavement Marking in non-reflective CR/TP Paint Lm or Lft

for Lines of 20cm width.
187. 904-5.2.4 Pavement Marking in non-reflective CR/TP Paint Each

for Lines of 4.0M arrows.
188. 904-5.2.5 Pavement Marking in non-reflective CR/TP Paint Each

upto 6.0M arrows.
189. 904-5.2.6 Pavement Marking in non-reflective CR/TP Paint m2 or Sft

for various sign.
190. 904-5.2.7 Pavement Marking in reflective CR/TP Paint for Lm or Lft
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Draft 2004
SECTION 1101
Lines of 12cm width.
191. 904-5.2.8 Pavement Marking in reflective CR/TP Paint for Lm or Lft

Lines of 15cm width.
192. 904-5.2.9 Pavement Marking in reflective CR/TP Paint of Lm or Lft

20cm width.
193. 904-5.2.10 Pavement Marking in reflective CR/TP Paint for Each

4.0M arrows.
194. 904-5.2.11 Pavement Marking in reflective CR/TP Paint upto Each

6.0M arrows.
195. 904-5.2.12 Pavement Marking in reflective CR/TP Paint for m2 or Sft

various sign.
196. 904-5.2.13 Pavement Marking by retro reflective preformed m2 or Sft

pavement markings (Tape)
197. 905-6.1 Reflectorized Pavement Stud (Flush Surface Type) Each
198. 905-6.2 Reflectorized Pavement Stud (Raised Profile Type) Each
199. 906-6.1 Chain Link Fabric Fencing Lm or Lft
200. 906-6.2 Barbed Wire Fencing Lm or Lft
201. 911-12.1 Bearing devices of specified material/ dimension Kg / Lb or per Unit
202. 921-6.1 Bridge Deck joint seals of specified material Lm or Lft
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Draft 2004
SECTION 1101
203. 931-6.1 Rain Water Outlets Each
204. 941-9.1 Ordinary Kilometer stone on Provincial Highways Each

& major District Roads, complete.
205. 941-9.2 5th Kilometer stone on Provincial Highways & Each

major District Roads, complete
206. 941-9.3 Kilometer stone for District &Farm to Market Each

Roads, complete
207. 941-9.4 Right of way Markers, complete Each
CHAPTER 1000 ROADWAY CONSTRUCTION MATERIALS
208. 1001-13.1 Supply of Portland cement of Specified Quality Metric ton (Tonne)
209. 1011-9.1 Supply of bituminous binder of specified quality Tonne or 100 Lbs
and grade when measured by
weight.
210. 1011-9.2 Supply of bituminous binder of specified quality Imp gallon or U.S.
and grade gallon or litre when
measured by volume
at 16 OC (60 OF)
211. 1031-9.1 Supply of Coarse aggregate of specified gradation m3 or 100 Cft

for cement concrete
212. 1032-13.1 Supply of Fine aggregate of specified gradation for m3 or 100 Cft
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Draft 2004
SECTION 1101
cement concrete
213. 1033-10.1 Supply of Mortar Sand m3 or 100 Cft
214. 1034-6.1 Supply of Mineral Filler m3 or 100 Cft
215. 1041-11.1 Supply of Bricks of approved quality & size 1000 Nos.
216. 1041-11.2 Supply of Tiles of approved quality & size 1000 Nos.
217. 1046-12.1 Supply of Stone for Random Rubble Masonry m3 or 100 Cft
218. 1046-12.2 Supply of Stone for Course Rubble Masonry m3 or 100 Cft
219. 1046-12.3 Supply of Stone for Ashlar Masonry m3 or 100 Cft
220. 1051-7.1 Supply of Water 1000 Liters
221. 1052-8.1 Air Entraining Admixture for Concrete Kg or Lb
222. 1052-8.2 Chemical Admixture for Concrete Kg or Lb
********************
- 431 -
Draft 2004
Annexure-1
RECOMMENDED MAJOR CONSTRUCTION EQUIPMENT
SEC. DESCRIPTION CONSTRUCTION MACHINERY FOR

NO. Major Projects Rehabilitation/ Maintenance
Medium Size Projects Projects.
301 Clearing and 1. Bulldozer (160 H.P.) or
Grubbing. Grader (140 H.P.)
-- --
2. Dumper (10 T)
302 Removal of Trees 1. Excavator (0.3 CM) -- --
303 Stripping 1. Grader (140 H.P.) -- --
402 Structural 1. Excavator (0.3 CM) Plate Compactor Plate Compactor.

