Construction of bridge superstructure, bearings, expansion joints and quality control

1. Construction of RCC Superstructure

1.1 General
A method statement for construction, indicating the following, shall be submitted by
the Contractor for approval of the Engineer, well in advance of the commencement of
the construction of superstructure:
a) Sources of materials
b) Design, erection and removal of formwork
c) Production, transportation, laying and curing of concrete
d) Prestressing system, if applicable
e) Personnel employed for execution and supervision
f) Tests and sampling procedure
g) Equipment details
h) Any other point as desired by Engineer
Dimensions, lines and levels shall be set out and checked with respect to permanent
reference lines and permanent bench mark so that the final product is in accordance
with the drawings or as directed by the Engineer.
1.2 Reinforced concrete construction
1.2.1 Solid slabs
Where adjacent span of slab has already been cast, the expansion joint and filler board
shall be placed abutting the already cast span which shall form the shutter on that side
of the new span to be cast. The whole of the slab shall be cast with reinforcement
embedded for the road kerb and railings. No other construction joint shall be allowed
except with the express permission of the Engineer.
Where wearing coat is required to be provided, after the deck slab has been cast, the
surface of the slab shall be finished rough, but true to lines and levels as shown on the
drawings, before the concrete has hardened. The areas of construction joints shall be
treated in the prescribe manner.
The top of the slab shall be covered with clean moist sand as soon as the top surface
has hardened.
Where the slab is resting on bearings, the same shall be placed in position in
accordance with the drawings, before casting of deck slab.
1.2.2 RCC T-beam and slab
Provision of construction joint shall conform to the drawings or as per directions of
the Engineer. No construction joint shall be provided between the bottom bulb and the
web. If not indicated on the drawing, construction joint may be provided at the
junction of the web and the fillet between the web and the deck slab with the
permission of the Engineer.
The portions of deck slab near expansion joints shall be cast along with
reinforcements and embedments for expansion joints. For this purpose, the portion of

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 deck slab near expansion joints may be cast in a subsequent stage, if permitted by the
Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and levels
as shown on the drawings before the concrete has hardened. Care shall be taken for
settling of bearings as indicated on the drawings.
1.3 Prestressed concrete construction
1.3.1 PSC girder and composite RCC slab
PSC Girder may be precast or cast-in-situ as mentioned on the drawing or as directed
by the Engineer. Girders may be post-tensioned or pre-tensioned. Where precast
construction is required to be adopted, selection of casting yard and details of
methodology and of equipment for shifting and launching of girders shall be included
in the method statement.
In case of cast-in-situ construction, the sequence of construction including side
shifting of girders, if applicable, and placing on bearings shall be in accordance with
the drawings.
The PSC girder constituting the top flange, web and the bottom flange shall be
concreted in a single operation without any construction joint.
The portions of deck slab near expansion joints shall be cast along with
reinforcements and embedments for expansion joints. For this purpose, the portion of
deck slab near expansion joints may be cast in a subsequent stage, if permitted by the
Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and levels
as shown on the drawings before dry concrete has hardened. Care shall be taken for
settling of bearings as indicated on the drawings.
1.3.2 Box girder
Box girders may be simply supported or continuous. Simply supported box girders
shall have minimum construction joints as approved by the engineer. In the case of
continuous box girders the sequence of construction and location of construction
joints shall strictly follow the drawings.
The box section shall be constructed with a maximum of one construction joint
located in the web below the fillet between the deck slab and web. If permitted by the
Engineer, one additional construction joint may be permitted and this construction
joint shall be located in the web above the fillet between the soffit slab and web.
The portions of deck slab near expansion joints shall be cast alongwith reinforcements
and embedments for expansion joints. For this purpose, the portion of deck slab near
expansion joints may be cast in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and levels
as shown on the drawings before the concrete has hardened. Care shall be taken for
setting of bearings as indicated on the drawings.
1.3.3 Cantilever construction
Continuity of un-tensioned reinforcement from one segment to the next must be
ensured by providing full lap length as necessary.

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 The design of the superstructure shall take into account the following aspects which
form an integral part of the construction operations:
a) Stability against over-turning for each statical condition through which the
assembly passes, shall be checked.
b) Stresses at each preceding segment joint with the addition of every segment or
change of statical conditions shall be checked. The load of equipment as well as
construction live load shall be taken into account.
c) Precambering of the superstructure during construction shall be done in such a
manner that the finally constructed structure under permanent load strains the final
profile intended in the drawings.
2. Fabrication, testing and installation of bearings
2.1 Metallic Bearings
2.1.1 Workmanship and tolerances
2.1.1.1 All surfaces of the major components like top plates, saddle plate, base plates, rollers
of the bearings shall be machined all over for correct alignment, interchangeability,
proper fitting, etc.
2.1.1.2 Plates
a) The plate dimensions shall be in accordance with the approved drawing.
Tolerance on the length and width of the plate shall not exceed +1.0 mm,
tolerance on the thickness of the plate shall not exceed +0.5 mm and no minus
tolerance shall be allowed.
b) All rolling, rocking and sliding surfaces shall have a machine smooth finish to 20
micron maximum mean deviation as per IS: 3073.
2.1.1.3 Rollers and curved surfaces
a) The tolerance on the diameters of both rollers and convex surfaces shall conform
to K7 of IS: 919.
b) The tolerance on the diameter of concave surfaces shall conform to D8 of IS: 919.
2.1.1.4 Castings
No minus tolerance will be allowed in the thickness of any part of the castings. The
edge of all ribs shall be parallel throughout their length.
2.1.2 Acceptance criteria
Unless agreed upon otherwise between the Engineer and the manufacturer, the
manufacturer shall furnish a complete Quality Assurance Programme (QAP)
compromising the process of quality control, raw material testing, various stages of
manufacture, testing on bearing components as well as testing on complete bearing,
etc. in conformity with relevant codal stipulations prior to the commencement of
manufacture. The said quality assurance programme shall be approved by the
Engineer/Accepting Authority. Manufacturing process, quality assurance, testing,
documentation, etc., shall be carried out in the presence of authorized representative
of the Engineer and in conformity with the approved quality assurance programme.
Proper documentation, records and certificates shall be maintained at all stages of
manufacture and inspection by manufacturer to ensure to the conformity with the
approved Quality Assurance Programme.

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 The engineer may appoint an authorized inspection agency on his behalf for the
purpose of inspection as per approved Quality Assurance Programme to certify the
acceptance or otherwise of the bearings.
2.1.2.1 Test certificates of reputed testing laboratories for all raw materials shall be
submitted. If such test certificates are not available then bearing manufacturer shall
perform the necessary confirmatory tests as per relevant codes of practice and shall
furnish the test results. Engineer or his representative may carry out independently
tests on raw materials and witness the manufacturing process.
2.1.2.2 All casting and forgings shall be annealed/normalized and the heat cycle record shall
be submitted to the Inspecting officer/ engineer for scrutiny. Inspecting
officer/engineer may ensure the proper reduction ratio. Suitable weld data record shall
be maintained and submitted.
2.1.2.3 The Engineer shall reserve the right to witness such inspection at manufacturer’s
workshop. For this, bearing manufacturer shall have in-plant minimum testing
facilities as follows:
a) Fully equipped chemical test laboratory to find out carbon, sulphur, phosphorous,
manganese, silica and other elements as required.
b) UTM of minimum 40 MT capacity.
c) BHN testing equipment of 3000 Kgf. (Hydraulic Type)
d) Ultrasonic Flaw Detector
e) Metalography for checking of microstructure of different materials
f) Load testing machine of required capacity having facilities of rotation and lateral
loading.
2.1.2.4 Bearing manufacturer shall maintain a list of consumption of raw materials including
test records, for a period of atleast preceding two years.
Test certificates of bearings, manufactured during preceding two years shall be made
available to the Inspecting Officer(s)/Engineer at manufacturer’s works.
2.1.2.5 Bearing manufacturer shall employ full time sufficient graduate engineering staff for
manufacture and quality control of bearings and shall have full time trained scientist
in chemical and physical testing and also have qualified person for ultrasonic testing.
Bearing manufacturer shall have qualified/certified welders.
2.1.3 Testing
2.1.3.1 The manufacturer has to produce test certificate from original producers of raw
materials used in the manufacture of the bearings. Irrespective of the producers test
certificates, the manufacturer will carry out the detailed tests on raw materials (both
physical and chemical) for different types of raw materials used in the manufacture of
the bearings as per relevant codes for such raw materials. For this purpose they will
identify stock materials with certain batch number and draw samples from such stock
materials and mark the same with same batch numbers. For each batch, 3 sets of
samples will be drawn separately for tests of physical and chemical properties on
samples. The manufacturer will carry out tests on chemical and physical properties on
one set of samples and keep the remaining 2 sets of samples duly identified with the
batch number for verification by the Engineer and/or his authorized representatives
for conformatory tests with respect to the results obtained by the manufacturer. Such

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 tests can be carried out on a few samples selected at random by the discretion of the
Engineer and/or his representatives. The following IS codes may be referred for
carrying out such tests (both physical and chemical):
IS: 1030 for casting
IS: 2062 for mild steel components
IS: 2004 for forging
Other special materials shall be as per relevant IS/BS/AISI Codes.
2.1.3.2 All machined cast steel components shall be tested for ultrasonic testing to level IIIrd
of IS: 9565. Critical surface shall also be checked by Dye Penetration Test (DPT)
and/or magnatic particle test for detecting presence of surface defects.

