Vol 4 Div H OCS Part 1 of 2

DESIGN, CONSTRUCTION AND COMPLETION OF UNDERGROUND STATIONS AND TUNNEL
INCLUDING FINISHES FROM KAPODRA RAMP TO SURAT RAILWAY STATION FROM

CHAINAGE 3700M TO CHAINAGE 7160.6M, COMPRISING TWIN BORED UNDERGROUND
TUNNEL BETWEEN NORTHERN RAMP AND SURAT RAILWAY METRO STATION, ALL CUT
AND COVER PORTION INCLUDING THREE UNDERGROUND STATIONS VIZ. KAPODRA,
LABHESHWAR CHOWK AND CENTRAL WAREHOUSE WITH ENTRY/EXITS & CONNECTING
SUBWAY BY BOX PUSHING METHOD AND A PORTION OF NATM AND LAUNCHING AND
RECEIVING CHAMBERS OF TBM FOR SURAT METRO RAIL PROJECT, PHASE-I
TENDER NO.: GMRC/CONS/UG-1/PKG-CS2/PH-1/2020
VOLUME - 4
DIVISION H - OUTLINE CONSTRUCTION

SPECIFICATION
PACKAGE – UG-1/PKG CS2
Gujarat Metro Rail Corporation (GMRC) Limited

(SPV of Govt. of Gujarat and Govt. of India)
Formerly known as Metro Link Express for Gandhinagar and Ahmedabad (MEGA) Co. Ltd.
Block No.1, First Floor, Karmayogi Bhavan, Behind Nirman Bhavan,
Sector 10/A, Gandhinagar: 382010,
Gujarat, India
Corporate Identification No (CIN): U60200GJ2010SGC059407

DIVISION H1
CIVIL AND STRUCTURAL WORKS
TABLE OF CONTENTS
SECTION PAGE
1.1 General........................................................................................................... 1
1.2 Excavation...................................................................................................... 24
1.3 Roadwork....................................................................................................... 34
1.4 Piling And DiaphragmWalling...................................................................... 37
1.5 Structural Concrete: Plain, Reinforced &Pre-stressed.................................... 54
1.6 Formwork....................................................................................................... 98
1.7 PrestressedMembers...................................................................................... 106
1.8 Structural Steelwork ..................................................................................... 124
1.9 Cut and Cover Construction........................................................................... 169
1.10 Shaft Excavation In Rock.............................................................................. 181
1.11 Blasting.......................................................................................................... 182
1.12 Roof Sheeting………………………………………………………………... 191
1.13 Road Works………………………………………………………………….. 196
GMRC/CONS/UG-1/PKG-CS2/PH-1/2020 Volume 4, OCS, Div H1 – Civil & Structural Works
1.1 General
1.1.1 Introduction
1.1.1.1 These Specifications cont ai ned herein shall be read in
conjunction with other Contract Documents.
The Outline Construction Technical Specifications as follow are based
on latest edition of “Specifications for Road and Bridge works” of Ministry
of Road Transport & Highways (MORTH) as published by Indian Roads
Congress, Indian Railway Standards and CPWD/ PWD Government of
Gujarat specifications – latest editions with correction slips & amendments up
to date to the extent they are applicable to the Works covered under scope of
works. However, the provisions of MORTH `specifications take precedence
over CPWD/Gujarat PWD specifications. Further the specifications contained
herein will supersede the provisions of the MORTH & CPWD/ Gujarat PWD
specifications to the extent of their applicability.
The Indian and International Standards as scheduled below have been used as
base for the specifications. The Contractor shall be responsible for detailing in
his specifications submitted to the Engineer, as part of the Definitive Design
Submission, the standards on which his materials and workmanship will be
based. These shall be of similar or higher standard than those listed below.
The Contractor is required to notice in the first instance the Indian
Standards, and base the specifications on Indian Standards to the extent that
they are applicable.
Alternative or additional codes and standards proposed by the Contractor
shall be internationally recognized codes and shall be equivalent to or better
than, Indian Standards issued by the Bureau of Indian Standards or any other
Indian professional body or organization, subject to being, in the opinion of
the Engineer, suitable for incorporation or reference into the specifications.
The specifications have been divided into different sections / sub-heads for
convenience only. They do not restrict any cross-references. The Contractor
shall take into account inter-relations between various parts of works/trades.
No claim shall be entertained on the basis of compartmental interpretations.
1.1.1.2 Reference to the Standard Codes of Practice

Legend:
IRS Indian Railway Standards

IS Indian Standards
BS British Standard
CPWD Central Public Works Department
BS British Standard
CPWD Central Public Works Department
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
ASTM American Society for Testing Materials
DIN Deutsches Institute für Normung e.v.
IRC Indian Road Congress
IRCEM Institution de Retraite Complementary des Employees de
Particular
GMRC JULY 2020 Page 1 of 218
JIS Japanese Industrial Standard

MORTH Ministry of Road Transport and Highways
Gujarat Public Works Department Government of Gujarat PWD
UIC International Union of Railways
The detailed list of Standards referred to is mentioned in Section 1.1.3
Contractor to Provide
The Contractor shall provide and maintain at site throughout the period of
works the following at his own cost and without extra charge, cost being held
to be included in the Contract:
1 General works such as setting out, site clearance before setting out and on
completion of works. All weather approach roads to the site office should
also be constructed and maintained in good condition.
2 All labour, materials, plant, equipment and temporary works, overhead

charges as well as general liabilities, obligations, insurance and risks
arising out of GCC, required to complete and maintain the works to the
satisfaction of the Engineer.
3 Adequate lighting for night works, and also at other times whenever and
wherever required by the Engineer.
4 Continuous & Rigid temporary fences, barricades/hoardings on both sides

of the site occupied by the contractor including, guards, lights and
protective work necessary for protection of workmen, supervisors,
engineers, General public and any other persons permitted access to the
site as approved by the Engineer. Contractor shall provide proper
signages as directed.
All fences, barricade/hoardings shall be as per approved drawings and

painted with colour shades as specified by the Engineer. The
barricading/hoardings should be of adequate height to ensure visual
obstruction of work from public view.
5 All equipment, instruments, labour and materials required by the Engineer

for checking alignment, levels, slopes and evenness of surfaces
measurements and quality etc.
6 Design mixes and testing them as per relevant clauses of specifications

giving proportion of ingredients, sources of aggregates and binder along
with accompanying trial mixes. Test results to be submitted to the
Engineer for his approval before adoption on works.
Method Statements, for each main activity of the work (temporary and
permanent) to be executed detailing the purpose, scope, resources
required, sequence / procedure of execution, persons responsible, time
frame, safety requirements & measures, risk analysis, Inspections, and

Test Procedures along with standard values / acceptable criteria etc. duly
approved by the Engineer before start of that particular activity at site.
Contractor shall also prepare / approve and make available to the Site
Engineer the work procedure for each sub-activity to be done at the site,
detailing the procedure / process to be followed including work sequence,
safety measures, to be followed, level of quality to be maintained, type of
material to be used, type of finishing required and responsibility assigned
etc. Preparation and compliance with provision of a quality assurance
control programme as per provisions of Special Conditions of Contract.
Cost of safety measures and requirements of site safety plan as per

provisions of Special Conditions of Contract.
A testing laboratory as specified by the Engineer equipped with the

following minimum apparatus, materials and competent trained staff
required for carrying out tests, as specified in the relevant sections of the
specifications/Codes:-
A testing laboratory as specified by the Engineer equipped with the

following minimum apparatus, materials and competent trained staff
required for carrying out tests, as specified in the relevant sections of the
specifications/Codes, but not limited to these.
• Set of standard sieves for testing grading of sand with
mechanical sieve shaker.
• Sieves with openings respectively of 4.75mm, 10mm, 20mm,
25mm, and 30mm for testing and grading of aggregates.
• Digital Weighing Balance of capacity up to 10 Kg. reading up
to 1 gm.
• Electric Thermostat controlled oven and pans for drying of
sand and aggregates.
• Glass measuring flasks /2, 1 liter & 2 liter capacities.
• Flask for determining moisture content of sand.
• Slump cone with rod and V B Apparatus, flow table to
measure slump or DIN Specifications (separate sets for
laboratory and at Site).
• Apparatus to measure permeability of concrete as per
Appendix 1700/II of MORTH Specifications.
• Minimum 24 Nos. steel ISI moulds for 150mm x 150mm x
150mm concrete test cubes. It may be necessary to provide
more steel cube moulds depending upon concreting
programme.
• 25mm dia vibrator for compaction of concrete in test cubes
and also vibrating table.
• Digital Concrete cube testing machine of 200 tonnes
Minimum capacity with print out facility.
• Work benches, shelves, desks, sinks and any other furniture
and lighting as required by the Engineer.
• Abrasion, Flakiness & Impact testing Equipment for Testing

coarse aggregates.
• Silt Testing Equipment.
• Any other equipment specified by Engineer.
• Permeability Testing Apparatus.
Note: All the above equipment and apparatus shall be calibrated at the time of
setting up and at specified intervals by NABL accredited agency.
Quality Assurance & Quality Control