Excavation and 2. Plate Compactor
Backfill
403 Roadway 1. Bull Dozer 1. Bull Dozer (160 H.P.)

Excavation (160-200 H.P.)
2. Tractor/Trolley
2. Front End Loader (50 H.P.) --
(2-3 CM)
3. Dump Truck
(10-18T)
409, Sub-grade 1. Grader (140-165 HP)

410 Preparation with scarifier.
2. Water Tanker
(Tow –Type) -- --
3. Combination Roller
(10-12)
411 Formation of 1. Grader (140-165 HP) 1. Grader (140 HP) 1. Heavy Duty
Embankment. Tractor with Blade
2. Combination/sheep- 2. Combination/ sheep-foot
foot or pneumatic or pneumatic Roller (80 H.P.)
roller (8-12T) (8-12T)
2. Static Roller
3. Water Tanker 3. Water Tanker (8-12T)
(Bowser Type) (Bowser Type)
3. Water Tanker
(Tow-Type)
501, Granular Sub-Base. 1. Power Broom/Air 1. Heavy Duty Tractor 1. Tractor/Trolley

521 Compressor with Blade. with Blade
(50 HP)
2. Grader with 2. Water Tanker
Scarifier (140 H.P.) (Tow Type) 2. Water Tanker
(Tow Type)
3. Water Bowser. 3. Static Roller (10-12T)
3. Static Roller
4. Combination Roller (10-12T)
(10-12T)
551-A, Base Course 1. Power Broom/Air 1. Grader (140 HP) with 1. Heavy Duty
551-B Compressor Articulated Blade. Tractor/Trolley
with Blade
2. Front End Loader 2. Water Tanker (80 HP)
(2-3 CM) (Tow Type)
2. Water Tanker
- 173 -
Draft 2004
Annexure-1

3. Pug mill (50-100T/ Hour) (Tow Type)
4. Dumper (10-15T) 3. Combination Roller 3. Static Roller
(10-12T) (10-12T)
5. Base Paver
(4M wide) 10-12T
601, Bitumen Prime 1. Power 1. Manual Operated 1. Manually

611 Coat/Tack Coat. Broom/Air-Compressor Bitumen Pressure Operated
Distributor Bitumen
2. Engine Operated Bitumen (Tow Type) pressure
Pressure distributor distributor
(Auto-Type) (Tow Type)
621, Asphaltic Base 1. Power Broom/Air 1. Front End loader 1. Bitumen

651 Course/Wearing Compressor. (1.50-2.50 CM) Aggregate.
Course Plant Mix. Asphalt Plant
2. Front End Loader (20-40T) Mixer (1 CM)
(2-3 CM)
2. Dumper (10 T) 2. Wheel Barrow
3. Asphalt Plant (0.5 CM)
(80-120T) 3. Paver
. (4M wide) 3. Tandem Vibratory
4. Paver (4 M wide) Roller (8-10T)
4. P.T.R.
5. Dumper (10-18T) (9 Wheeled) 18-T 4. Tractor/Trolley
(50 H.P.)
6. P.T.R. (9 Wheeler 21 T) 6. Tandem Vibratory
7. Tandem Vibratory Roller (8-10T)
Roller (10-12T)
631 Bituminous Surface 1. Power Broom/Air 1. Aggregate Spreader 1. Tractor/Trolley

Treatment. Compressor. 3-4 M Wide) (50 H.P.)
2. Aggregate Spreader. 2. Bitumen Distributor 2. Bitumen Sprayer
Auto or Tow-Type (manual) static
3. Engine Operated
Bitumen Pressure 3. Dump Truck 3. Tandem Roller
Distributor (Auto Type) (10 T) Static (180 T)
4. Dump Truck (10 T) 4. Tandem Roller (8-10T)
5. Rubber Mounted
Tandem Roller or
P.T.R. (9 Wheeled-18 T)
652 Re-Cycling of 1. Re-cycling Machine.