2.1.3.3 All forged steel components after machining will be subjected to ultrasonic testing.
Guidelines given in Appendix-3 could be referred to. To ensure the reduction ratio,
macro-etching test will be conducted on the integral test piece (per heat) attached to
anyone of the forging.
2.1.3.4 All bearings shall be tested to 1.25 times design load. Recovery should be 100 per
cent. Contact surfaces and welding shall be examined by illumination
source/ultrasonic test/DPT for any defects/cracks etc.
2.1.3.5 All welding shall be checked by Dye Penetration Test. If specifically required by
Engineer, the X ray test may also be done.
2.1.3.6 Engineer may carry out the destructive testing of any component/components of
bearings supplied for conformity of test results submitted.
In case there is any major discrepancy regarding materials, Engineer may declare the
whole lot of bearings as unacceptable.
2.1.4 Placing and positioning the bearings
2.1.4.1 General considerations
On supporting structures, pockets shall be provided to receive the anchor bolts.
Appropriate method for leveling/grouting of the bearing to both beams and pedestal
structure shall be adopted. The pocket shall be filled with mortar of mix 1:1 and the
concrete bearing area. Also shall be finished level by a thin mortar pad of mix 1:1 just
before placing of bearing assemblies or bottom plate on the concrete seat.
2.1.4.2 Positioning of bearings
a) During installation the bearings shall be pre-set with respect to the bearing axis to
account for the movements due to the following:
 Temperature variation between the average temperature prevailing at the time
of installation and the mean design temperature.
 Shrinkage, creep and elastic shortening.
b) For bridges in gradient the bearing plates shall be placed in a horizontal plane.
2.1.4.3 Precautions during construction
a) In prestressed construction where launching of girders is employed, in order to
avoid slipping or jumping of rollers due to vibrations or jolts, it is suggested that

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 the roller bearings be provided after launching operations or otherwise adequate
measures taken to ensure that the roller assembly is not disturbed. It is normal
practice to provide rocker bearings on the launching end and place the beam on
the rocker end slightly in advance of placing on the roller.
b) During concreting of girders, the bearings shall be held in position securely by
providing temporary connection between the top and bottom plates in case of
fixed bearings, and between top plate, saddle plate and base plate in case of a
roller-cum-rocker bearing or by any other suitable arrangement which prevents the
relative displacement of the components. The bearing plate shall be kept level
during concreting.
c) In prestressed precast girders where recesses are left on the underside of girders to
receive the anchor bolts, grout holes extending to the beam sides or to the deck
level shall be provided. The grout shall have a mix of 1:1.
2.2 Elastomeric bearings
2.2.1 Fabrication
2.2.1.1 Bearing with steel laminates shall be cast as single unit in a mould and vulcanized
under heat and pressure. The mould will be kept at a uniform temperature for 15
minutes to ensure effective vulcanization of the bearing.
Casting of elements in separate units and subsequent bonding is not permitted, nor
shall cutting from large size cast be permitted.
2.2.1.2 Bearings of similar size to be used in particular bridge project shall be produced by
identical process and in one lot as far as practicable. Phased production may only be
resorted to when the total number of bearings is large enough.
2.2.1.3 The moulds used shall have standard surface finish adequate to produce bearings free
from any surface blemishes.
2.2.1.4 Steel plates for laminates shall be sand, blasted, clean of all mill scales and shall be
free from all contaminents prior to bonding by vulcanization. Rusted plates with
pitting shall not be used. All edges of plates shall be rounded.
2.2.1.5 Spacers used in mould to ensure cover and location of laminates shall be of minimum
size and number practicable. Any hole at surface or in edge cover shall be filled in
subsequently.
2.2.1.6 Care shall be taken to ensure uniform vulcanizing conditions and homogeneity of
elastomer through the surface and body of the bearing.
2.2.1.7 The bearings shall be fabricated with the tolerances specified in Table 01.

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 Table 01: Tolerances
S.No Items Tolerances
1. Overall plan dimensions (lo, bo) -0, +6 mm
2. Total bearing thickness (ho) -0, +5%
3. Parallelism
(a) Of top surface of bearing with respect to the bottom 1 in 200
surface as datum
(b) Of one side surface with respect to the other as datum 1 in 100
4. (a) Thickness of individual internal layer of elastomer (ht) ± 20 %
(max. of 2 mm)
(b) Thickness of individual outer layer (ho) -0, +1 mm
5. (a) Plan dimensions of laminates (l, b) -3 mm, +0
(b) Thickness of laminate ± 10 %
(c) Parallelism of laminate with respect to bearing base as 1 in 100
datum

2.2.1.8 The vulcanizing equipment/press should be such that between the plattens of the press
the pressure and temperature are uniform and capable of being maintained at constant
values as required for effecting an uniform vulcanization of the bearing.
2.2.1.9 The moulding dyes utilized for manufacturing the bearings should be so set inside the
platten of the press so that the pressure developed during vulcanization of the product
is evenly distributed and the thickness maintained at all places are within acceptable
tolerance limits taking into consideration, the shrinkage allowance of vulcanizate.
2.2.1.10 The raw compound which has been introduced inside the metal dies for
vulcanization, should be accurately weighed each time and it must be ensured that
sufficient quantity has been put inside the die for proper flow of material at every
place so that a homogeneous and compact bearing is produced without any sign of
spongyness or deficiency of material at any place.
2.2.1.11 Before any vulcanizate of any batch of production is used for producing vulcanized
bearings, test pieces in the form of standard slab and buttons should be prepared in
accordance with prescribed standards and salient properties tested and recorded
regularly against each batch of production to monitor the quality of the products.
2.2.2 Acceptance specification
2.2.2.1 The manufacturer shall have all test facilities required for process and acceptance
control tests installed at his plant to the complete satisfaction of the Engineer. The test
facilities and their operation shall be open to inspection by the Engineer on demand.
a) All acceptance and process control tests shall be conducted at the manufacturer’s
plant. Cost of all materials, equipment and labour shall be borne by the
manufacturer unless otherwise specified or specially agreed to between the
manufacturer and Engineer.
b) Acceptance testing shall be commenced with the prior submittal of testing
programme by the manufacturer to the Engineer and after obtaining his approval.

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 c) Any acceptance testing delayed beyond 180 days of production shall require
special approval of the Engineer and modified acceptance specification, if deemed
necessary by him.
d) All acceptance testing shall be conducted by the inspector with aid of the
personnel having adequate expertise and experience in rubber testing provided by
the manufacturer, working under the supervision of inspector and to his complete
satisfaction.
e) Lot by lot inspection and acceptance shall be made.
2.2.2.2 Acceptance lot
A lot under acceptance shall comprise all bearings, including the pair of extra test
bearings where applicable, of equal or near equal size produced under identical
conditions of manufacture to be supplied for a particular project.
a) The size and composition of acceptance lot shall be got approved by the Engineer.
b) For the purpose of grading levels of acceptance testing lots will be classified as
below:
 A lot size of 24 or larger number of bearings shall be defined as a large lot.
 A lot size of less than 24 bearings shall be defined as a small lot.
c) When the number of bearings of equal or near equal size for a single bridge
project is large and phased production and acceptance is permitted, the number of
bearings supplied in any single phase of supply shall compromise a lot shall be
considered as a large lot for the purpose of acceptance testing.
2.2.2.3 Levels of acceptance inspection
The level of acceptance testing shall generally be graded into Level 1 acceptance
testing and Level 2 acceptance testing depending on lot size:

a) Acceptance testing Level 1 is a higher level inspection and shall be applicable to

large lots only, unless otherwise specified. This shall involve manufacture of two
extra bearings for each lot to be used as test bearing and eventually consumed in
destructive testing.
b) Acceptance testing Level 2 shall be applicable to small lots only, unless otherwise
specified and shall not involve any destructive testing of finished bearings.
Acceptance inspection Level 1 may be specified at the sole discretion of the
Engineer, taking into account the special importance of bridge project, for small
lots also under the purview of special acceptance inspection. The cost of extra test
bearings, in such cases shall be borne by the user, while cost of all other materials,
equipment and testing shall be borne by the manufacturer.
2.2.3 Testing
Acceptance testing shall compromise:
 General Inspection
 Test on specially moulded test pieces

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  Test on complete bearings or sections for measurements of various quality
characteristics detailed below.
2.2.3.1 Acceptance Testing Level-1
a) General Inspection
 All bearings of the lot shall be visually inspected for absence of any defects in
surface finish; shape or any other discernible superficial defects.
 All bearings of the lot shall be checked for tolerances specified in Table 01.
 All bearings of the lot shall be subjected to an axial load correspond to σm = 15
Mpa applied in steps and held constant while visual examination is made to
check for discrernible defects like,
 Misalignment of reinforcing plates
 Poor bond at laminate/steel interface
 Variation in hi or he
 Any surface defects
 Low stiffness
Deflection under loads between σm = 5 Mpa and σm = 15 Mpa shall be
measured and recorded for all bearings with sufficient accuracy (± 5 percent).
Variation in stiffness of any individual bearing from the mean of the measured
values for all such bearings of the lot shall not be larger than 20 per cent (of
the mean value).
b) Tests on specially moulded test pieces
 Test pieces shall be moulded by the manufacturer with identical compound
and under identical vulcanizing conditions as used in the manufacture of the
bearings of the acceptance lot. The process shall be open to inspection by the
inspector or Engineer.
 Test pieces offered for inspection shall be identified by suitable markings and
duly certified by the manufacturer.
 The quality characteristics to be tested are listed below:
 Composition
 Hardness
 Tensile strength
 Elongation at break
 Compression set
 Accelerated ageing
 Adhesion strength
 Ozone resistance
Note 1: For acceptance testing Level 1, the ash content and specific gravity of
elastomer of test pieces from test pieces from test bearing shall be
compared with those for corresponding specially moulded test pieces