The work shall conform to high standards of design and workmanship, shall
be structurally sound and aesthetically pleasing. The Contractor shall
conform to the Quality standards prescribed, which shall form the backbone
for the Quality Assurance and Quality Control system.
At the site, the Contractor shall arrange the materials, their stacking/storage in
as per MORTH standards manner to ensure the quality. The Contractor shall
provide all the necessary equipment and qualified manpower to test the
quality of materials, assemblies etc., as directed by the Engineer. The tests
shall be conducted at specified intervals and the results of tests properly
documented. The cost of all such testing shall be included in the quoted rates
and nothing extra shall be paid for in this regard. In addition, the Contractor
shall keep appropriate tools and equipment for checking alignments, levels,
slopes and evenness of the surfaces.
Testing of Materials.
The Engineer shall be free to carry out such tests as may be decided by him at
his sole discretion, from time to time, in addition to those specified in this
document as per provisions of General Conditions of Contract. The
Contractor shall provide the samples and labour for collecting the samples.
Nothing extra shall be payable to the Contractor for samples, or for the
collection of the samples. The test shall be conducted at the Site laboratory
that may be established by the Contractor or at any other Standard Laboratory
having NABL certification.
The Contractor shall transport the samples to the laboratory for which nothing
extra shall be payable. In the event of the Contractor failing to arrange
transportation of the samples in proper time the Engineer shall have them
transported and recover two times the actual cost from the Contractor's bills.
All testing shall be performed in the presence of Engineer or his authorised

representative. Testing may be witnessed by the Contractor or his authorised
representative if permitted by the Test House. Whether witnessed by the
Contractor or not, the test results shall be binding on the Contractor.
Cost of all such tests shall be borne by the Contractor and nothing extra shall
be payable on this account.
The Engineer shall have the right at all times to inspect all operations
including the sources of materials, procurement, its transportation, layout and
storage of materials, all equipment including the concrete batching and

mixing equipment, and the quality control system. Such an inspection shall be
arranged and the Engineer's approval obtained prior to starting of the
particular item of work. This shall however, not relieve the Contractor of his
responsibilities. All materials which do not conform to these specifications
shall be rejected. In the event of contractor not being able to arrange the
material conforming to these specifications or in the event of failure of the
contractor to get the sources approved within the agreed schedule submitted
by contractor, the Engineer shall have the powers to cause the Contractors to
purchase and use such materials from any particular source, as may, in the
Engineer's opinion, be necessary for the proper execution of work. Nothing
extra shall be payable to the contractor on this account.
Dimensions
Figured dimensions on drawings shall only be followed and drawings to a
large scale shall take precedence over those to a smaller scale. Special
dimensions or directions in the specifications shall supersede all others at
tender stage where as those mentioned in the construction drawings
supersedes all others. All dimensions shall be checked at site prior to
execution.
The levels, measurements and other information concerning the existing site
as shown on the drawings are believed to be correct, but the Contractor
should verify them for himself and also examine the nature of the ground as
no claim or allowance whatsoever will be entertained on account of any
errors or omissions in the levels or the description of the ground levels or
strata turning out different from what was expected or shown on the
drawings.
Setting out of Works

The Contractor shall set out the Works. The Contractor shall provide suitable
stones with flat tops and build the same in concrete for temporary bench
marks. All the pegs for setting out the Works and fixing the levels required
for the execution thereof shall, if desired by the Engineer, likewise be built in
masonry at such places and in such a manner as the Engineer may direct. The
Contractor shall carefully protect and preserve all bench marks and other
marks used in setting out the works. The contractor will make overall layout
of complete work and get it checked from engineer. The cost of all operations
of setting out including construction of bench marks is deemed to be included
in the contractors’ scope of work.
All the survey work except leveling shall work shall be carried out using total
stations with one second accuracy. The leveling work shall be carried out
using Auto level.
The triangulation points given by Employer/Engineer before start of work

shall be maintained during execution and handed over back to Employer /
Engineer after completion of work.
Materials

Source of Materials
It shall be the responsibility of the contractor to procure all the materials
required for construction and completion of the contract. The contractor shall
indicate in writing the source of materials well in advance to the Engineer,
after the award of the work and get it approved from the Engineer before
commencing the work. If the material from any source is found to be
unacceptable at any time, it shall be rejected by the Engineer.
Quality
All materials used in the works shall be of the best quality of their respective
kinds as specified in technical specifications herein, obtained from sources
and suppliers approved by the Engineer and shall comply strictly with the
tests prescribed hereafter, or where tests are not laid down in the
specifications, with the requirements of the latest issues of the relevant Indian
& other Standards.
Sampling and Testing

All materials used in the works shall be subjected to inspection and test in
addition to test certificates. Samples of all materials proposed to be employed
in the permanent works shall be submitted to the Engineer at least 45 days in
advance for approval before they are brought to the site.
Samples provided to the Engineer for their retention are to be labeled in

boxes suitable for storage. Materials or workmanship not corresponding in
character and quality with approved samples will be rejected by the Engineer.
Samples required for approval and testing must be supplied sufficiently in

advance in required quantity and number to allow for testing and approval,
due allowance being made for the fact that if the first samples are rejected
further samples may be required. Delay to the works arising from the late
submission of samples will not be acceptable as a reason for delay in
completion of the works.
Materials shall be tested before leaving the manufacturer’s premises, quarry

or source, wherever possible. Materials shall also be tested at site and they
may be rejected if not found suitable or in accordance with the specifications,
notwithstanding the results of the tests at the manufacturer’s works or
elsewhere or test certificates or any approval given earlier.
The contractor will bear all expenses for sampling and testing, whether at the
manufacturer’s premises at source, at site or at any testing laboratory or
institution as directed by the Engineer subject to the provisions of Clause
1.1.9 above. No extra payment shall be made on this account.
Dispatch of materials
Materials shall not be dispatched from the manufacturer’s works to the site
without written authority from the Engineer.
Test certificates
All manufacturer’s certificates of test, proof sheets, etc showing that the

materials have been tested in accordance with the requirement of these

specifications and of the appropriate Indian Standards are to be supplied free
of charge on request to the Engineer.
Rejection
Any materials that have not been found to conform to the specifications or
otherwise not acceptable to the Engineer will be rejected forthwith and shall
be removed from the site by the Contractor at his own cost within three days
or as instructed by the Engineer.
1.1.1.3 Storing of Materials at site

All materials used in the Works shall be stored on racks, supports, in bins,
silos, godowns, under cover etc. as appropriate to prevent deterioration or
damage from any cause whatsoever to the entire satisfaction of the Engineer.
The storage of materials shall be in accordance with IS 4082
“Recommendation on stacking and storage of construction materials on site”
and as per IS 7969 “Safety code for handling and storage of building
materials”.
The materials shall be stored in a proper manner at places at site agreed by
the Engineer. Should the place, where material is stored by the Contractor,
be required by the Employer for any other purpose, the Contractor shall
forthwith remove the material from that place at his own cost and clear the
place for the use of the Employer within the time as communicated by the
Engineer and at no extra cost to the Employer.
Water
Water from approved source
Potable water only shall be used for the works. Contractor shall have his own
source of water required for the works including curing duly approved by
Engineer. However, the contractor will have to obtain necessary permission
for use of such water, if any, from concerned authorities. The water shall be
free from any deleterious matter in solution or in suspension and be obtained
from an approved source. The quality of water shall conform to IS 456.
Storage
The Contractor shall make his own arrangements for storing water, if
necessary, in drums or tanks or cisterns, to the approval of the Engineer. Care
shall be exercised to ensure that water is not contaminated in any way.
Testing
Before starting any concreting work and wherever the source of water
changes during the currency of works, the water shall be tested for its
chemical and other impurities to ascertain its suitability for use in concrete
and other works including curing for approval of the Engineer. No water
shall be used until tested and found satisfactory.
Cost of arranging, storing and testing of water shall be deemed to be included

in the quoted rates in the Bill of Quantities and nothing extra shall be payable
in this regard.