Asphalt Concrete.
-- 2. Bitumen Bowser --
plus all equipment for
Asphaltic Concrete under
Item 621
701 Concrete 1. Concrete Batching 1. Concrete Static Mixer 1. Concrete Static

Plant (30 CM/H) (1 – CM) Mixer (1/2-1 CM)
2. Front End Loader 2. Tractor Trolley 2. Tractor/Trolley
(2-3 CM) (50 HP) (50 HP)
3. Concrete Transit 3. Crane (20-T) 3. Vibrator.
Mixer (6 CM)
4. Water Tanker 4. Wheel Barrows.
4. Crane (20-45T) (Tow Type)
5. Vibrator 5. Vibrator
- 174 -
Draft 2004
Annexure-1

(40 mm-50mm) (40mm-50mm)
6. Concrete Finisher.
711 Concrete Pavements 1. Concrete Batching Plant

(30 CM/H)
2. Concrete Paving Machine
(4 M wide) -- --
3. Front End Loader (2-3 CM)

4. Concrete Transit mixer
(6 CM)
811 Prestressed Concrete 1. Prestressing

Structures Equipment plus all
equipment contained
in Item No.701. -- --
2. Heavy Duty Crane or
Beam launching Truss
851, Piling. Piling Equipment plus all those

852 equipment mentioned in Item
701, for major projects. -- --
904 Pavement Marking Road Marking Machine Manual Manual
*******************
- 175 -
Draft 2004
Annexure-2
SCHEDULE FOR SAMPLING AND TESTING OF

EMBANKMENT AND SUBGRADE
(ITEM NO. 409 TO 411)
Sampling and
Material Test Designation Testing
Frequency
Classification AASHTO M-145 1/2,000 CM
CBR AASHTO T-193 1/2,000 M

Soil
Swelling AASHTO T-193 1/2,000 CM
Moisture Density AASHTO T-180 1/2,000 M

(Lab) or
Relative Density ASTM D-4254-83
1/1,000 M
Field Density AASHTO T-191 1/200 M
- 176 -
Draft 2004
Annexure-2
SCHEDULE FOR SAMPLING AND TESTING OF GRANULAR SUB-BASE

(ITEM NO. 501)
Sampling and Testing

Material Test Designation
Frequency
Gradation AASHTO T-27 3/Source plus 1/1000 CM

3/Source plus as required
AASHTO T-89
Plasticity Index base on visual
and T-90
observation.
Aggregate CBR AASHTO T-193 based on variation in
gradation or 1/1000 CM
Abrasion AASHTO T-96 3/Source plus 1/500 CM

Moisture
AASHTO T-180 1/1,000 CM
Density
4/layer/400 M laid, 3
AASHTO T-191
Field Density Minimum/layer if less
T-238 and T-239
than 400 M laid.
3/source plus as required
Sand
AASHTO T-176 based on visual
Equivalent
observation
- 177 -
Draft 2004
Annexure-2
SCHEDULE FOR SAMPLING AND TESTING OF BASE COURSE

(ITEM NO. 551-A, 551-B)

Frequency
Gradation AASHTO T-27 3/Source plus 1/1000 CM
AASHTO T-89 3/Source plus as required

Plasticity Index
and T-90 base on visual observation.
3/Source/stock pile plus as
CBR AASHTO T-193 required base on variation
in gradation.
Aggregate Abrasion AASHTO T-96 3/Source plus 1/5,000 CM
Sodium Sulphate
AASHTO T-104 3/Source plus 1/5,000 CM
Soundness
Fractured Faces Visual based on visual
observation.
Moisture
AASHTO T-180 1/1000 CM
Density
AASHTO- T-191 4/layer/400 M laid 3