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 furnished by the manufacturer. The following variations shall be
deemed maximum acceptable.
Specific Gravity 0.2
Ash content ± 0.5
Hardness (as per table 1, item 1.1 of IRC: 83 Part II)
Tensile strength (table 1, item 1.2 of IRC: 83 Part II)
Elongation at break (table 1 item 1.3 of IRC: 83 Part II)
Compression set (table 1-2 of IRC: 83 Part II)
Accelerated ageing (table 1-3 of IRC: 83 Part II)
Adhesion strength (clause 915.2.2 of IRC: 83 Part II )
Note 2: Ozone resistance test can be waived by the Engineer for bearings of
CR, when satisfactory results of ozone resistance tests on similar grade
of elastomer may be available from process control records or
development test data furnished by the manufacturer.
Where such process control data are not available or the frequency of
testing not deemed adequate, ozone resistance test shall be mandatory
for acceptance of bearings of CR.
However, such tests may not be insisted for bearings not located under
adverse conditions of exposure and where the test on accelerated
ageing could be considered as adequate.
Process and acceptance control tests for ozone resistance by an
independent testing agency shall be acceptable.
c) Tests on complete bearings or sections
 Two bearings shall be selected at random from the lot as test bearings. These
bearings shall be excluded from the lot accepted.
 The following tests shall be conducted on test bearings :
 Test for determination of shear modulus
 Test for determination of elastic modulus (short term loading)
 Test for determination of adhesion strength
 Test for determination of ultimate compressive strength
The test specifications and acceptance criteria shall conform to those given in
Appendix 2 of IRC: 83 Part II.
2.2.3.2 Acceptance Testing Level-2
a) General Inspection
This shall conform to the provision given for Level 1 above in all respects.
b) Test on specially moulded test pieces
This shall conform to the provisions given for Level 1 in all respects.
c) Test on complete bearings

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 Test for determination of shear modulus shall be conducted using two bearings of
the lot selected at random and conforming to relevant provisions given for Level
1. These bearings shall however be part of the lot accepted.
2.2.3.3 Special acceptance inspection
a) Special acceptance inspection may compromise the following:
 Acceptance testing Level 1 for the small lots
 Acceptance testing by an independent external agency with separate or
supplemental test facilities provided by it.
 Acceptance testing on test pieces prepared from the surface or body of the test
bearings instead of specially moulded test pieces.
 Acceptance tests not covered by this code and according to the specifications
laid down by the Engineer.
b) Special acceptance inspection may be specified under the following conditions:
 Special contract agreement
 Unsatisfactory evidence of process or acceptance control
2.2.3.4 Inspection certificate
a) A lot under inspection shall be accepted by the inspector and so certified, when no
defect is found with respect to any of the quantity characteristics tested on
samples drawn from the lot according to specifications covering general
inspection and tests on specially moulded test pieces and on complete bearings.
In case of any bearing with defect, the lot shall be rejected by the inspector and so
certified.
b) In case any bearing is found defective to any quality characteristic, discovered by
general inspection; tests on specially moulded test pieces and complete bearings
as applicable, shall nevertheless be completed. If the said lot, rejected by general
inspection, satisfies the acceptance criteria in respect of these other tests, the lot
and individual bearings found defective shall be clearly identified in the
inspection certificate.
c) The manufacturer shall obtain from the inspector, immediately on completion of
his inspection, an inspection certificate which shall include the details of a lot or
lots accepted/rejected by him and records of all test measurements.
2.2.3.5 Quality control certificate
The manufacturer shall certify for each lot of bearing under acceptance:
 That an adequate system of continous quality control was operated in his plant.
 That the entire process remained in control during the production of the lot of
bearings under acceptance as verified from the quality control record/charts which
shall be open to inspection of the engineer/inspector on demand.
A certified copy of the results of process control testing done on samples of elastomer
used in the production of the lot shall be appended and shall include at least the
following information.

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 Composition of the compound raw elastomer and ash content, the grade of raw
elastomer used (include name, source, age on shelf), test results of hardness, tensile
strength, elongation at break, compression set, accelerated ageing, etc.
A higher level certification of the process quality control shall be called for at the sole
discretion of the Engineer in special cases e.g., where adequate historical information
about the process from acceptance inspection of bearings similar to those
compromising the lot under inspection produced in the same plant is not available
with the Engineer or in case of any evidence of process or acceptance control being
deemed unsatisfactory. The higher level certification shall comprise submittal of a
complete quality control report as given in Appendix 3 of IRC: 83 Part III,
supplementing the quality control certificate.
2.2.3.6 Acceptance
a) The manufacturer shall furnish the following to Engineer for the acceptance
judgment:
 Quality control certificate
 Inspection certificate
b) The manufacturer shall furnish any supplementary information on the system of
quality control and/or process and acceptance control testing as may be deemed
necessary by Engineer.
c) In case of any evidence of process or acceptance control testing being deemed
unsatisfactory by him, Engineer at his sole discretion may call for a special
acceptance inspection of the lot according to specifications laid down by him,
without any prejudice to his right to reject the lot. The entire cost of such
supplementary inspection shall be borne by the manufacturer.
d) Engineer shall be the sole authority for acceptance of a lot on scrutiny of the
certificates along with any supplementary evidence and complete satisfaction
therewith.
e) In case of rejection of a lot, Engineer shall reserve the right to call for special
acceptance inspection for the succeeding lots offered for inspection, according to
the specifications laid down by him. The entire cost of such tightened inspection
shall be borne by the manufacturer.
2.2.4 Certification and marking
2.2.4.1 Bearings shall be transported to bridge site after final acceptance by Engineer and
shall be accompanied by an authenticated copy of the certificate to that effect.
2.2.4.2 An information card giving the following details for the bearings, duly certified by the
manufacturer shall also be appended:
a) Name of manufacturer
b) Date of manufacture
c) Elastomer grade used
d) Bearing dimensions
e) Production batch no.
f) Acceptance lot no.

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 g) Date of testing
h) Specific bridge location, if any
i) Explanation of markings used on the bearing
2.2.4.3 All bearings shall have suitable index markings identifying the information given in
IRC: 83 Part II. The markings shall be made in indelible ink or flexible paint and if
practicable should be visible after installation. The top of the bearing and direction of
installation shall be indicated.
2.2.5 Installation
2.2.5.1 Care shall be taken in packing, transportation, storage and handling to avoid any
mechanical damage, contamination with oil, grease and dirt, undue exposure to
sunlight and weather.
2.2.5.2 Installation of multiple bearings one behind the other on a single line of support is not
permitted.
2.2.5.3 All the bearings installed along a single line of support shall be of identical
dimensions.
2.2.5.4 Bearings must be placed between true horizontal surfaces (maximum tolerance 0.2
percent perpendicular to load) and at true plan position of their control lines marked
on receiving surfaces (maximum tolerance ± 3 mm). Concrete surfaces shall be free
from local irregularities (maximum tolerance ± 1 mm in height).
Design shall be checked for the actual inclination in seating if larger inaccuracies than
those specified in IRC: 83 Part II are permitted.
2.2.5.5 For cast-in-place concrete construction of superstructure, where bearings are installed
prior to its concreting, the forms around the bearings shall be soft enough for easy
removal. Forms shall also fit the bearings snugly and prevent any leakage of mortar
grout. Any mortar contaminating the bearings during concreting shall be completely
removed before setting.
2.2.5.6 For precast concrete or steel superstructure elements, fixing of bearing to them may
be done by application of epoxy resin adhesive to interface, after specified surface and
preparation. The specifications for adhesive material, workmanship and control shall
be approved by the Engineer. Care shall be taken to guard against faulty application
and consequent behavior of the adhesive layer as a lubricant. The bonding by the
adhesive shall be deemed effective only as a device for installation and shall not be
deemed to secure bearing against displacement for purpose of design.
2.2.5.7 As a measure of ample safety against accidental displacement, the bearings shall be
placed in a recess as shown in Fig.01 (this provision shall not be deemed to secure
bearings against displacement for the purpose of design).

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 Fig.01: Pedestal for elastomeric bearing
2.2.6 Tests on completely bearings or sections
a) All tests shall be conducted on test bearings (or sections taken therefrom) chosen
at random from the lot under acceptance testing.
b) All testing shall be conducted by skilled personnel under competent supervision
with adequate experience in rubber testing, to the complete satisfaction of the
inspector.
c) All testing shall be done at room temperatures.
d) No bearings shall be tested earlier than a week after vulcanization.
e) Bearing sections shall be cut from test bearings without overheating the rubber
and with smooth cut square edges and no after treatement of the section shall be
permitted.
f) Test for determination of Es may precede that of G, when both tests are conducted
on the same pair of test bearings.
g) All details of test equipment and method shall be furnished with the submittal of
the acceptance testing program as given in IRC: 83 Part II.

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2.2.6.1 Test for determination of shear modulus
a) Scope
The test shall determine the value of shear modulus G under specified short term
loading.
b) Test Piece
Two test bearings
c) Test Procedure
 Test assembly : as in Fig.02.
 Conditioning load: Bearings shall be preloaded with maximum horizontal
load Htest (with Ntest held constant) and unloaded before test loading.
 Rate of loading: Ntest corresponding to σm = 5 Mpa shall be held constant
during test and the horizontal loading H shall be gradually increased to yield a
shear stress rate of approximately 0.05 to 0.1 MPa per minute.
 Maximum test loading Htest: The horizontal loading H shall be increased
upto a maximum Htest which corresponds to horizontal deflection equal to h.
 Measurement : Load and deflection measurements shall be made at
approximately equal intervals not less than 5.