Cement:
The grade of cement shall be as specified and conforming the relevant IS
code and shall be purchased from the approved manufacturers.
Supply/procurement of cement shall be through bulk carrier and stored in

silos of adequate capacity. Procurement of cement in bags should be an
exception with the specific approval of Engineer-in-charge. Separate go-
downs shall have to be provided for different grades of cement. The fresh
cement should be used. The cement older than 3 months will not be allowed
to use at site. The cement should be stored in a water tight shed and on
wooden planks giving sufficient gaps between walls floors and cement piles.
The actual issue and consumption of cement in works shall be regulated and
proper accounts maintained as provided in the relevant clause of the contract.
The theoretical consumption of cement shall be worked out as per procedure
prescribed in relevant clause of the contract and shall be governed by
conditions laid therein.
Cement (OPC of 53 grade/PPC/PSCas specified shall be arranged by the

contractor.
Coarse Aggregate :
Coarse aggregate in size and quality shall be conforming to the relevant IS
code and as specified in the documents. The coarse aggregates procured shall
be from the crusher with VSI facility.
The nominal maximum size of aggregate (MSA) to be used in RCC and PSC
work shall be 20mm. The other requirement shall be as per IS 383
specification.
The aggregate shall be stored in such a way as to prevent mixing with foreign
materials. Different sizes of coarse aggregate shall be stored in separate stock
piles sufficiently away from each other in order to prevent intermixing the
materials at the edges of the stock piles.
Fine Aggregate:
Fine aggregate (River sand / Manufactured sand) in size and quality shall be
conforming to the relevant IS code and as specified in the documents. The
quality, tests and acceptance criteria for fine aggregates shall be same as per
IS 383 specifications. The fine aggregate shall conform to Zone II or Zone III
of IS 383 specifications as per requirement of trial mix design (or any
combination of the two as approved by Engineer and the decision of Engineer
in this respect shall be final).
The silt content of fine aggregate (River sand) used for trial mixes shall be
recorded & the silt content by volume in fine aggregate used shall neither
exceed 8% nor 1% more than that of the fine aggregate used in the trial-mix
(whichever is lesser).
Use of manufactured sand as per IS 383 and 456 is permitted with the

specific approval of Engineer-in-charge. The silt content by volume in fine

aggregate used shall neither exceed 12% nor more than 1% used in the trial-
mix.
1.1.1.4 Materials
All m a t e r i a l s s h a l l b e o f b e s t q u a l i t y a n d s h a l l
c o n f o r m t o m a n u f a c t u r e r ’ s specification. Wherever, no specific
code of practice of IRS/IRC/BIS is applicable, the decision of Engineer
shall be final and binding.
All other materials not specifically mentioned above shall be of best quality
and shall conform to manufacturer’s specification. Wherever, no specific
code of practice of IRS/IRC/BIS is applicable, the decision of Engineer shall
be final and binding.
1.1.1.5 Workmanship
(1) All works shall be true to level, plumb and square and the corners,
edges and rises in all cases shall be unbroken and neat.
(2) Any work not to the satisfaction of the Employer or Engineer will be
rejected and the same shall be rectified, or removed and replaced with
work of the required standard of workmanship by the Contractor at no
extra cost to the Employer.
1.1.1.6 Load testing on Completed Structures
1.1.1.7 During the period of construction or within the defect liability period, the
Engineer may at his discretion order the load testing of any completed
structure or any part thereof if he has reasonable doubts about the adequacy
of the strength of such structure for any of the following reasons.
a) Results o f compressive strength on concrete test cubes falling
below the specified strength.
b) Premature removal of formwork.
c) Inadequate curing of concrete.
d) Overloading during the construction of the structure or part thereof.
e) Carrying out concreting of any portion without the prior notice to the
Engineer.
f) Honey combed or damaged concrete which will affect the stability of
the structure to carry the design load, more so in important or critical
areas of the structure.
g) Any other circumstances attributable to the Contractor which may
result in the structure or any part thereof being of less than the strength
or performance required under the Contract.
1.1.1.8 All the loading tests shall be carried out by the Contractor in accordance
with the agreed methods and Standards. Such tests shall be carried out only
after expiry of minimum 28 days or such longer period as may be decided
by the Engineer. The structure s h a l l be subjected to a superimposed
load equal to the specified. Superimposed load assumed in the design.
This load shall be maintained for a period of 24 hours before removal. During
the test, struts strong enough to take the whole load shall be placed in position
leaving a gap under the members. The deflection due to the superimposed

load shall be recorded by sufficient number of agreed deflectometers capable

of reading to an accuracy of 0.02 mm and suitably located under the
structure. The structure shall be deemed to have passed the test if the
maximum deflection at the end of 24 hours of loading does not exceed the
deflection given by the following expressions:
D = 0.001 L2/25 T, where,
D = max deflection due to imposed load only

L = span of the member under load test (the shorter span in case of slabs).
The span is the distance between center’s of the supports or the clear distance
between the supports plus the depth of the member, whichever is smaller. In
case of cantilever, this shall be taken as twice the distance from the support to
the end and deflection shall be adjusted for movement of the support.
T = depth of member.
If within 24 hours of the removal of the superimposed load, the structure does
not recover at least 75% of the deflection under the superimposed load, the
test loading shall be repeated after a lapse of 72 hours. If the recovery after
the second test is less than 80% of the maximum deflection shown during the
second test, the structure shall be considered to have failed to pass the test
and shall be deemed to be unacceptable.
1.1.1.9 In such cases the portion of the Work concerned shall be taken down or cut
out and reconstructed to comply with the specifications. Other remedial
measures may be taken to make the structure secure at the discretion of the
Engineer. However such remedial measures shall be carried out to the
complete satisfaction of the Engineer.
1.1.1.10 All costs involved in carrying out the tests defined in Clause 1.1.1.7 above,
(including load and integrity test for piles) and other incidental expense
thereto shall be borne by the Contractor regardless of the result of the tests.
In case of failure the Contractor shall take down or cut out and reconstruct the
defective work or shall take the remedial measures, as instructed, at his own
cost.
1.1.1.11 In addition to the above load tests, non-destructive tests on various elements
such as core test and ultrasonic pulse velocity test etc. shall be carried out by
the Contractor at his own expense. Such tests shall be carried out by an
agency agreed with the Engineer. The acceptance criteria for these tests shall
be as specified by the testing agency or good Engineering practice subject
to the Notice of No Objection by the Engineer.
Survey Work
The said work involves at the very start of work taking-over of reference
point from the Engineer, establishment of control points, triangulation points,
bench marks, grid layout for all the piers and other structures maintaining
horizontal and vertical control within the permissible limits, incorporating
changes (if any), submission of full data in the tabulation form and survey
drawings...
a) Establishing GPS stations, if require, at an interval not more than 2-2.5

Km with one pair at the interval of not more than 200-250 m. The GPS
station shall be located on permanent structure or providing and fixing
concrete pillar 600 mm x 600 mm x 1000 mm or on building roof free
from any displacement disturbance. Stainless Steel (SS) Plate 100 mm x
100 mm x 4 mm with center punch shall be fixed on the top of the
station. GPS instrument accuracy shall be minimum horizontal 5 mm +
0.5 ppm and vertical 10 mm + 0.5 ppm in static observation. The base
line measurement shall be based on minimum 4 hrs static observations
and other observations shall be with minimum 2 hrs static observations.
b) Closed traversing shall be carried out storing in total station Angle and
Distance from GPS to GPS with an accuracy of 1: 50000 by observing
minimum 3 sets of face right and 3 set of face left. Stations shall be
established at an interval not more than 200 m. closing error shall be
distributed with least square method in commercial software. Total
station raw data, calculations shall be submitted to the employer along
with before and after adjustment coordinates in tabular form.
c) Detailed Topographical survey, if require, shall be carried out with

adjusted traverse co-ordinates. All surface features, ground levels, and
over-ground utilities shall be taken. Total Station raw data and
calculations shall be submitted to Employer for No Objection.
Drawings, raw data and calculations shall be submitted in soft and hard
copy.
d) Closed levelling shall be carried out from Survey of India Bench Mark
with accuracy √1K. Digital levelling instrument shall be used to
establish bench mark. Raw data from digital level shall be submitted
along with adjusted and unadjusted levels in tabular form.
NOTE:
Digital levelling instrument to be used for the work shall have the minimum
accuracy of the order of ± 0.3 mm per km double run with least count not
more than 0.01 mm
Total station instrument shall have minimum accuracy for:
a) Angle measurements (Hz, V) of the order of 1"
b) Distance measurement of the order of 1mm+2 ppm
Barricading
The work covers barricading for the work done along the median and areas
affecting road traffic. Barricading for the other areas like casting yard,
batching plant, storage and other working area shall be done at own cost by
the contractor. The detailed scope of work is as follows:
Providing and installing the barricade of the design and type as shown in the
typical sketch furnished as per the approved plan firmly to the ground and
maintaining it during the progress of work.