Field Density or minimum/layer if less than
T-238 and T-239 400 M laid.
Sand Equivalent AASHTO T-176 based on visual
observation.
- 178 -
Draft 2004
Annexure-2

ASPHALTIC BASE COURSE
(ITEM NO. 621)

Frequency
Gradation AASHTO T-27 1/1000 CM
3/Source stock pile plus

Abrasion AASHTO T-96
1/5000 CM
Sodium
Coarse Sulphate AASHTO T-104 3/Source plus 1/5000 CM
Aggregate Soundness
Striping AASHTO T-182 3/Source plus 2/5,000 CM
3/Source plus as required based

Fractured faces Visual
on visual observation.
Flat and
Elongated Visual -do-
Particle.
Specific
4/Source for each size in Hot
Gravity and AASHTO T-85
bins of Asphalt Plant.
Absorption
Sand AASHTO- T-176
3/Source plus as required based
Equivalent
on visual observation. 2/1000
or AASHTO T-89
Fine CM
Plasticity Index and T-90
Aggregate
Specific
AASHTO T-84 4/Source
Gravity.
Friable
AASHTO T-112 2/5000 Cm
Particles
Specific
AASHTO T-228 2/Shipment
Asphalt Gravity
Cement 3/Week of plant operation
Penetration AASHTO T-49 Samples taken from heating
tank at staggered intervals.
- 179 -
Draft 2004
Annexure-2

ASPHALTIC BASE COURSE (Contd.)
(ITEM NO. 621)

Frequency
Extraction AASHTO T-164

Gradation T-30
Bulk AASHTO T-166
Mixture Sp.Gravity. Method B
2/day's production
Maximum
AASHTO T-209
Sp.Gr.
Air Voids AASHTO T-269
1/layer @ 100 M interval per

Thickness AASHTO T-230
Mixture lane
Compacted in
place
AASHTO T-230 1/layer @ 100 M interval per
Compaction
ASTM D 2950 lane
Note :
Test locations will be selected at random.
- 180 -
Draft 2004
Annexure-2

WEARING COURSE, PLANT MIX
(ITEM NO. 651)

Frequency
Gradation AASHTO T-27 1/1000 CM
Abrasion AASHTO T-96 3/Source plus 1/5000 CM

Sodium
Coarse Sulphate AASHTO T-104 3/Source plus 1/5000 CM
Aggregate Soundness
3/Source plus 1/5,000
Stripping AASHTO T-182
CM
Fractured faces Visual based on visual
observation.
Flat and
Elongated Visual -do-
Particle
Specific Gravity 4/Source for each size in
AASHTO T-85
and Absorption Hot bins of Asphalt Plant.
Sand Equivalent AASHTO- T-176
base on visual
Fine or AASHTO T-89
observation. 1/1000 CM
Aggregate Plasticity Index & T-90
Specific
AASHTO T-84 2/Source
Gravity.
Friable Particles AASHTO T-112 1/5000 CM
Specific Gravity AASHTO T-228 2/shipment

Asphalt 3/week of plant
Cement operation. Samples taken
Penetration AASHTO T-49
from heating tank at
staggered intervals.
- 181 -
Draft 2004
Annexure-2

WEARING COURSE, PLANT MIX (Contd.)
(ITEM NO. 651)

Frequency
Extraction AASHTO T-164
Gradation AASHTO T-30
Premix Asphalt
Flow AASHTO T-245
Stability AASHTO T-245 2/day's production.
Bulk Sp. Gravity AASHTO T-166

Loss Stability AASHTO T-245
1/layer @ 100 M
Thickness AASHTO T-230
Mixture interval per lane
Compacted in
place
AASHTO T-230 1/layer @ 100 M
Compaction
ASTM D 2950 interval per lane
Note :
Test locations will be selected at random.
- 182 -
Draft 2004
Annexure-2
SCHEDULE FOR SAMPLING AND TESTING OF CONCRETE

(ITEM NO. 701)

Frequency
Gradation AASHTO T-27 2/Stock pile plus 1/1000 CM
Coarse Unit Wt. AASHTO T-19 1/Source plus 1/1000 CM