Fig.02: Test assembly

2.2.6.2 Evaluation
a) A shear stress strain curve shall be plotted and the value of shear modulus G
determined as shown in Figure 03.
b) The test result shall be deemed-satisfactory if G determined is within ± 20% of 1
MPa and provided there is no evidence of instability, defect or damage discovered
by close inspection during the test.
Note: For level 2 acceptance testing, the test bearings used for this test shall not be
excluded from the lot under acceptance.

15
 Fig.03: Shear stress strain curve and G
2.2.6.3 Test for determination of elastic modulus
a) Scope
The test shall determine the value of apparent elastic modulus Ea under specified
short term axial loading.
b) Test piece
Two test bearings.
c) Test procedure
 Test assembly as shown in Figure 04.
 Conditioning load: Bearing shall be preloaded upto Ntest. The load shall be
retained for 10 minutes and unloaded up to σm = 2 MPa before test loading.
 Rate of loading: The axial load N is increased gradually at a rate yielding
approximately σm = 0.5 MPa to 1 MPa per minute.
 Maximum test loading Ntest.
Maximum test loading shall correspond to σm = 20 MPa
 Measurement : Load and deflection measurements shall be made in
approximately equal load intervals not less than 5. Deflection shall be
measured at four edges and mean value accounted for.
d) Evaluation
A compressive stress strain curve shall be plotted and the value of apparent elastic
modulus Ea shall be determined as shown in Figure 05.
e) Acceptance criteria
Test result shall be deemed satisfactory if Ea determined is within ± 20 percent of
1/(0.2/S2 + 0.0005) and provided there is no evidence of any defect or damage
discerned by close visual inspection during the test.

16
 Fig.04: Test assembly

Fig.05: Compressive stress strain curve and Ea

2.2.6.4 Test for determination of stripping strength
a) Scope
This test shall determine whether requisite adhesion exists between the elastomer
and steel laminate.

17
 b) Test piece
Two identical test pieces shall be cut from the test bearing. The plan dimensions
of each test piece shall not be less than 100 mm X 200 mm, Figure 06.
Two opposing ends of each test piece shall be beveled to an angle of 45 degree.
c) Test procedure
 Test assembly : as shown in Figure 06.

Fig.06: Determination of adhesion strength

 Maximum test loading: Ntest corresponding to a σm = 4 MPa is to be held
constant during the test.
 The horizontal loading H shall be increased gradually upto a maximum
yielding τ = 3 MPa.
d) Evaluation
Examine the test pieces for evidence of cracking or peeling both in the strained
and unstrained state.
e) Acceptance criteria
If neither test piece shows evidence of peeling or separation at or near the
interface between rubber and reinforcement layers the bearing shall be deemed to
have satisfactory adhesion.
2.2.6.5 Test for determination of ultimate compressive strength
The test pieces are to be loaded either till the failure of the steel laminate or till the
irreversible squeezing out of elastomer whichever is earlier. The test assembly and the
test pieces may be identical to that for test for determination of shear modulus.
However, a small section (not less than 100 X 200 mm) cut from test bearing and
testing to failure by placing directly between the plates of the testing machine shall
also be permitted. The rate of loading shall not exceed 10 MPa per minute. The result
of the test shall be deemed satisfactory if the σm at failure is not less than 60 MPa.

18
2.2.7 Quality control report
2.2.7.1 Where deemed necessary and so demanded specifically by the Engineer, the
manufacturer shall furnish to him a complete report on the process quality control
compromising the following:
a) A general description of the system of quality control including sampling, testing
and quality control records and/or charts used.
b) Test results for the quality characteristics mentioned above.
c) The information shall pertain to a period not less than 180 days of production of
the same grade of elastomeric and the type of bearings as under acceptance.
d) Engineer shall reserve the right to call for the above report at any stage of
acceptance inspection, before and after acceptance testing.
2.2.7.2 Mean, standard deviation, range and minimum values of the following characteristics
shall be reported for the period of report mentioned above.
a) Composition (raw elastomeric and ash content)
b) Hardness
c) Tensile Strength
d) Elongation at break
e) Compression set
f) Accelerated ageing
g) Shear modulus
2.2.7.3 The test methods shall conform to those mentioned above.
2.2.7.4 The results reported shall be based on random sampling. In case of more than one test
measurement of any characteristics from a single batch, their mean value shall only be
taken into account as representative of the batch.
The test results reported shall represent a grand lot comprising not less than 50
separate inspection lots.
2.2.7.5 Results of ozone resistance tests and frequency of testing shall be reported.
Reports of any other control tests conducted on moulded samples of finished bearings
may also be reported.
3. Fabrication, testing and installation of expansion joints
3.1 Fabrication
3.1.1 Buried joint
3.1.1.1 General
a) This joint shall consist of continuously laid bituminous/asphaltic surfacing over
the joint gap bridged by a steel plate resting freely over the top surface of the deck
concrete.
b) The width of the joint gap shall be kept as 20 mm.

19
 c) The steel plate shall be 12 mm thick and 200 mm wide. The plate shall be made of
minimum number of pieces (not exceeding two pieces per traffic lane width)
welded together to form the required length.
d) 8 mm dia., 100 mm long nails, spaced at 300 mm centres along the centre line of
the plate shall be welded to the bottom surface of the steel plate to protrude
vertically into the joint gap in order to prevent dislodging of the plate.
e) The concrete surface shall be free from any loose material and cleared of any
grease, oil, paint, etc. and the surface shall be sand blasted, clean of all laitance
and level true prior to placement of the steel plate.
f) The plate shall be placed symmetrical to the centre line of the joint and it shall be
ensured that the plate does not get displaced from its position while laying the
wearing course.
3.1.1.2 Material
a) The steel for plate and nails shall be weldable structural steel conforming to IS:
2062.
b) The plate and the nails shall be protected against corrosion by galvanizing or any
other approved anti-corrosive coating with a minimum thickness of 100 micron.
These shall be completely free of oil, rust, loose paint or other similar material
before application of anti-corrosive coating.
3.1.2 Filler joint
3.1.2.1 The components of this type of joint shall be atleast 2 mm thick corrugated copper
plate placed slightly below the wearing coat, 20 mm thick compressible fibre board to
protect the edges, 20 mm thick pre-moulded joint filler filling the gap upto the top
level of the wearing coat, sealed with a joint sealing compound.
3.1.2.2 The material used for filling expansion joint shall be bitumen impregnated felt,
elastomer or any other suitable material, as specified on the drawings. Impregnated
felt shall conform to the requirements of IS: 1838. The joint filler shall consist of
large pieces.
Assembly of small pieces to make up the required size shall be avoided.
3.1.2.3 Surfaces of the joint grooves shall be thoroughly cleaned with a wire brush to remove
all loose materials, dirt and debris, then washed or jetted out.
3.1.2.4 Pre-moulded expansion joint filler shall not be placed in position until immediately
prior to the placing of the abutting material. If the two adjacent surfaces of the joint
are to be placed at different times, this type of joint filler shall not be placed until the
second face is about to be placed.
3.1.3.5 Sealants shall be finished approximately 3 mm below the upper surfaces of the joint.
3.1.3 Asphaltic plug joint
This joint shall consist of a polymer modified bitumen binder, carefully selected
single size aggregate, closure/bridging metallic plate and heat resistant fom
caulking/backer rod.

20
3.1.3.1 General
a) The joint shall extend to the full depth of the wearing course down to structural
concrete. Where needed, a recess may be cut into the deck slab concrete to
accommodate the minimum required depth (75 mm) of the joint.
b) The joint shall be provided over the entire width of the structure including kerb
and/or footpath. A recess in the kerb and/or footpath shall be made to allow the
joint to pass beneath them. The expansion gap in the adjoining kerbs and/or
footpaths shall be sealed with a suitable sealant such as polysulphide sealant.
c) Asphaltic Plug joint may be used to carter for a maximum horizontal movement
upto 25 mm and maximum vertical movement of 2 mm. This shall be certified by
the manufacturer/supplier of the joint.
d) The minimum width (in traffic direction) of the joint shall be 500 mm and
maximum width shall be 750 mm.
e) Minimum depth of joint shall be 75 mm and maximum depth shall not exceed 100
mm.
f) The joint shall be capable of performing satisfactorily within the temperature
(ambient) range of -5 to 50 degree Celsius.
3.1.3.2 Material
a) Binder
The polymer modified bitumen binder shall have the capacity to fill the gaps and
voids between single size aggregate and to impart flexibility to accommodate
various design movements. It shall be a patented blend of bitumen, synthetic
polymer, fillers and surface active agent and shall be so formulated as to combine
necessary fluidity for the installation process, low temperature flexibility and flow
resistance at high ambient temperatures. The binder shall satisfy the following
requirements:
Softening point: 100 oC minimum,
Core penetration at 25 oC, 0.1 mm (BS 2499): 100 mm max.,
Flow resistance at 70 oC, 5 hours (BS 2499): 3 mm max.,
Extension test (blocks prepared as per ASTM D 1190 and tested to limits as
per BS 2499):
5 cycle of extension to 50 % at a rate of 3.2 mm/hour at 25 oC.
Safe heating temperature: 210 oC.
b) Aggregates
The aggregate shall be single size aggregate chosen from basalt, granite, grit stone
or gabro group. The nominal size of aggregate shall be 12.5 mm for depths of
joints upto 75 mm and 20 mm for joints of more depths. The aggregate shall not
be flaky and the flakiness index shall not be more than 25 percent. The aggregate
shall satisfy grading requirements stipulated in Table 02.