Providing adequate road safety devices. A tentative list given hereunder

identifies minimum items, which may be required. However, actual numbers
required will be as per approved plan by the Engineer and clearance from the
traffic department, Surat. The contractor shall not be paid extra for any
addition to this list if required during the execution of works.
Providing Temporary barricade shall be of plain MS sheet 16 Gauge fixed
with steel frame as per drawing, painting (including primer of approved
quality) with synthetic enamel paint of approved colour, quality and brand,
writing lettering and logo of Metro including maintenance of the same duly
cleaning the same on fortnightly basis and painting for every 12
months. arrangement for blinker lights on barricades during night as per
requirement and as per the instruction of the engineer. Barricading should be
rugged. During the construction, barricading has to be kept continuously.
There should not be any opening at the end of barricade except at locations
approved by
Engineer.
Note:
(i) Once barricade has been provided and work started, removal of barricade is
not permitted till completion work
(ii) While erecting barricade, the bottom gap between barricade and road
should be plugged with cement concrete from inside.
(iii) There should be minimum openings at the end of barricade to allow
access of trucks / lorries and machine to site work area. Even these spacing
should have proper opening & closing arrangements.
(iv) For 2.0m barricades adequate blinking lights on barricade during night
time must be ensured. It includes provision for power pack / Generator set
etc. so as to ensure the blinking of lights in night time as long as barricades
are in position at the work spot.
(v) If the cleaning is not done including removal of posters regularly, a
recovery shall be made at the rate of 0.1% of the accepted item of payment
per fortnight on pro rate basis of length not cleaned.
Note: It is specifically highlighted that barricading during construction shall
be limited to width, given the traffic constraint.
Barricading drawing as per Part-2, Volume 4, Division-I
Supply of Progress Photographs and Album

The work covers the supply of digital color photographs along with soft copy
in an album to serve as a permanent record of various stages/facets of work
needed for an authentic documentation as approved by the Engineer.
The photographs shall be of acceptable quality and they shall be taken by a

professionally competent photographer will camera having the facility to
record the date of the photographs taken in the prints and negative. The
Digital camera, type and quality of photo paper shall be of standard make

approved by the Engineer. Each photograph in the album shall be suitably

captioned and dated.
The frequency, time and extent of coverage for each work shall be as decided
by the Engineer. The rate for the supply of record photographs shall include
the cost of taking the photographs, developing and obtaining the colour
prints, cost of albums, mounting and captioning the photographs.
The photographs and materials including softcopies shall form a part of the
records of (GMRC) COMPANY LTD and the prints cannot be supplied to
anybody else or published without the written permission of (GMRC)
COMPANY LTD.
Supply of DVD of Works

The work consists of taking video film of important activities of the works as
directed by Engineer during the currency of the project and editing them to
make a video film of approved make and specified duration. No extra
payment shall be made for this as it is included in the scope of contract.
1.1.2 Structural Work

1.1.2.1Unless otherwise specified, only controlled concrete with design mix and
weigh batching is to be used for the Works.
1.1.2.2 Minimum cement content for various grades/ elements of concrete shall be as
agreed by the Engineer as part of the Contractor’s DAAR keeping in view the
durability and other requirements. However, larger content of cement shall be
provided if demanded by mix design or as per the requirement of relevant
codes.
1.1.2.3 Mix design using smaller aggregates of 10 mm and below shall also be done
in advance for the use at the junctions, where reinforcement is congested.
1.1.2.4 Procedure of mixing the admixtures shall be strictly as per the

manufacturer’s recommendations.
1.1.2.5 All the water tanks and other liquid retaining concrete structures shall
undergo hydro testing.
1.1.2.6 Special benches shall be provided at site for stacking reinforcement bars of
different sizes.
1.1.2.7 Formwork for beams of Reinforced Cement Concrete works shall be

designed in such a way that the formwork of the adjacent slabs can be
removed without disturbing the props/supports to the beams.
1.1.2.8 Wherever there are tension/suspended concrete members which are

suspended from upper level structural members, the shuttering/scaffolding of
such members at lower level shall be kept in place until such time as the
upper level supporting members have achieved the required minimum
strength.
1.1.2.9 The Contractor shall incorporate seismic considerations of anchoring and

isolation in the design and detailing of the finishes. The element to be
anchored shall have its motion suitably restrained and isolated so as not to be
affected by the deformations/vibrations of the building during Construction.
1.1.2.10Formwork shall be provided for full height at all locations. Special

precautions for such tall formwork shall be taken to ensure its safety and
stability.
1.1.2.11The contractor shall carry out expeditiously and without delay the following
works within the mobilization period itself:
a. Identify and get approved the sources of various major constitution
materials.
b. Material testing and mix designs of concrete as contemplated in the
specifications.
c. Setting up of full-fledged site laboratory as per the requirements of these
specifications.
d. Setting up concrete batching & mixing plant.
e. Site office for the use of the Engineer’s staff.
f. Contractor’s site office setup.
g. Casting yard with complete facilities.
h. Any other pre-requisite items required for final execution.
1.1.2.12 Casting yard shall have following minimum facilities:

a. Casting beds for casting of segments.
b. Sets of form work / moulds as required.
c. All handling facilities for precast elements like over gantry, etc.
d. Curing arrangements as required.
e. Stacking arrangements for material and precast elements.
f. Storing arrangement of materials.
g. Proper drainage and all weather approach roads.
The load testing of spans / piles etc. shall be done using certified and
calibrated dial gauges only. Use of levelling instruments for measuring
deflections shall not be allowed.
1.1.3 Applicable Codes, Standards & Publications for Structural & Architectural
Work
The important Codes, Standards and Publications to Contract are listed here under:
A General
IS:875 (Part 3) Code of practice for design loads (other than earthquake) for
buildings and structures
IS:1322 Bitumen felts for water proofing and damp-proofing

IS:1893 Criteria for earthquake resistant design of structures
IS:2572 Code of Practice for construction of hollow concrete block

IS:2974(Part 1) masonry
Code of Practice for Design & Construction of machine
Foundation
IS:3414 Code of practice for design and installation of joints in buildings
IS:3764 Excavation Work- Code of Safety
IS:6408 (Parts 1,2) Recommendations for modular co-ordination in building industry
– tolerances
IS:10958 General check list of functions of joints in building
Classification of joints in buildings for accommodation of
IS:11817 dimensional deviations during construction
Method of test for laboratory determination of air permeability of
IS:11818 joints in buildings
IS:12440 Precast concrete stone masonry blocks
IS 383 Specification for coarse and fine aggregates

BS:476 (Part 7) Method for classification of the surface spread of flame of
products
BS:476 (Part 20) Method of determination of the fire resistance of elements of
construction (general principles)
BS:476 (Part 22) Methods for determination of the fire resistance of non-load
bearing elements of construction
BS:5215 Specification for one-part gun grade polysulphide-based sealants
BS:5606 Guide to accuracy in building
BS:6093 Code of practice for the design of joints and jointing in building
construction
BS:8200 Code of practice for the design of non-load bearing external
vertical enclosure of building
ASTM C 332 Specification for light weight aggregate for insulating concrete
SP 7 National Building Code of India

SP 23 (S&T) Hand Book on Concrete Mixes
BS:5215 Specification for one-part gun grade polysulphide-based sealants
BS:5606 Guide to accuracy in building
BS:6093 Code of practice for the design of joints and jointing in building
construction
Code of practice for the design of non-load bearing external
BS:8200 vertical enclosure of building

ASTM C 332 Specification for light weight aggregate for insulating concrete
SP 7 National Building Code of India

SP 23 (S&T) Hand Book on Concrete Mixes
B Bitumen
IS:702 Industrial Bitumen
Specification for bitumen primer for use in waterproofing and
IS:3384 damp-proofing
C Building Construction Practices
IS:1838 Parts I and Specifications for preformed fillers for expansion joint in
II. concrete pavements and structures.
IS:1946 Code of Practice for use of fixing devices in walls, ceilings, and
floors of solid construction.
IS:6509 Code of Practice for installation of joints in concrete pavements.
IS:11134 Code of Practice for setting out of buildings.
IS:11433 Parts I and II. Specifications for one part Gun grade polysulphide
based joint sealant.
Code of Practice for provision of water stops at transverse
IS:12200 contraction joints in masonry and concrete dams
D Cement
IS:269 33 grade ordinary Portland cement
IS:455 Portland Slag Cement
IS:650 Specification for standard sand for testing cement.
IS:1489 (Part 1) Portland pozzolana cement: Flyash based
IS:1489 (Part 2) Portland pozzolana cement: Calcined clay based
IS:3535 Method of Sampling Hydraulic Cements

IS:4031 (Parts 1 to 13) Methods of physical tests for hydraulic cement.
IS:4032 Method of chemical analysis of hydraulic cement.
IS:6925 Methods of test for determination of water soluble chlorides in
concrete admixtures.
IS:8042 White Portland Cement
IS:8112 Specification for 43 grade ordinary Portland cement.
IS:12269 Specification for 53 grade ordinary Portland cement.
IS:12330 Specification for sulphate resistant Portland cement.

IS:456 Code of practice for plain and reinforced concrete.