Aggregate
Sp.Gravity AASHTO T-85 2/Source plus 1/1000 CM
Absorption AASHTO T-85 1/Source plus 1/500 CM

Abrasion. AASHTO T-96 1/Source plus 1/5000 CM
Soundness AASHTO T-104 1/Source plus 1/5000 CM

Deleterious
AASHTO M-80 1/Source plus 1/5000 CM
Substance
Gradation AASHTO- M-6 2/Source plus 1/1000 CM

Fine
Aggregate
Unit Wt. AASHTO T-19 4/Source plus 1/800 CM
Specific
AASHTO T-84 4/Source plus 1/1000 CM
Gravity
Absorption AASHTO T-84 1/Source plus 1/1000 CM
Asphalt Organic
AASHTO T-21 1/Source plus 1/1000 CM
Cement Impurities
Soundness AASHTO T-104 1/Source plus 1/5000 CM
Fineness AASHTO M-6 1/Source plus 1/1000 CM

Deleterious
AASHTO M6 1/Source plus 1/5000 CM
Substance
Petrographic - 1/Source plus 1/5000 CM
- 183 -
Draft 2004
Annexure-2
SCHEDULE FOR SAMPLING AND TESTING OF CONCRETE (Contd.)

(ITEM NO. 701)

Frequency
Yield Test for
AASHTO T-121 1/Lot or 1000 Bags
Cement Content
Setting Time AASHTO T-131 1/Lot or 1000 Bags

Cement
Mortar Strength AASHTO T-132 1/Lot or 1000 Bags
Water Chemical Tests AASHTO T-26 1/Source

Compression
6/Shift or 50 CM (2 sets
(Cube or AASHTO T-22
of 3 each)
Concrete Cylinder)
mix
Slump AASHTO T-119 2/shift or 50 CM
*********************
- 184 -
Draft 2004
Annexure-3
CONVERSION FACTORS
LENGTH
km m mm mile Yard ft in
1 1000 106 0.6214 1094 3281 3.937x104

10-3 1 1000 6.214x10-4 1.0936 3.281 39.37
10-6 10-3 1 6.214x10-7 1.094x10-3 3.28x10-3 3.937x10-2
1.6094 1609.4 1.609x106 1 1760 5280 63360
9.144x104 0.9144 914.41 5.682x10-4 1 3 36
3.048x10-4 0.3048 304.8 1.894x10-4 0.3333 1 12
2.54x10-5 0.0254 25.4 1.578x10-5 2.778x10-2 8.333x10-2 1
AREA
km2 m2 cm2 mm2 sq.mile acre yd2 ft2 in2
1 10-6 1010 1012 0.38612 247.11 1.196x106 1.076x107 1.550x109

10-6 1 104 106 3.86x10-7 2.471x10-4 1.196 10.764 1550
10-10 10-4 1 100 3.86x10-11 2.471x10-8 1.16x10-4 1.076x10-3 0.155
10-12 10-6 10-2 1 3.86x10-13 2.471x10-10 1.196x10-6 1.076x10-5 1.550x10-3
2.59 2.59x106 2.59x1010 2.59x1012 1 639.96 3.097x106 2.788x107 4.01x108
4.047x10-3 4047 4.047x107 4.047x109 1.563x10-3 1 4840 43560 6.273x106
8.36x10-7 0.8361 8361 8.36x105 3.228x10-7 2.066x10-4 1 9 1296
9.29x10-8 9.29x10-2 929 92900 3.587x10-8 2.296x10-5 0.1111 1 144
6.45x10-10 6.45x10-4 6.4516 645.16 2.491x10-10 1.594x10-7 7.716x10-4 6.944x10-3 1
VOLUME
m3 dm3 (litre) cm3 (ml) yd3 ft3 in3 UK gallon US gallon
1 103 106 1.3079 35.311 6102 219.97 264.17