21
 Table 02: Grading requirements of aggregates
Nominal size of Aggregates
IS Sieve Designation 20 mm 12.5 mm
Percentage by weight passing the sieve
26.5 mm 100 -
19.9 mm 85 – 100 100
13.2 mm 0 – 35 85 – 100
09.5 mm 0–7 0 – 35
06.3 mm - 0–7
02.3 mm 0–2 0–2
600 micron - -
75 micron 0–1 0–1

The aggregates should have good:

 Polished Stone Value (PSV)
 Aggregate Abrasion Value (AAV)
 Aggregate Impact Value (AIV)
 Aggregate Crush Value (ACV)
In addition, surface characteristics should promote proper adhesion. The following
are the required values:
PSV > 60,
AAV < 05,
AIV < 18,
ACV = 10 – 25
c) Closure plate
The closure plate shall be weldable structural steel conforming to IS: 2062. The
minimum thickness of steel plate shall be 6 mm and the width shall not be less
than 200 mm. Closure plate shall be provided with as large length as possible and
welded together to form the required length. The number of pieces shall not be
more than two per traffic lane width. It shall be provided with equidistant holes at
a maximum spacing of 300 mm centres for anchorage to the caulking/backer rod
along the longitudinal centre line of the plate. The plate shall be protected against
corrosion by galvanizing or any other approved anti -corrosive coating paint with
a minimum thickness of 100 micron.
d) Foam caulking/backer road
A closed cell polyolefin or open cell polyurethane foam cylindrical caulking or
backer rod having diameter equal to 150 percent of the joint opening shall be
provided. It shall be heat resistant and possess good flexibility and recovery
characteristics with density of 25 to 30 kg/m3.
3.1.4 Single strip/box seal expansion joints

22
3.1.4.1 General
a) Edge beam
This shall be either extruded or hot rolled steel section including continuously
shop welded section with suitable profile to mechanically lock the sealing element
in place throughout the normal movement cycle. Further, the configuration shall
be such that the section has a minimum thickness of 10 mm all along its cross-
section (flange and web). Thickness of lips holding the seal shall not be less than 6
mm. The minimum height of the edge beam section shall be 80 mm. The
minimum cross sectional area of the edge beam shall be 1500 mm2.
b) Anchorage
The edge beams of single strip/box seal joints shall be anchored in the concrete
with rigid loop anchorage or headed shear stud anchors. In case of headed shear
stud anchors it is to be ensured that the studs are anchored in concrete adequately
reinforced around the studs and are not in plane concrete shoulders. The
anchorage system shall satisfy the requirement as given in following section. The
anchor loops shall be connected to the edge beam by means of anchor plates
welded to the edge beam. Total cross sectional area of anchor loop or headed
shear studs on each side of the joint shall not be less than 1600 mm 2 per meter
length of the joint and the centre to centre spacing shall not exceed 250 mm for
loop anchors and 150 mm for headed shear studs. The thickness of anchor plate
shall not be less than 0.7 times the diameter of anchor loop or 12 mm whichever is
higher. The anchor at the edge profiles should be at a right angle to the joint.
Planned deviations of this direction are allowable only for the range of 90 o +/- 20
o
. (The anchoring reinforcement of the construction must lie parallel to the anchor
loops).
c) Sealing element
This shall be a preformed/extruded single strip of such a shape as to promote self-
removal of foreign material during normal joint operation. The seal shall possess
high tear strength and be insensitive to oil, gasoline and ozone. It shall have high
resistance to ageing. The specially designed proprietary type of locking system of
seal in the housing of edge beam shall be such to ensure 100 percent water
tightness as well as ease of installation and replacement. Mechanical fastening of
sealing element with edge beam shall not be permitted. Sealing element shall be
continous over the entire joint.
3.1.4.2 Material
a) The steel for edge beam shall conform to any of the steel grade equivalent to RST
37-2 or 37-3 (DIN), S235JRG2 or S355K2G3 of EN10025 (DIN 17100), ASTM
A 36 or A 588, CAN/CSA Standard G40, 21 grade 300 W or grade B of IS 2062.
For subzero condition, material for steel shall conform to IS 2062 Grade C.
b) The sealing element shall be made of chloroprene rubber (CR). The properties of
the material shall be as specified in Table 7.4.2.2.1 of IRC: SP: 69 for CR.
c) All steel sections shall be protected against corrosion by one of the following two
methods :-
 Hot dip galvanizing with a minimum thickness of 150 micron,

23
  Epoxy coating: All surfaces of the steel inserts and anchorage including the
surfaces to be in contact with or embedded in concrete shall be sand/shot
blasted to SA 2.5 and provided with a coat of epoxy primer enriched with
metallic zinc. Surfaces not to be in contact with or embedded in concrete shall
be provided with an additional coat of epoxy primer enriched with metallic
zinc, one intermediate coat of high build epoxy paint reinforced with MIO
(micaceous iron oxide) and one coat of high performance epoxy finish paint as
per paint manufacturer’s specification with a minimum total dry film thickness
of 150 micron.
d) Anchorage steel shall conform to grade B of IS: 2062 or equivalent standard.
e) Joints for which the gap width does not close fully, the movement capacity shall
be (80-minimum opening) i.e., the capacity of the joint having a minimum
opening gap width of 20 mm will be 60 mm. Only for joints that close fully, the
movement capacity of joint shall be 80 mm.
f) Minimum gap for inserting the chloroprene seals in the expansion joint shall be 25
mm.
3.2 Testing
3.2.1 This section of the guidelines is aimed to lay-down the pre-installation criteria of
acceptance based on predetermined methods of evaluation including testing of
materials.
3.2.2 Before installing joints in a bridge, sufficient evidence of the reliability of the
proprietary products must be furnished. A copy of the fatigue and wear test reports, as
applicable depending upon the type of joint, carried out by a recognized
laboratory/university/institute on the joint components as a part of product
development test shall be furnished once for the entire lot of supply. The tests covered
in clause 3.2.2.1 to 3.2.2.5 below need not be carried out on the materials of the joints
of supply lot but should be carried out from time to time by the original manufacturer
as per their product development and quality plan for the same type of joints to ensure
the performance requirement of the particular joint component against fatigue and/or
wear.
3.2.2.1 For single strip seal, modular strip seal and finger joints the manufacturer shall
produce complete report of the test of anchorage system in a recognized laboratory to
determine the optimum configuration of anchorage assembly under dynamic loading
in support to the efficacy of the anchorage system adopted for the joints of entire lot
of supply.
3.2.2.2 For modular strip seal joints, the manufacturer shall produce a test report from a
recognized laboratory that the sliding bearings have been fatigue tested for 6 x 10 6 (6
million) load cycles with a frequency of 5 Hz. The durability test should be carried
out for 3 loads levels viz., 80 kN, 120 kN and 160 kN.
3.2.2.3 For modular strip seal joints, the manufacturer shall produce a test report from a
recognized laboratory that the wearing of sliding interface of bearings of modular
joints has been tested for a total sliding distance of 5000 m at a load of 48 kN.
3.2.2.4 For modular strip seal joints, the manufacturer shall produce a test report from a
recognized laboratory that the sliding material of sliding springs of expansion joints
has been tested for a total sliding distance of 20,000 m with a load equivalent to a
stress of 30 MPa.

24
3.2.2.5 For modular strip seal joints, the manufacturer shall produce a test report from a
recognized laboratory that the butt-welded splicing of centre beams has been tested
with 2 x 106 (2 million) load cycles with a frequency of 5.55 Hz and a load equivalent
to a stress of 165 MPa.
3.2.2.6 In case of reinforced elastomeric joints/reinforced coupled elastomeric joints, abrasion
resistance test shall be carried out in accordance with IS: 3400 (Part 3) or DIN 53516.
3.2.2.7 An expansion joint assembly in a bridge deck shall have minimum number of joints,
subject to the manufacturer’s specification for the proprietary products.
3.2.3 Pre-installation criteria
The pre-installation criteria should include the following off-site tests.
3.2.3.1 Routine tests
Routine tests including tests for materials conforming to specifications shall be
carried out by the original manufacturer i.e., in case of imported joints by the foreign
manufacturer as part of their quality control procedure for all joints to be supplied by
them. Detailed documentation of all the tests and inspection data as per complete
quality control procedure shall be supplied by the original manufacturer in the form of
quality control report. Routine tests shall primarily include:
 Raw materials inspection
 Process inspection
 Complete dimensional check as per approved drawings
a) Raw material inspection
Tests on all raw materials used for the manufacturing of joints as per relevant
material standards based on this specifications shall be carried out by the
manufacturer.
- Confirmation of the grade of steel
Grade of the steel for the edge beam should be confirmed by the conducting
tests for yield stress, tensile strength, elongation, etc. corresponding to RST
37-2 or 37-3 or 52-3 (DIN), S235 JRG2 or S355K2G3 of EN10025 (DIN
17100), ASTM A36 or A 588, CAN/CSA standard G 40. 21 grade 300W or
equivalent to grade B of IS: 2062. The manufacturers/suppliers shall have in-
house testing facilities for conducting these tests.
- Steel for the anchorage should conform to IS: 2062 for single gap strip seal
joints.
- The following tests as indicated in table 7.4.2.2 (of IRC: SP: 69) should be
made for checking the properties of the chloroprene seal:
 Hardness
 Tensile strength
 Elongation at fracture
 Tear propagation strength
 Residual compressive strain