IS:457 Code of practice for general construction of plain and reinforced
concrete for dams and other massive structures.
IS:460 (Parts I to Specification for Test Sieves
II)
IS:516 Methods of test for strength of concrete.
IS:1199 Methods of sampling & analysis of concrete.
IS:1200 Method of measurement of building and civil Engineering
IS:1343 Code of practice for prestressed concrete
IS:1607 Method of Test Sieving
IS:2386 Parts I-VIII. Methods of tests for aggregates for concrete.
IS:2430 Methods of Sampling of Aggregates of Concrete

IS:2438 Specification for roller pan mixer
IS:2514 Specification for concrete vibrating tables
IS:2571 Code of practice for laying in-situ cement concrete flooring

IS:2645 Specifications for integral cement water proofing compounds
IS:2722 Specifications for portable swing batchers for concrete (double
bucket type)
IS:2770 Methods of testing bond in reinforced concrete part I pull out test
Methods of sampling and test (physical and chemical) for water
IS:3025 & waste water
IS:3370 Code of practice for concrete structures for storage of liquids
IS: 3935 Code of practice for composite construction

IS:4326 Code of practice for earthquake resistant construction of building
IS:6925 Methods of test for determination of water soluble chlorides in
concrete Admixtures
IS:7242 Specifications for concrete spreaders
IS:7251 Specifications for concrete finishers
IS:7861 Parts I & II. Code of practice for extreme weather concreting.
IS:7969 Safety code for handling and storage of building materials
IS:8989 Safety code for erection of concrete framed structures
IS:8142 Methods of test for determining setting time of concrete by
penetration resistance

IS:9103 Specifications for admixtures for concrete
IS:9013 Method of making, curing and determining compressive

strengths of accelerated cured concrete test specimens
IS:9284 Method of test for abrasion resistance of concrete
IS:10262 Recommended guidelines for concrete mix design.
Specifications for Road and Bridge Works, Ministry of Road
MORTH Transport and Highways (Roads Wing)
IRS : CBC Concrete Bridge Code
IRC 21 Standard Specifications and Code of Practice for Road Bridges

Section III – Cement Concrete (Plain & Reinforced)
IRC:18 Design criteria for Prestressed Concrete Road Bridges (Post –
ASTM - C - 94 Tensioned Concrete)
IS 4926 Ready Mix Concrete
Ready Mixed Concrete – Code of Practice
ASTM – C – 1240 Specifications for Silica Fume for use in Hydraulic Cement and
Mortar
F Construction Plant and Machinery.
IS:1791 Specification for batch type concrete mixers.
IS:2505 General requirements for concrete vibrators: Immersion type.

IS:2506 General requirements for screed board concrete vibrators.
IS:3366 Specification for pan vibrators.
Code of Practice for use of immersion vibrators for consolidating
IS:3558 concrete.
IS:4656 Specifications for form vibrators for concrete.
IS:4925 Specification for concrete batching and mixing plant.
IS:11993 Code of Practice for use of screed board concrete vibrators.
G Formwork
IS:4990 Specifications for plywood for concrete shuttering work.

IRC:87 Guidelines for the design and erection of false work for road
bridges.
IS:806 Code of practice for use of steel tubes in general building
construction.
IS:1161 Specification of steel tubes for structural purposes.
IS:1239 Specification for mild steel tubes. Tubulars and other wrought
steel fittings.

H Gypsum and Gypsum Board
IS:2095 Gypsum plaster boards

IS:2542 (Part 1/Sec Methods of test for gypsum plaster, concrete and products:
1 to 12) plaster and concrete
IS:2542 (Part 2/Sec Methods of test for gypsum plaster, concrete and products:
1 to 8) Gypsum products
IS:2547 (Part 1) Gypsum building plaster: Excluding premixed lightweight
plaster
IS:2547 (Part 2) Gypsum building plaster: Premixed lightweight plaster
I Handling and Storage
IS:4082 Recommendation of Stacking and Storage of construction
materials
IS:8348 Code of practice for stacking and packing of stone slabs for
transportation
J Instruments For Testing Cement and Concrete
IS:5513 Specification for vicat apparatus.

IS:5514 Specification for apparatus used in Le-Chaterlier test.
IS:5515 Specification for compaction factor apparatus.
IS:7320 Specification for concrete slump test apparatus.
Specification for apparatus to determine constituents of fresh

IS:7325 concrete.
IS:10080 Specification for vibration machine.
IS:10086 Specification for moulds for use in tests of cement and concrete.
IS:10510 Specification for vee-bee consistometer.
K Joint Fillers
IS:1838 (Part 1) Preformed fillers for expansion joint in concrete pavements and
structures (non extruding and resilient type): Bitumen
impregnated fibre
L Paints and Coatings
IS:102 Ready mixed paint, brushing, red lead, non-setting, priming
Ready mixed paint, brushing, priming, plaster, to Indian

IS:109 Standard Colour No. 361 and 631 white and off white.
IS:347 Varnish, shellac, for general purpose.

IS:2074 Ready mixed paint, air drying, red oxide-zinc chrome, priming
Specification for powder organic coatings for application and

stoving to aluminum alloy extrusions, sheet and preformed
sections for external architectural purposes, and for the finish on
BS:6496 aluminum alloy extrusions, sheet and preformed sections coated
with powder organic coatings
Specification for electrolytically zinc coated cold rolled steel flat
BS:EN:10152 products. Technical delivery conditions
ASTM A 164-71 Specification for electrodeposited coatings of zinc on steel
M Pigment for Cement
Specification for pigments for Portland cement and Portland

BS:1014 cement products
N Reinforcement & Structural Steel
IS:280 Mild steel wire for general Engineering purposes
Part I. Mild steel and medium tensile steel bars. Part II Hard-
IS:432 drawn steel wire.
IS:814 Parts I & II. Electrodes for metal arc welding of structural steel.
IS:815 Classification coding of covered electrodes for metal arc welding
of structural steels
IS:816 Code of Practice for use of metal arc welding for general
construction in mild steel.
IS:1566 (Part I) Specifications for hard-drawn steel wire fabric for
concrete reinforcement.
IS:1786 Specification for high strength deformed steel bars and wires for
concrete reinforcement.
IS:2502 Code of Practice for bending and fixing of bars for concrete
reinforcement.
IS:2629 Recommended practice for hot-dip galvanizing of iron and steel.
IS:2751 Code of Practice for welding of mild steel plain and deformed
bars for reinforced concrete construction.
IS:4759 Hot-dip zinc coating on structural steel and other allied products.
IS:5525 Recommendations for detailing of reinforcement in reinforced
concrete works
Recommendations for welding cold-worked steel bars for
IS:9417 reinforced concrete construction.
Uncoated stress relieved low relaxation steel class 2 for Pre-
IS:14268 stressed concrete
IS:226 Structural steel (Standard Quality)

Code of practice for use of structural steel in general building

IS:800 construction.
IS:813 Scheme of symbols for welding.
Covered electrodes for metal arc welding of structural steel. (Part

IS:814 I & Part II)
Code of practice for use of metal arc welding for general
IS:816 construction in mild steel.
IS:822 Code of practice for inspection of welds.
IS:961 Structural steel (High Tensile)
Code of practice for use of welding in bridges and structures
IS:1024 subject to dynamic loading.
IS:1161 Steel tubes for structural purposes.
Recommended practice for radiographic examination of fusion

IS:1182 welded butt joints in steel plates.
IS:2062 Structural steel (Fusion welding quality)
IS:3757 Specification for high tensile friction grip bolts.

IS:5624 Specification for foundation bolts.
Code of practice for testing of fusion welded (Part I) joints and
IS:3600 weld metal in steel.
IS:4923 Hollow steel sections for structural use.
IS:6227 Code of practice for use of metal arc welding in tubular structure.
IS:801 Code of practice for use of cold formed light gauge steel
structural members in general building construction.
IS:811 Specifications for cold formed light gauge structural steel
IS:8500 sections.
IS:8910 Structural Steel Micro alloyed (Medium and high strength
IS:9595 qualities)
IS:7205 General requirements of supply of weldable structural steel
Recommendations for metal arc welding of carbon & carbon-
Manganese steels
Safety Code for erection of Structural Steel Works
O Aggregates
IS:383 Coarse and fine aggregates from natural sources for concrete.
P Scaffolding
IS:2750 Specification for steel scaffoldings
IS:3696 (Part 1) Safety Code of scaffolds and ladders: Scaffolds
IS:3696 (Part 2) Safety Code of scaffolds and ladders: Ladders

IS:4014 (Part 1) Code of practice for steel tubular scaffolding: Definition and
materials
Code of practice for steel tubular scaffolding: Safety regulations
for scaffolding
IS:4014 (Part 2) Guidelines for the design and erection of false work for road
IRC:87 bridges
Q Sealants
IS:10959 Glossary of terms for sealants for building purposes
IS:11433 (Part 1) One part grade polysulphide base joint sealant: General
requirements
IS:11433 (Part 2) One part grade polysulphide base joint sealant: Methods of test
IS:13055 Methods of sampling and test for anaerobic adhesives and
sealants
BS:5889 Specification for one part gun grade silicone-based sealants.
R Wood
IS:303 Plywood for General Purposes
Synthetic resin adhesives for plywood (phenolic and amino
IS:848 plastic)
IS:1141 Seasoning of Timber - Code of Practice
IS:1328 Veneered decorative plywood
IS:1659 Block Boards