10-3 1 103 1.308x10-3 3.53x10-2 61.02 0.22 0.2642
10-6 10-3 1 1.308x10-6 3.531x10-5 6.102x10-2 2.199x10-4 2.642x10-4
0.7646 764.6 7.646x105 1 27 46650 168.19 201.99
2.832x10-2 28.32 2.832x10-4 3.704x10-2 1 1728 6.229 7.481
1.639x10-5 1.639x10-2 16.387 2.144x10-5 5.787x10-4 1 3.605x10-3 4.329x10-3
4.546x10-3 4.546 4.546x103 5.946x10-3 0.1605 277.42 1 1.2008
3.785x10-3 3.785 3.785x103 4.951x10-3 0.1337 231 0.8327 1
WEIGHT
Tonne
kg g UK ton US ton cwt lb Oz
(Mg)
1 1000 106 0.9842 1.1011 19.66 2.205x103 3.527x104

10-3 1 1000 9.842x10-4 1.101x10-3 1.966x10-2 2.2046 35.274
10-6 10-3 1 9.842x'10-7 1.101x10-6 1.966x10-5 2.204x10-3 3.527x10-2
1.016 1016 1.016x106 1 1.12 20 2240 35840
0.9081 908.1 9.08x105 0.8928 1 17.856 2000 32000
5.085x10-2 50.85 5.085x104 0.05 0.0560 1 112 1792
4.536x10-4 0.4536 453.6 4.46x10-4 5x10-4 8.92x10-3 1 16
2.835x10-5 2.835x10-2 28.349 2.79x10-5 3.125x10-5 5.580x10-4 6.25x10-2 1
- 185 -
Draft 2004
Annexure-3
CONVERSION FACTORS
PRESSURE, STRESS AND MODULUS OF ELASTICITY
MN/m2 kN/m2 kp psi psf

MPa kPa Kgf/cm2 Ton/ft2 lbf/in2 lbf/ft2
1 1000 10.197 9.320 145.04 20886
0.001 1 1.019x10-2 0.0093 0.14504 20.886
9.807x10-2 98.07 1 0.9139 14.223 2048.1
0.1073 107.3 1.0942 1 15.562 2240
6.895x10-3 6.895 7.031x10-2 6.426x10-2 1 144
4.788x10-5 4.788x10-2 4.883x10-4 4.464x10-4 6.944x10-3 1
DENSITY
Tonne/m3
Mg/ m3 pcf
3 3 3 3 3
g/cm Kg/ m Lb/in UK ton/yd US ton/yd Lb/ft3
1 1000 0.03613 0.75247 0.8428 62.43
10-3 1 3.613x10-5 7.525x10-4 8.428x10-4 6.243x10-2
27.680 27680 1 20.828 23.328 1.728x103
1.3289 1.328x103 4.801x10-2 1 1.12 82.955
1.1865 1.186x103 4.287x10-2 0.8929 1 74.074
1.602x10-2 16.019 5.787x10-4 1.205x10-2 1.35x10-2 1
FORCE AND WEIGHT

MN KN N Kgf Tonf lbf
1 1000 106 1.0196x10 5
100.4 2.248x105
10-3 1 103 101.96 0.1004 224.82
10-6 10-3 1 0.10196 1.004x10-4 0.2248
9.807x10-6 9.807x10-3 9.807 1 9.842x10-4 2.2048
9.964x10-3 9.964 9964 1016 1 2240
4.448x10-6 4.448x10-3 4.448 0.45455 4.464x10-4 1
TEMPERATURE POWER
Kelvin (K) = (tF + 459.67) / 1.8 1 hp (horse power) = 745.700 W (J/s)

= tc + 273.15 1 lbf/s = 1.35582 W
Celsius (C) = (tF - 32) / 1.8
Fahrenheit (F) = (tc x 1.8) + 32
VISCOSITY, KINEMATIC DENSITIES (at 20oC) g/cm3
1 m2 / s = 10.7639 ft2 /s Pure Water : 0.99820

1 cSt (Centistokes)= 5.58001 in2/h Sea Water : 1.04
= 1 mm2/s Mercury : 13.564
= 10-6 m2/s Kerosene (approx) : 0.80
1 ft2/h = 0.092903 m2/h Paraffin wax (m.p. 52-52oC) : 0.912
1 in2/s = 645.16 mm2/s Microcrystalline wax (m.p. 60-63 oC) : 0.915
- 186 -
Draft 2004
REFERENCES
1. Standard Specification for Road and Bridge Construction 1971, Punjab