25
  Change in hardness
 Change in tensile strength
 Change in elongation at fracture
 Ageing in ozone and
 Swelling behavior in oil
The manufactures/suppliers shall have in house testing facilities for
conducting these tests.
b) Process inspection
Process inspection generally including inspection of all manufacturing processes
adopted to manufacture the joints e.g., welding, corrosion, protection, clamping,
presetting, greasing, bonding by adhesives, riveting, etc., as appropriate, shall be
carried out by the manufacturer.
c) Complete dimensional check
Complete dimensional check of all components of joint as well as the assembled
joint with respect to the approved drawings and tolerances as per this
specification, shall be carried out by the manufacturer.
3.2.3.2 Acceptance tests
In addition to the tests specified under clause 8.3.1.1 of IRC: SP: 69, the manufacturer
as well as the local supplier in case of imported joints should have complete in house
testing facilities the following tests. These tests, as applicable (table 8.3.3 of IRC: SP:
69), shall be carried out by the manufacturer once in every six months and records
shall be maintained. Test specified in clause 8.3.2.5 of IRC: SP: 69 should however be
carried out on modular strip/box seal joint at least once which shall be certified by an
external institute/university of international repute. The client should insist upon these
records before acceptance of the joint.
a) Cyclic motion
Cyclic motion test maybe carried out once on one meter sample piece selected at
random from the entire lot of supply for each type of joint irrespective of
movement capacity. The test sample shall be fixed to the test frame using
fastening bolts and subjected to 5000 expansion and contraction cycles @
minimum 30 cycles per hour. The test movement shall be 10 percent more than
the design/contraction movement. Any sign of distress or permanent set of any
component or the assembly due to fatigue will cause rejection of entire lot of
supply.
b) Ponding
Water shall be continuously ponded along one meter length of joint for a
minimum period of 4 hours for a depth of 25 mm above the highest point of joint
top. The width of ponding shall be at least 50 mm beyond the anchorage block of
the joint on either side. The depth of water shall not fall below 25 mm anytime
during the test. A close inspection of the underside of the joint shall not reveal any
leakage.

26
 c) Debris expelling test
Debris expelling test shall be carried out on one meter sample piece selected at
random from the entire lot of supply. The fully open gap shall be filled with
granular debris flush with joint top and cycled 25 times for full opening and
closing. The mass of debris repelled after 25 cycles shall be expressed as the
percentage of initial mass. The percentage expelled shall not be less than 75
percent.
d) Pull out test
Pull out test shall be carried out on one meter sample piece selected at random
from the entire lot of supply. The joint shall then be stretched until the sealing
element slips off from its housing. The minimum stretching of the joint before slip
off shall be at least 150 percent of the rated movement capacity of the seal.
e) Opening Movement Vibration (OMV) test
The opening movement vibration (OMV) test is designed to test the ability of the
modular expansion joint to withstand the repeated movement demands of the
bridge superstructure while being subjected to a simulated traffic load. The OMV
test simulates the most common movement of the joint, the movement due to the
daily thermal expansion and contraction of the superstructure by opening and
closing the expansion joint with an actuator. Traffic loads are simulated by
attaching a powerful pneumatic vibrator to one of the lamella/centre beams. This
test shall be carried out in accordance with NCHRP Report 467. The joint should
be tested for the equivalent of 75 years of 365 daily thermal cycles.
f) Arrangement for protection of steel sections against corrosion should be checked.
3.2.3.3 Applicability of acceptance tests on different types of joints
The acceptance tests described in this clause shall be applicable as per Table 03 for
different types of joints.
Table 03: Applicability of acceptance tests on different types of joints
Performance Evaluation Buried Joint/ Filler Single Gap Strip/ Modular Strip/
Tests Joint/ Asphaltic Plug Box Seal Joint Box Seal Joint
Joint
Cyclic Motion Not Applicable Applicable Applicable
Ponding Not Applicable Applicable Applicable*
Debris Expelling Test Not Applicable Applicable Applicable*
Pull out Test Not Applicable Applicable Applicable*

* For modular strip seal expansion joint ponding test, debris expelling test and pull-
out test shall be carried out on one meter edge beam samples only, complete with
sealing element and anchorage.
Note: Since the above mentioned joints are proprietary products, clients may like to
ensure a suitable specified minimum guarantee period for joints considering overall
service life of structure.

27
3.3 Installation
3.3.1 This section serves as general guidelines for installation of Expansion Joints.
Expansion Joints should always be installed under thorough supervision of the
manufacturer’s/suppliers engineer in order to ensure the quality of installation so that
expansion joints function as intended during their entire life span. Detailed installation
manual should be supplied by the joint manufacture.
3.3.2 The design of an expansion joint is performed by determination of the extreme values
of the expected movements and the position of installation. The installation data
depends on the planned construction sequence.
3.3.3 Taking the width of gap for movement of the joint into account, the dimensions of the
recess in the decking shall be established in accordance with the drawings or design
data of the manufacturer.
3.3.4 Detailing of structure should be done with due consideration of the type of joints,
movement capacity, presetting detail, recess dimension required for installation,
requirement of reinforcements and its detailing to avoid removing or cutting off
interfering reinforcing bars during installation.
3.3.5 The presetting of expansion joint may be done by means of an auxiliary construction.
3.3.6 it is recommended to lay the road surfacing/wearing coat before commencing
installation of joint. Before laying the wearing coat, the recess portion shall be filled
with sand and wearing coat shall be laid in a continous manner over the deck slabs
and recess portion. Prior to the installation of the joints, portion of wearing coat over
the recess shall be removed by a suitable method e.g., saw cutting and the infill sand
shall be removed subsequently.
3.3.7 Preparation of the recess
The recess must suit in size and form to the geometry of the expansion joint.
However, the width shall not be less than the specified value for a particular type of
joint. In order to avoid difficulties during installation, the following points must be
checked and considered:
 Dimension check of recess
 Check of the levels
 Check of the skew and slope
 Check of the designed gap between bridge deck and abutment and/or between
adjoining decks
 Checking of the existing structural reinforcement according to the drawings
Missing rebars must be replaced by inserting bars penetrating sufficiently deep into
the concrete. Rebars that would obstruct the installation of the expansion joints should
be bent to accommodate the expansion joint anchorages. Removing or cutting off
interfering reinforcing bars shall only be done after consultation with the Engineer-in-
charge.
The recess shall be cleaned thoroughly. If necessary, the surface should be roughened.
All loose dirt and debris shall be removed by wire brushing, air blowing and dried
with hot compressed air.

28
3.3.8 Shuttering
Shuttering must be used to seal the space between the underside of the joint and the
vertical face of the recess. The shuttering must be fitted in such a way that it forms an
appropriate seal against the edge of the recess. The recess shall be shuttered in such a
way that dimensions in the drawing are maintained. The formwork shall be rigid and
firm.
3.3.9 Placing in the recess
Level marks must be set next to the recess by the installation engineer. This enables a
controlled leveling of the expansion joint. Lowering the expansion joint/joint
construction/insert etc. into the recess should be done in such a way that the entire
length of the joint is evenly lowered into the recess. Thereafter, the joint/joint
construction/insert is precisely leveled and adjusted in the longitudinal, transverse and
vertical planes. If required, the joint/joint construction/insert must also be adjusted to
the gradient of the final surface level. As soon as the joint/joint construction/insert is
accurately placed, the engineer-in-charge shall provide a written confirmation of the
correct placement of the same.
3.3.10 Connecting
3.3.10.1 It is recommended to install the expansion joint/joint construction/insert in the early
morning when the temperature is distributed almost uniformly over the whole
bridge. Immediately before the installation, the actual temperature of the bridge
should be measured. If it is not within the considered tolerance, the present
adjustment must be corrected. The joint/joint construction/insert shall be lowered in
a predetermined position. Following placement of the joint/joint construction/insert
in the prepared recess, the joint/joint construction/insert shall be leveled and finally
aligned and the anchorage steel on one side of the joint welded to the exposed
reinforcement bars of the structure. Upon completion, the same procedure shall be
followed for the other side. With the expansion joint/joint construction/insert finally
held at both sides, the auxiliary brackets shall be released, allowing it to take up the
movement of the structure. After carrying out the final fixing, the protection against
corrosion is completed.
3.3.10.2 For fully assembled joints with one end fixed and other end movable eg., modular
strip/box seal joint, connection is detailed below:
The 1st Side
The fixed side of the assembled joint (either the abutment or the bridge deck side) is
designated the 1st side for connecting the joint. The preliminary fixing is made by
evenly placing and then welding the rebars over the entire length between the
anchor loops and the deck reinforcement. To facilitate concreting, it is
recommended that the gap between recess and shuttering is sealed by a grout seam.
The seam must be left to dry prior to final concreting. After this, additional rebars
are welded until all anchor loops are firmly connected to the deck reinforcement.
The expansion joint is sufficiently fixed when no vibrations are noted on lightly
bouncing on the joint.
The extent of the fixing of the expansion joint described above is not designed to
accept dynamic load from traffic. It serves only to firmly pin the expansion joint in
the recess until the concrete has been poured and sufficiently cured. It is, therefore.