Decorative thermosetting synthetic resin bonded laminated
IS:2046 sheets
Wooden flush door shutters (solid core type): Plywood face
IS:2202 (Part 1) panels
Wooden flush door shutters (solid core (type): Particle face

IS:2202 (Part 2) panels and hardboard face panels
S Bearings
Standard specifications and code of practice for road bridges

IRC:83 Part-II Elastomeric Bearings
IRC:83 Part-III Pot Bearings
T UPVC Pipe For Drainage

IS 4985 Unplasticized PVC Pipes for portable water supplies
U PILING
IS :2911 PART-I Bored Cast in-situ Concrete Piles

IRC:78 Foundation And Substructure

V All Indian Railway Standards
MORTH Specifications for Road and Bridge works (latest

W Revision)
CPWD / PWD Government of Gujarat Specifications
X (latest Revision)

1.2 Excavation
1.2.1Preliminaries
1.2.1.1 Site Clearance
(1) The Contractor shall clear the Site as required by demolishing all
buildings, structures and the like, and removing vegetation, debris,
trees along with their roots and the like to locations agreed with the
Engineer either on or off Site
(2) Stumps and major roots shall be grubbed up and disposed of off
Site. The Contractor shall take precautions to protect all adjacent
public and private property during these operations and shall be
responsible for all and damage arising from such.
(3) The Contractor shall prevent erosion of all cleared excavation and
fill areas by providing suitable protection.
(4) The Contractor shall also prevent siltation of all areas adjacent to the
Works as a result of fines being transported from the Works by
provision of suitable silt fences.
1.2.1.2 Topsoil Stripping

(1) Topsoil shall be removed as required and deposited in separate
heaps at locations agreed with the Engineer.
1.2.1.3 Removal of Unsuitable Material

(1) Unsuitable materials are defined in Volume 4, Division H1, Clause
1.2.2.2
(2) The Contractor shall remove all unsuitable materials and dispose of
such as per the Contract stipulations.
1.2.1.4 General Excavation

(1) Excavation shall be carried out to the lines, levels and profiles
shown on the Drawings that have Notice of No Objection from
Engineer. The Work shall be carried out by the Contractor in such a
way as to avoid soil erosion, groundwater pollution, accidents in
habitational or frequented places, disturbance to the surrounding
ground or structures, accident to workmen and any other untoward
incident. Particular care shall be taken to maintain stability when
excavating in close proximity to existing Works. Fencing, caution
signage’s with red lights and other safety measures shall be
employed to avoid accidents. Where necessary, Signal men shall be
employed to guide the movement of people, vehicles and
equipment.
(2) The Work shall be carried out in a careful manner to ensure that
the exposed surfaces are as sound as the nature of the material
permits and that no point shall protrude inside the lines shown on
the Drawings except as given Notice of No Objection by the
Engineer. In soft soil excavation which is to remain open
permanently, exposed faces shall be formed accurately to the
required slopes and profiles and properly protected by turfing or

pitching as given Notice of No Objection by Engineer.

(3) The Contractor shall dispose of all material arising from excavations
either off the site or to noticed heaps on the Site, as required.
(4) The Contractor shall be responsible for keeping all excavations free
from water from whatever cause arising and shall provide such
pumping capacity and other measures as may be necessary for this
purpose.
(5) The Contractor shall be responsible for the safety and stability of all
excavations performed by him or under his control. In case of any
slips or blows in the excavation, the same shall be cleared by the
Contractor at his own cost.
(6) The Contractor shall notify the Engineer without delay of any
permeable strata, joints, faults, fissures or unusual ground
conditions encountered during excavation and any excavation
instability and/or collapse.
(7) The Contractor shall ensure that no air pollution takes place during
excavation, storage and transportation of earth/spoil by providing
suitable measures such as appropriate cover and the like.
(8) The Contractor shall provide to the Engineer full details of the
proposed rock excavation methods for Notice of No Objection.
Excavation should be carried out by controlled blasting where feasible
and permitted by the Engineer duly controlling the noise, dust and
vibration levels to be within the acceptable limits. However there may
be certain stretches on the alignment where blasting shall not be
permitted and at such locations appropriate excavation methods such
as mechanized or manual or by expansive chemical agents shall be
employed duly complying with all other stipulations of the Contract in
this respect. Similarly, the Contractor shall submit his plans for
methods for monitoring ground stability, noise and vibration
adjacent to residential area and sensitive structures including heritage
structures.
(9) The Contractor shall carry out ground stabilization measures without
delay before and/or after excavation, the Contractor may request the
Engineer to accompany him when inspecting structures and excavated
rock surfaces revealed after excavation operations.
(10) The Contractor shall make provision for all shoring, de-watering,
dredging, bailing out or draining water whether subsoil or rain or other
water and the excavation shall be kept free of water while concrete
work is in progress and until the Engineer considers the work well set
(Refer IS:3764 Safety Code for Excavation Work). The sides of
trenches shall be kept vertical and the bottom level throughout or
properly stepped as directed by the Engineer. No extra payment shall
be made on this account.
(11) De-watering shall be carried out by suitable means with adequate
stand-by arrangements as may be approved by the Engineer. The level
of ground water shall be maintained at least 1000 mm below the lowest
level of excavation during the laying of foundations. The Contractor
shall be deemed to have satisfied himself with regard to feasibility of
all aspects of de-watering including site constraints due to existing
structures. Though the method of de-watering is left to the contractor,

he shall be required to submit method statement of de-watering scheme

including requisite justifications to the Engineer and seek his prior
written approval.
Approval of the Engineer, however shall not relieve the contractor of
the responsibility of adequacy and appropriateness of de-watering and
protection arrangements for the quality and safety of the work. The
contractor shall satisfy the Engineer as to the capacity of the drains or
disposal site to take the required quantity and flow of water to be
pumped out at various stages of excavation. The Contractor shall
obtain necessary approvals of local bodies for discharging and
disposal of the pumped out water. All the de-watering pumps shall
therefore also have dedicated D.G. Power supply which shall start
automatically in case of failure of electrical supply. Monitoring of
water table shall be done using electronic probes or by other suitable
methods.
(12) The Contractor shall erect and maintain during progress of works
temporary fences / barricading around the work area with all safety
measures. The dangerous excavations, excavations near habitations,
public movement areas and all works along the roads, shall be,
provided with proper caution signs and marked with red lights,
reflectors at night to avoid accidents. The contractor shall take all
adequate protective measures to see that excavation operations do not
affect or damage adjoining structures.
(13) Excavation material required for filling shall be stacked or dumped
where indicated by the Employer. Excavated material not required for
filling and any surplus material shall be removed and spread on the site
anywhere within the premises and as directed by the Engineer or carted
away from the site as directed by the Employer. Dumping of this
surplus material shall be in an environmental friendly manner using
dumper with tarpaulin or suitable cover, placer etc. and according to
the levels/grades as indicated by the Employer. Levelling and
Compaction, if required, at the dumping ground shall also be carried
out. The cost of such removal and spreading shall be borne by the
Contractor and deemed to be included in the Contract Rates. Necessary
approval from the local authorities for carting and dumping surplus
material is to be obtained by the contractor at his own cost.
(14) The Contractor shall notify to the Engineer when the excavation is
completed and no base or Concrete or Masonry shall be laid until the
Engineer has inspected and approved of the soil conditions obtained
for each individual footing or the full raft area.
(15) The Contractor shall ensure the stability of the excavation so that the
surrounding ground and all adjoining structures and plants will be safe
against settlement, subsidence and damage and that there is no risk of
injury to personnel.
(16) In case any underground structures / utilities, that need to be protected
(like underground sewer lines etc.) are encountered, the Contractor
shall bring the same to the notice of the Engineer immediately and
shall take all such steps as the Engineer may instruct for protection of
such structures. Such protective measures shall be done at the
Contractor’s cost If any damage occur to such structures / utilities

which were required to be protected during execution, the same shall

be made good by contractor at his own cost otherwise client will
arrange to make it good at the risk and cost of Contractor.
(17) The Contractor is free, within the framework of rules and regulations
of the local authorities, to deal with the surplus earth in any manner
suitable to him. The Contractor may dispose off the surplus earth from
the project site to a place/ places as may be permitted by the Engineer/
appropriate authority/ body. The transportation of the surplus earth
shall be done by mechanical means only. The Contractor shall at his
own cost obtain necessary clearances/ permissions statutory or
otherwise needed for the purpose. Dumpers may be used for
transporting slushy, material excavated from pile boring / well boring /
pile cap / Open Foundation with precautions for non-spillage of muck.
In case earth is used for backfilling in foundation and plinth, it shall

be got approved from the Engineer. In the foundation the backfilling
shall be done in layers not more than 200mm thick and shall be
thoroughly watered and consolidated by approved method.
In case sand is used for backfilling in foundation and plinth, it shall be
got approved by the Engineer. In the foundation the backfilling shall be
done in layers not more than 200 mm thick and shall be thoroughly
watered and consolidated by approved method. The rate for backfilling
using sand in foundation is deemed to have been included in the
excavation rate.
For foundation resting on rock, if sound rock is located at shallow
depths, the contractor is required to cut the rock (of all type or
strength) to a depth so that open foundation with a minimum earth
cushion of 500mm can be accommodated. No extra payment for this
work will be made as it is included in the scope of work.
1.2.1.5 Excavation beyond True Lines and Levels