Highway Department.
2. Standard Specifications, National Highway Authority 1998, Government
of the Pakistan.
3. General Specification for Roads 1994, Sultanate of Oman.
4. AASHTO/ASTM Specifications (U.S.A.)
5. British Standard Specifications (BSS)
6. Asphalt Institute Manual Series.
7. Standard Specifications for Rural Road Construction Project, Phase-I in
Punjab___ Project Engineering Cell, Punjab C&W Department.
****************
- 187 -

Draft 2004 - Rev01

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GOVERNMENT OF THE PUNJAB

COMMUNICATION AND WORKS DEPARTMENT

PUNJAB HIGHWAY DEPARTMENT

(MOHAMMAD IQBAL KHOKHAR)

(RANA MOHAMMAD GHOUS) (CH.KHUDA YAR)

(MOHAMMAD YOUSAF KHAN) (KHAYYAM QAISER)

CONCISE TABLE OF CONTENTS

CHAPTER 100 GENERAL 1

CHAPTER 200 CONSTRUCTION EQUIPMENT AND 22

CHAPTER 300 SITE CLEARANCE 30

CHAPTER 400 EARTH WORK AND RELATED 38

CHAPTER 500 SUB-BASE AND BASE CONSTRUCTION 70

CHAPTER 600 BITUMEN BASE AND SURFACING 99

CHAPTER 700 CEMENT CONCRETE 129

CHAPTER 800 HIGHWAY STRUCTURES 169

CHAPTER 900 INCIDENTAL CONSTRUCTION 296

CHAPTER 1000 ROADWAY CONSTRUCTION 367

CHAPTER 1100 MISCELLANEOUS 410

DETAILED TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

CHAPTER 100 GENERAL 1

SECTION DESCRIPTION PAGE

SECTION DESCRIPTION PAGE

841 WELL FOUNDATION 216

902 CEMENT CONCRETE BEAM 300

SECTION DESCRIPTION PAGE

CHAPTER 1000 ROADWAY CONSTRUCTION 367

Annexure-1 RECOMMENDED MAJOR 429

Annexure-2 SCHEDULE FOR SAMPLING AND 432

Annexure-3 CONVERSION FACTORS 441

The Specifications have been formulated for road and bridge

i) Construction of limited access roads, new Highways, Bridges

All the above aspects of construction and rehabilitation have been

These Specifications describe the requirements and procedures for

Contractor shall also provide skilled manpower in adequate number,

Number and kind of Equipment required for different items of work

While a few of these specifications may provide that equipment of a

The Contractor may request, in writing, permission from the Engineer

The Engineer Incharge before considering or accepting such request

If such permission is granted by the Engineer Incharge, it shall be

Nothing in this clause shall relieve the Contractor of his responsibility

Articles or materials to be supplied or incorporated in the work shall be

101-1.7 Defective Materials

All materials which the Engineer Incharge has determined as not

101-1.8 Trade Names and Alternatives

For convenience in designation on the plans or in the specifications,

The responsibility of proof as to quality and suitability of alternatives

Whenever the specifications permit the substitution of a similar or

101-1.9 Frequency of Tests & Test Designation

Frequencies of tests for the items of construction have been given in

Unless otherwise specified, all tests shall be performed in accordance

Whenever the specifications provide an option between two or more

Whenever a reference is made in the specifications to a specification

When desired by the Engineer Incharge, the Contractor shall furnish,

101.1.11 Utility Lines.

The Contractor shall conduct his operations, make necessary

101-1.12 Safety Precautions.

The Departmental Engineers and consultant (where employed) shall at

101-1.14 Removal of Rejected and Unauthorized Work.

All works, which have been rejected, shall be remedied, or removed

Upon order of the Engineer Incharge, unauthorized work shall be

Upon failure of the Contractor to comply promptly with any order of

101-1.15 Alternative Methods of Construction.