29
 vital that the expansion joint is not subjected to any loads that could in any way
displace the precise location of this fixing.
The 2nd Side
Depending on the size of the expansion joint and the expected movement during the
installation, the most suitable time must be determined for the fixing of the 2nd
(moveable) side. Usually this is the early morning hours with the smallest
temperature deviations. The procedure is identical to that at the 1st side. As fast as
possible, preferably with several fitters at the same time, the joint is provisionally
fixed to the reinforcement.
Immediately afterwards, the fixation brackets must be removed. The expansion joint
can now follow the longitudinal movement of the bridge.
Thereafter, the gap between recess and shuttering should be sealed with grout seam
and the remaining rebars should be welded as described previously.
3.3.11 Concreting
3.3.11.1 Prior to final concreting, the position of the joint/joint construction/insert must be
recorded. The Engineer-in-charge must give written confirmation of the correct
position of the joint and the recess concreting. The recess must be thoroughly
watered. This prevents too much water draining from the fresh concrete. Before
pouring the concrete, the joint construction should be protected by a cover.
Controlled concrete having strength not less than that in superstructure subject to
the minimum of M 35 shall be filled into the recess. The water cement ratio shall
not be more than 0.4, if necessary and admixtures may be used to improve
workability. The filling concrete must feature low shrinkage. Good compaction and
careful curing of concrete is particularly important. The freshly placed concrete is to
be properly vibrated. Damage to the shuttering must be avoided during vibration.
The filling concrete must be finished flush with the carriageway surfacing. It is
recommended that the concrete is kept damp until it has cured in order to avoid
fissures caused by drying too fast. After the concrete has cured, the movable
installation brackets and shuttering still in place shall be removed.
3.3.11.2 For modular strip seal joint the space beneath the joist boxes must be completely
filled with concrete. This ensures that traffic loads are safely transmitted onto the
structure. Incorrectly placed concrete and/or cavities beneath the joist boxes will
lead to damage of the joint.
3.3.12 As soon as the concrete in the recess has become initially set, a sturdy ramp shall be
placed over the joint to protect it from site traffic.
3.3.13 The elastomeric sealing element may be field installed. For strip seal and modular
strip seal joints, the sealing element should be in continuous lengths spanning the
entire roadway width. Proper fit of the seal of the sealing element must be ensured.
The seal shall be installed without any damage to the seal by suitable hand method or
machine tools.
3.3.14 Specific procedure for asphaltic plug joint
3.3.14.1 The recess in the deck slab, if required, shall be repaired with epoxy mortar and
cleaned and dried again.
3.3.14.2 The foam caulking/backing rod shall be placed about 25 mm down into the joint
opening.

30
3.3.14.3 The aggregate shall be washed, cleaned and heated to a temperature between 120-
180 oC prior to placement.
3.3.14.4 The binder shall be preheated to temperature of 170-190 oC before application.
3.3.14.5 While sealing the joint opening with preheated binder, care shall be taken that the
binder does not spill on to the joint surface of the deck.
3.3.14.6 The joint shall not be installed when the ambient temperature goes below +5 oC or
above + 35 oC or while it is raining/snowing (planning for installation must take into
account the weather condition).
3.3.14.7 When element weather resumes, the joint installation may be continued after the
upper layer and/or exposed surface of the partially completed joint has been
prepared by heating and/or coating with binder as necessary.
3.3.16 Specific procedure for single strip/box seal joint
3.3.16.1 Taking the width of gap for movement of the joint into account, the dimensions of
the recess in the decking shall be established in accordance with the drawings or
design data of the manufacturer.
3.3.16.2 The recess shall be shuttered in such a way that dimensions in the joint drawing are
maintained. The formwork shall be rigid and firm.
3.3.16.3 Immediately prior to placing the joint, the presetting shall be inspected. Should the
actual temperature of the structure be different from the temperature provided for
presetting, correction of the presetting shall be done. After adjustment, the brackets
shall be tightened again.
3.3.16.4 To ensure proper fit of the seal and enchance the ease of installation, dirt, spatter or
standing water shall be removed from the steel cavity using a brush, scrapper or
compressed air.
3.3.16.5 The actual junction of the surfacing/wearing coat with the block out concrete/steel
edge section shall be formed by a wedge shaped joint with the sealing compound.
The horizontal leg of the edge beam shall be cleaned beforehand. It is particularly
important to ensure thorough and careful compaction of the surfacing in order to
prevent any premature depression forming in it.

31
4. Laboratory testing
COARSE AGGREGATES
Test Reference Code
Particle Size and Shape IS: 383
i. Sieve Analysis IS: 2386 (Part-I)
ii. Flakiness Index and Elongation Index
Deleterious Materials IS: 383
IS: 2386 (Part-II)
Specific Gravity and Density IS: 383
IS: 2386 (Part-III)
Mechanical Properties IS: 383
i. Aggregate Crushing Value IS: 2386 (Part-IV)
ii. Impact Value

iii. 10 Percent Fines

iv. Abrasion Value
Soundness IS: 383
IS: 2386 (Part-V)
Surface Moisture Content IS: 383
IS: 2386 (Part-III)
Alkali Reactivity IS: 383
IS: 2386 (Part-VII)
Petrographic Examination IS: 383
i. Trade Group IS: 2386 (Part-VIII)
ii. Petrological name and Description
iii. Description of Bulk
iv. Particle shape
v. Surface texture

FINE AGGREGATES
Test Reference Code
Particle Sizes IS: 383
IS: 2386 (Part-I)
Deleterious Materials IS: 383
IS: 2386 (Part-II)
Silt Content IS: 383
IS: 2386 (Part-II)
Specific Gravity and Density IS: 383
IS: 2386 (Part-III)
Water absorption IS: 383
IS: 2386 (Part-III)
Soundness IS: 383
IS: 2386 (Part-V)

32
WATER
Test Reference Code
Chemical Analysis
i. pH value IS: 456
ii. Chlorides (as Cl) IS:3025(Part24)
iii. Sulphates (as SO3) IS:3025(Part32)
iv. Neuterlisation with NaOH (with IS:3025(Part22)
phenolphathalein as indicator)
v. Neuterlisation with H2SO4 (with mixed
indicator)
IS:3025(Part 23)

Physical Analysis
i. Suspended matter IS:3025(Part 17)
ii. Organic matter IS:3025(Part 18)
iii. Inorganic matter IS:3025(Part 18)

ORDINARY PORTLAND CEMENT (43/53 GRADE)

Test Reference Code
Chemical Tests IS: 8112 (for 43
i. Chlorides (as Cl) Grade)
ii. Ratio of Alumina to that of Iron Oxide IS: 12269 (for 53
iii. Magnesium (MgO) Grade)
iv. Total sulphate content
v. Loss on Ignition
vi. Insoluble Residue
vii. Lime saturation factor
Physical Tests IS: 8112 (for 43
i. Setting Time (Initial & Final) Grade)
ii. Soundness (Le-Chatelier Expansion) IS: 12269 (for 53
iii. Compressive Strength (3, 7 & 28 days) Grade)
iv. Fineness

33
PLASTICISER (NORMAL AND RETARDING TYPE SUPERPLASTICISER)
Test Reference Code
Water content, percent of control sample IS:9103

Slump
Time of Setting, allowable deviation from
control sample (Initial & Final)

Compressive strength, percent of control

sample (1, 3, 7 & 28 days, 6 months, 1 year)

Flexural Strength, percent of control

sample (3, 7 & 28 days)
Length change percent increase over control
sample
Bleeding, percent increase over control
sample
Loss of workability
Air content (%) over control specimen
Uniformity Tests
i. Dry Material Content
ii. Ash content
iii. Relative Density
iv. Chlorides ion content
v. pH

REINFORCING BARS (TMT)

Test Reference Code
Chemical Tests IS: 1786
i. Carbon
ii. Sulphur
iii. Phosphorus
iv. Sulphur + Phosphorus
Physical Test
i. Ultimate Tensile Strength
ii. 0.2% Proof stress
iii. Percentage Elongation
iv. Bend and Rebend
v. Mass per meter run

34
H. T. STRANDS (UNCOATED STRESS RELIEVED LOW RELAXATION SEVEN
PLY STRAND)
Test Reference Code
Chemical Test IS: 228 (Part-3)
i. Sulphur IS: 228 (Part-9)
ii. Phosphorus
Dimension, Tolerance and Mass IS: 14268
i. Tolerance in Diameter
ii. Nominal area
iii. Nominal Mass of strands
iv. Difference in dia of central course and
surrounding wires
v. Length of lay
Physical Properties IS: 14268
i. Breaking Strength of strands
ii. 0.2% Poof load
iii. Elongation
iv. Modulus of Elasticity
Relaxation Properties
i. 100 hours IS: 14268

ii. 1000 hours IS: 14268

35
PRESTRESSING SYSTEM
Test Reference Code
Static Load test with tendon–anchorage FIP
assembly Recommendations

Dynamic Load Test with Tendon–anchorage FIP

assembly Recommendations

Load transfer Test FIP

Recommendations

MS SHEATHING DUCTS
Test Reference Code
Physical Test IRC-112
i. Workability Test
ii. Transverse Load rating Test
iii. Tension Load Test
iv. Water Loss Test
Dimensions
i. Diameter
ii. Thickness
Chemical Composition

CORRUGATED HDPE SHEATHING DUCTS

Test Reference Code
Bond Test IRC-112
Compression Test

36
OTHER PRESTRESSING HARDWARE
Test Reference Code
Anchor Head DIN 17200
i. Ultrasound Test
ii. Chemical Analysis
iii. Dimensional Test
iv. Hardness
Barrel DIN 17200
i. Chemical Analysis
ii. Dimensional Test
iii. Hardness
Bearing Plates DIN 17200
i. Chemical Analysis
ii. Dimensional Test
iii. Hardness
Wedges Manufacturer’s
i. Dimensional Check Specifications
ii. Surface Hardness
iii. Load Test
Trumpet Cone Manufacturer’s
i. Dimensional Test Specifications
ii. Chemical Test