If from any cause whatsoever excavations are carried out beyond their true
line and level other than as per the noticed drawings then the Contractor shall
make good at his own cost to the required line and level with the appropriate
grade of filling to be contained in the true excavation, or with concrete or
other material in such a manner subject to the Notice of No Objection from
the Engineer.
1.2.1.6 Notice for Excavation

(1) When excavations have been taken out accurately to the profiles or
dimensions required for the Works, the Contractor shall inform the
Engineer for Notice of No Objection.
(2) The Contractor shall carry out additional excavation to such new
profiles or dimensions as the Engineer may give Notice of No
Objection to.
1.2.1.7 Excavations for Structures

(1) Open excavation to lay a foundation for a structure shall be carried
out to the lines and dimensions necessary to permit the proper
construction of that structure.

(2) Where a structure is to be founded on soft ground, the excavation

shall be taken down until the required suitable soil formation is
exposed and prepared to the Notice of No Objection of the Engineer.
(3) In the event of excavation having been made deeper than that
shown on the drawings or as noticed by the Engineer, the extra depth
shall be made up with concrete or masonry of the foundation grade at
the cost of the Contractor. Ordinary filling shall not be used for the
purpose to bring the base of foundation to required level.
(4) Prior to any construction within that excavation the bottom of the
excavation shall be re-compacted to achieve a dense smooth and level
surface longitudinally, transversely or stepped. Subject to the Notice
of No Objection from the Engineer, layers of granular fill not
exceeding 300 mm loose thickness shall be placed and compacted to
95% maximum dry density.
(5) Where required, filtered under drainage pipes shall be placed within
the granular fill layer in accordance with the noticed designs
(6) Surfaces of excavations or filling on which plain (unreinforced)
or reinforced concrete will be formed shall be prepared with a
blinding layer of concrete as shown on the Drawings or in such other
manner as will provide a suitable surface at the correct lines and levels
to the Notice of No Objection of the Engineer.
1.2.1.8 Trench Excavation for Utilities and Services

(1) Trench excavation shall be performed by the use of suitable
equipment, in such manner so as to minimize disturbance to the
required finished sides and bottom of the excavation.
(2) Trenches for pipes shall be excavated to a sufficient depth and
width to enable the utility or service and the specified joint, bedding,
haunching and surrounding to be accommodated and for all loose
material placed to be compacted to the required standards.
1.2.1.9 Trenches
(1) The Contractor shall carry out excavation in a safe manner such that
the sides of the trench are adequately supported and stable till the
completion of this work.
(2) The Contractor shall leave a clear adequate space between the
edge of the excavation and the inner toes of the spoil banks.
(3) Trenches shall be excavated to the lines and levels shown on the
Drawings.
(4) Trenches shall not be excavated too far in advance of pipe-laying
and the like, and shall be sufficiently wide to allow proper and
efficient jointing to be carried out in clean and dry conditions. Due
allowance shall be made for bedding and surrounds where these are
specified.
(5) The bottoms of all trenches shall be trimmed to grade and level and
compacted before any bedding is placed or pipes laid.
(6) The widths of trenches crossing roads or at other locations as directed
shall be as narrow as is practicably possible. The maximum width
measured between undisturbed soil in the trench sides shall not exceed
the outside diameter of the pipe being laid plus 550mm for pipes up to

and including 800mm in diameter and plus 750mm for pipes over
800mm in diameter.
(7) Trenches for pipes carrying water under pressure shall, except where
otherwise described in the Contract or agreed by the Engineer, be
excavated to a sufficient depth to ensure a minimum cover of 900mm
to the top of the pipes.
1.2.1.10 Road Crossings

The Contractor shall provide adequate support to all excavations within and
across existing roads. Care shall be taken by the Contractor to ensure that
existing roads and services are not damaged by road-crossing operations.
Excavations in roads shall be backfilled and roads repaired as soon as
practicable taking all safety precautions.
1.2.1.11 Channels
(1) Channels shall be excavated by methods which do not endanger the
stability of the side-slopes.
(2) Existing channels, which are to be reshaped, cleared and
trimmed, shall be cleared of all weeds and growth and the beds
graded to the required levels. The sides of channels shall be trimmed
to the required safe limits of slope and width.
(3) Side-banks of channels shall be trimmed to provide a neat appearance
and even surfaces.
(4) Any channels, streams, drains or pipes conducting water to or
from cultivated land shall be diverted so as to maintain their flow
before being moved or broken into. All diversions and their
subsequent reinstatement shall be carried out to the Notice of No
Objection from the Engineer
(5) The Contractor shall control the rates of filling and drawdown of
water in channels so as not to endanger the stability of the Works.
1.2.1.12 Notice for Excavations

(1) The Contractor shall seek Notice of No Objection from the
Engineer for all excavations prior to placing pavement layers, fill or
concrete.
(2) The Contractor shall maintain open excavations in a safe and stable
condition, and shall rectify the effects of deterioration due to weather.
1.2.2 Fill
1.2.2.1 Fill - General
(1) Prior to commencement of any filling either as backfill to
excavations or in the formation of embankments, the Contractor shall
submit in writing to the Engineer for ‘Notice of No Objection’ his
proposals for carrying out the Work such that the optimum use may
be made of excavated material. The proposals shall include details
of the compaction plant and methods for adjusting the moisture
content of the material.
(2) No filling shall commence until the ‘Notice of No Objection’ to his
proposals have been received from the Engineer.

1.2.2.2 Fill Material

(1) Fill material shall be obtained only from a source agreed with the
Engineer
(2) Fill material, other than for road works, shall be evenly graded
granular material.
(3) Before compacting the fill material, clods or hard lumps of earth
over 75mm in greatest dimension shall be broken up.
(4) The following types of material are considered unsuitable and shall
not be used for filling.
a) Materials from swamps, marshes or bogs.
b) Peat, loam, fine silt, log, stump or organic or perishable
materials.
c) Material susceptible to spontaneous combustion.
d) Clay of liquid limit exceeding 80% and plasticity index
exceeding 55%.
e) Materials containing salts prone to inducing leaching in the
embankment.
f) Any contaminated and environmentally unacceptable material.
(5) The Contractor shall carry out the following initial tests on the proposed
material. Thereafter, one set of tests shall be carried out for each 2000 m3
of fill, supplied to Site or as noticed by Engineer.
a) Wet sieve analysis.
b) Dry density/moisture content relationship.
1.2.2.3 Backfill - General

Except around structures, excavations shall be backfilled with suitable
excavated material and/or noticed material compacted in layers of 200mm
maximum loose thickness to achieve a density of at least 95% of the
maximum dry density.
1.2.2.4 Backfill to Structures

(1) The Contractor shall not backfill around structures until the
structural elements have attained adequate strength.
(2) The backfill material shall be selected excavated material or sand,
thoroughly compacted in layers not exceeding 200mm loose
thickness to achieve a density of at least 95% of the maximum dry
density.
1.2.2.5 Preparation of Base/Foundation for Embankment

(1) Prior to placing any embankment upon any area all clearing and
grubbing operations shall have been completed in accordance with
this Contract.
(2) Where the height of embankment is 1 meter or less all sod, grass and
vegetable matter shall be removed from the ground surface and the
top 150mm shall be processed as necessary and compacted to 90% of
the maximum dry density.
(3) Where new embankments are to be constructed against and on
existing slopes steeper than 1 vertical to 5 horizontal continuous
horizontal benches, each no greater than 500mm in vertical height
shall be cut into the existing slope and the embankment built up in
successive layers. Material in the existing slope which has been

loosened shall be re-compacted simultaneously with the first level
of embankment material placed.
(4) Where an embankment is to be placed against sloping ground
flatter than 1 vertical to 5 horizontal the existing ground shall first be
loosened to a depth no greater than 100mm to ensure adequate bond
between new and existing ground
(5) Unless otherwise shown on the Drawings, where existing unpaved
roads are to be covered with less than 300mm of fill, excluding
pavement, the top of the old road-bed shall be scarified and re-
compacted with the next layer of the new embankment. The total
depth of the scarified and added material shall not exceed the
permissible depth of layer.
(6) Granular material (egg. sand or gravel) shall be used as filling in
swamps or waterlogged ground. The Contractor shall submit details
of his proposed granular fill material to the Engineer for Notice of No
Objection. The Contractor shall first remove all unsuitable material
from the base of the proposed fill area and backfill with the agreed
granular material, placed and compacted in accordance with the
requirements of this Contract. Where deemed necessary the
Contractor may place a geo-fabric “separator” fabric to prevent
“punching of the fill into the underlying soft material in accordance
with cl 1.2.2.6 below.
1.2.2.6 Construction of Embankment