BENTONITE
Test Reference Code
Density MORTH
Marsh Cone Viscosity Specifications for
pH value Road & Bridge
Silt content Works
Liquid limit

37
EPOXY
Test Reference Code
Pot Life FIP
Open Time Guidelines
Thixotropy
Angle of Internal Friction (Squeezibility)
i. 15 Kg
ii. 200 Kg
iii. 400 Kg
Curing Rate
i. 12 hrs.
ii. 14 hrs.
iii. 168 hrs.
Compressive Strength
Bonding of cured bonding agent to
concrete surface to be joined
Tensile bonding strength
Shear strength
Heat resistance
Colour
Shrinkage
Water absorption and solvability in water

CHLOROPRENE ELASTOMER
Test Reference Code
Hardness MORTH
Minimum Tensile Strengths Specification for
Minimum Elongation at Break Road & Bridge
Maximum Compression set Works
Accelerated Ageing
i. Maximum Change in Hardness
ii. Maximum Change in Tensile strength
iii. Maximum change in elongation
Shear Modulus
Ash Content

POLY TETRA FLOURO ETHYLENE (PTFE)

Test Reference Code
Form BS:3784
Density at 23  20C BS:6564
Tensile Strength at break (Part 2)
Elongation at Break
Resistance to heat
Dimensional stability

38
CAST STEEL (FOR BEARING GRADE 280-250W)
Test Reference Code
Chemical Test IS: 1030
Physical Tests
i. Ultrasonic Tests
ii. Magnetic Particle Examination
iii. Liquid Penetration Examination
iv. Radiographic Examination

TESTS ON NEOPRENE SEAL (FOR STRIP SEAL EXPANSION JOINTS)

Test Reference Code
Hardness MORTH
Tensile Strengths Specification for
Elongation at Break Road & Bridge
Tar Propagation Strength Works
i. Longitudinal
ii. Transverse
Shock Elasticity
Abrasion
Residual Compressive strain (22h/70 C /30 %
strain)
Ageing in hot air
i. Maximum Change in Hardness
ii. Maximum Change in Tensile strength
iii. Maximum change in elongation
Ageing in Ozone (24h/50 pphm/ 25C/ 20 %
strain)
Swelling behavior in oil
i. Volume Change
ii. Change in Hardness
ASTM oil No. 3
i. Volume Change
ii. Change in Hardness
Cold Hardening Point

39
POT-CUM-PTFE BEARINGS
Test Reference Code
Dimensional Tolerance MORTH
i. Plan dimensions Specification for
ii. Overall Height Road & Bridge
iii. Height of any steel component (Machined Works
and Unmachined)
iv. Height of Elastomer IRC: 83 Part-III
Stainless steel sliding surface
i. Flatness
ii. Surface finish
Load Test
Friction Test
Ultrasonic Test
Dye Penetration Test
Raw Material Testing

STRIP SEAL EXPANSION JOINTS

Test Reference Code
Tests on Neoprene seal MORTH
Test on Edge Beams (Fatigue Strength) Specification for
Test on Anchorage system (Dynamic Loading Road & Bridge
characteristics) Works
Water Tightness test
Satisfactory Past Performance

40
5. Construction tolerances
5.1 Construction tolerances for open foundations:
a) Variation in dimensions = + 50 min – 10 mm
b) Misplacement from specified position in plan = 15 mm
c) Surface irregularities measured with 3 m straight edge = 5 mm
d) Variation of levels at the top = + 25 mm
5.2 Construction tolerances for pile foundations :
Bored piles:
a) Variation in cross sectional dimensions = + 50 mm, - 10 mm
b) Variation from vertical or specified rake = 1 in 50
c) Variation in the final position of the head in plan = 50 mm
d) Variation of level of top of piles = ± 25 mm
Pile caps:
a) Variation in dimensions = ± 50 mm – 10 mm
b) Misplacement from specified position in plan = 15 mm
c) Surface irregularities measured with 3 m straight edge = 5 mm
d) Variation of levels at the top = ± 25 mm
5.3 Construction tolerances for well foundations:
The permissible tilt shall not exceed 1 (horizontal) in 80 (vertical) and the shift at the
well base shall not be more than 150 mm in any resultant direction.
For the well steining and well cap the permissible tolerances shall be as follows:
a) Variation in dimension = + 50 mm – 10 mm
b) Misplacement from specified position in plan = 15 mm
c) Surface irregularities measured with 3 m straight edge = 5 mm
d) Variation of levels at the top = ± 25 mm
5.4 Construction tolerances for substructure:
a) Variation in cross sectional dimensions = + 10 mm, - 5 mm
b) Misplacement from specified position in plan = 10 mm
c) Variation of levels at the top = ± 10 mm
d) Variations of reduced levels of bearing areas = ± 5 mm
e) Variations from plumb over full height = ± 10 mm
f) Surface irregularities measured with 3 m straight edge
 All surfaces except bearing areas = 5 mm
 Bearing areas = 3 mm

41
5.5 Construction tolerances for metallic bearings:
Diameter of rollers, knuckle pins and bores
Tolerances on diameter of rollers and all convex surfaces shall conform to K7 of
IS:919.
Tolerances on diameter of all concave surfaces shall conform 10 D8 of IS:919.
Height of Bearings
Tolerances on height of any component casting shall not exceed + 0.5 mm. No minus
tolerance shall be allowed. The edges of all ribs shall be parallel throughout their
length.
Base Plate
Tolerance on length and width of the base plate shall not exceed + 1.0 mm, tolerance
on the thickness of the plate shall not exceed + 0.5 mm. No minus tolerance shall be
allowed. All rocking, rolling and sliding surfaces shall have a machine smooth finish
to 20 micron maximum mean deviation as per IS : 3073.
Castings
No minus tolerance shall be allowed in the thickness of any of the castings. The edges
of all ribs shall be parallel throughout their length.
5.6 Construction of tolerances for elastomeric bearings:
S.No. Items Tolerances
1. Overall Plan Thickness -0, + 5 mm
2. Total bearing thickness -0, + 5 mm
3. Parallelism
a) Of top surface of bearing with respect to the 1 in 200
bottom surface as datum
b) Of one side surface with respect to the other 1 in 200
as datum
4. a) Thickness of individual internal layer of ± 20 percent (max. of 2
elastomer mm)
b) Thickness of individual outer layer -0, + 1 mm
5. a) Plan dimensions of laminates -3 mm, + 0
b) Thickness of laminates ± 10 percent
c) Parallelism of laminate with respect to bearing 1 in 100
base as datum

5.7 Construction tolerances for POT/POT-cum-PTFE bearings:

a) Plan dimensions = - 0 to + 5 mm
b) Overall Height = - 0 to + 3 mm
c) Height of elastomer = ± 5 percent
d) Height of any steel component
 Machined = - 0 to + 1 mm

42
  Unmachined = Class 2 of IS:4897
e) Stainless steel sliding surface
 Flatness = 0.0004L (L=Length in direction of measurement)
 Surface Finish = Ra < 0.25 pm as per IS:3073.
5.8 Construction tolerances for superstructure :-
Precast concrete superstructure
Variation in cross sectional dimensions:
a) Upto and including 2 m = + 5 mm
Over 2 m = ± 5 mm
b) Variation in length overall and length between bearings shall not exceed + 10 mm
or ± 0.1 percent of the span length, whichever is lesser
c) Permissible surface irregularities when measured with a 3 m straight edge or
template shall not exceed 5mm
Cast-in-situ Superstructure
a) Variations in thickness of top and bottom slab for box girders, top and bottom
flange for T girders or slabs = - 5 mm to + 10 mm
b) Variations in web thickness = - 5 mm to + 10 mm
c) Variations in overall depth or width = ± 5 mm
d) Variation in length overall and length between bearings = shall not exceed or ±
0.1 percent of the span length, whichever is lesser
e) Permissible surface irregularities when measured with a 3 m straight edge or
template = 5 mm
6. Checklist for various activities of bridge construction
 Whether foundation excavations have been done as per specifications
 Whether lean concrete below foundations has been laid as per specifications
 Whether foundations have been constructed as per specifications
 Whether substructure have been constructed as per specifications
 Whether bearings have been installed as per specifications
 Whether superstructure has been constructed as per specifications
 Whether expansion joints have been installed as per specifications
 Whether wearing coat has been laid as per specifications
 Whether crash barriers, railing etc. have been constructed as per specifications
 Whether weep holes have been provided as per specifications
 Whether filter media has been provided as per specifications
 Whether filling behind abutments has been done as per specifications
 Whether approach slabs have been provided as per specifications

43
7. Documentation and project records
A detailed work program shall be submitted before start of the work for the purpose
of approved which shall be strictly adhered during the execution of the work. A
progress report shall be submitted on the 3rd day of every fortnight for the work done
during the last fortnight. Progress of the work shall be reviewed and shortfalls, if any,
shall be sorted out immediately. Necessary actions shall be taken to bring the work
back to the original schedule without further delays by increasing the number of staff,
capacity of the equipment etc. as per the requirements.
Two sets of hard bound copy and scanned soft copy of the approved design &
drawings, collected site data, site investigations done, methodology & sequence of
construction, method statement & checklists of various activities of construction etc.
shall be kept at the site as well as in the design office. One copy of the relevant codes,
specifications, contract documents etc. shall also be made available in both the
offices.
Digital colour photographs shall be taken and video recording shall be done at various
stages of construction of temporary and permanent work to keep the permanent record
(two sets of hard & soft copies) of each activity of the entire work at the site office
and design office.

44