(1) General
Except as otherwise required all embankments shall be constructed in
layers approximately parallel to the finished grade of the track/road-
bed. During construction of embankment, a smooth grade having an
adequate crown or super elevation shall be maintained to provide
drainage. Embankments shall be constructed to the required grade,
and completed embankments shall correspond to the shape of the
typical sections as shown on the Drawings.
(2) Earth Embankment
a) Earth embankments shall be defined as those principally of
material other than rock, and shall be constructed of noticed
material brought from designated or other noticed sources.
b) Except as specified for embankment in swamps, earth
embankments shall be constructed in successive layers, for the
full width of the cross-section and in such lengths as are suited
to the compaction and watering methods used.
(3) Placing in swampy or waterlogged ground
a) Embankment in or over swamps or in water shall be
placed by placing granular material in a uniformly distributed
layers of thicknesses greater than that necessary to support
the equipment while placing subsequent layers, after which
the remainder of the embankment shall be constructed in
layers and compacted as specified.
b) Separation layers of either suitable geo-fabric and/or graded
sand shall first be placed in controlled layers to prevent

excessive penetration and/or the development of mud-waves.

(4) Preparation of sub-grade:
The surface of the finished sub-grade shall be neat and workmanlike
and shall have the required form, super elevation, levels, grades, and
cross-section. The surface shall be constructed to sufficient accuracy
to permit the construction of subsequent layers of material to the
thickness, surface tolerance, and compaction specified.
1.2.2.7 Compaction of Embankments

(1) When necessary, each layer before being compacted shall be
processed as required to bring the moisture content sufficiently close
to optimum to make possible its compaction to the required density.
The material shall be worked as to have uniform moisture content
through the entire layer.
(2) Each layer of material shall be compacted uniformly by use of
adequate and appropriate compaction equipment. The compaction
shall be done in a longitudinal direction along the embankment and
shall generally being at the outer edges and progress towards the
center in such a manner that each section receives equal amount of
compaction.
(3) Hauling equipment shall be operated over the full width of each layer
in so far as practicable. There should be a minimum overlap of
150mm between each run of the rollers.
(4) Embankment or backfill compaction shall be carried out in the
following way.
a) The top 200mm of the finished embankment shall be
compacted to a dry density equal to or greater than 98% of the
maximum dry density.
b) Other embankment layers more than 200mm below finished
surface or the underside of the lowest layer of base, sub-base
and shoulder shall be compacted to a dry density equal to or
greater than 95% of the maximum dry density.
1.2.2.8 Inverted Filter

(1) An inverted filter comprising of durable coarse stone
aggregates with an appropriate filter layer or geo-fabric between the
filter and the sub-grade shall be constructed behind earth retaining
structures.
(2) The inverted filter shall be constructed simultaneously with the filling
work to the retaining structure. Care shall be taken during placing of
the filter media to ensure that it does not cause damage to structural
members or application of excessive pressure against the retaining
structure.
1.2.3 Tests
1.2.3.1 Testing of Fill – General
(1) Classification tests as per relevant Standards to which the Engineer
has given his Notice of No Objection shall be carried out to ensure
that true comparisons can be made between in-situ densities,
laboratory compaction densities and field trial densities so that the

variations in properties of the fill materials can be determined.

(2) Tests shall be carried out on fill to determine the degree of
compaction achieved, at the rate of one test for either each 1000 m3
placed or each layer whichever is the more frequent. Compacted
layers shall not be covered without Notice of No Objection from the
Engineer.
(3) The density of individual compacted layers shall be determined
by a method agreed by the Engineer.
(4) The in-situ dry density of fill shall average 95% of the maximum
reached in trials.
No single result shall be less than 92% and no more than 25% of the
results on any one layer shall fall between 92% and 95%. The
average shall be computed from the total number of tests on any one
layer where the extent of the layer is defined by the Contractor when
submitting same for inspection.
1.2.3.2 Materials for Topmost Layer of Fill
(1) In addition to the general requirements for fill material, the material in
the topmost layer shall not exceed the following test values.
Plasticity Index: 6%
Liquid Limit: 35%
(2) Total fines content shall not exceed 15% and Uniformity Coefficient
(Cu) shall not be less than 4.
(3) The laboratory California Bearing Ratio (CBR) value at 95%
maximum dry density achieved after soaking for 96 hours shall not be
less than 30%.
1.2.3.3 Testing of Top Layer of Fill

(1) Tests shall be carried out on the top layer of fill as shown in the
following table. Tests shall be carried out as required by the accepted
test procedures.
Test Frequency of test

(Not less than one test per...)
A. Laboratory tests to monitor the consistency of
the noticed material during construction:
Maximum dry density 1000 m2
Optimum moisture content 1000 m2
Grading 1000 m2
Plasticity index 1000 m2

Linear shrinkage 1000 m2
CBR Value 2000 m2
B. In situ tests to confirm that the required
degree of compaction is being achieved during
Dry density
construction: 250 m2
CBR Value 1500m2

1.3 Roadwork
1.3.1 Control of Traffic

1.3.1.1 General
(1) The Contractor shall be responsible for designing, and implementing
all Temporary Traffic Management (TTM) schemes required for the
execution of the Works. The Contractor shall obtain Notice of No
Objection from the Engineer and approval from Relevant Authorities
for the TTM schemes.
(2) The preliminary traffic diversion scheme/report, available with the
Employer, may be made available to the Contractor for information
only. Prior to the Implementation of any works affecting road and
pedestrian traffic, the Contractor Shall determine the requirements for
the TTM schemes and conduct a detailed assessment of the proposed
outline TTM schemes for Notice of No Objection by Engineer and
for approval by Relevant Authorities. The assessment shall include:
a notice of the construction sequence, programme and outline
TTM schemes submitted, and the impact on traffic;
estimates of the peak volume of construction traffic that will be
generated during each phase of construction together with plans
showing the proposed routing of construction traffic to and from the
Site;
additional de t ai l s of traffic management schemes, including
diversion routes, that the Contractor intends to implement for the
construction of his Works;
traffic impact analyses to demonstrate the impact of construction
traffic and the Contractor’s proposed traffic management schemes on
the surrounding Road network;
additional field surveys and studies to establish traffic conditions
where appropriate;
all such additional information as may be required for the detailed
design of The traffic management schemes;
consultation and liaison with Relevant Authorities with a view to
developing a design that causes minimal impact and is acceptable
to all affected parties; and
Inversion routes’ road capacity improvement measures such as
parking restrictions, removal of road humps, over head constraints
due to wires and trees, road pavement improvement, junction
widening for ease of vehicle turning, signal timing change, etc.
(3) The Contractor shall also provide Engineer and the Relevant
Authorities with plans and diagrammatic representations to
accompany publicity materials relating to the approved TTM schemes.
(4) The Contractor shall be responsible for the construction,
manufacture, supply, erection, relocation, and subsequent removal
of all temporary traffic signs, directional signs, bollards, street
furniture, street lights, roads and road markings related to the TTM
schemes. All temporary signs required for the implementation of
traffic diversions and the Contractor’s TTM schemes shall be
designed in accordance with the relevant Code of Practice such as
the Indian Roads Congress, Ministry of Road Transport & Highways

and Indian Standards.

(5) The Contractor shall note that no traffic signals, traffic signs and
road markings in the public roads shall be erected, relocated or
removed unless authorized by Engineer, Traffic Police and Relevant
Authorities. Furthermore, no roads, lanes or footpaths shall be
opened or closed unless authorized by Engineer, Traffic Police and
Relevant Authorities.
(6) The Contractor shall protect the Works related to TTM schemes
from damage until such time as the Works have developed sufficient
strength to carry normal traffic loads without any damage to those
works. The Contractor shall also take up the maintenance
responsibilities of the TTM schemes.
(7) The Contractor shall be responsible for the temporary removal of
all existing signs (regulatory, warning and information type),
bollards, street furniture, and street lights, associated ducting, road
markings, etc that may affect the TTM schemes.
(8) Before any existing pedestrian route is severed or diverted, the
Contractor shall submit a detailed proposal to the Engineer, for
his onward submission to Relevant Authorities for approval.
However, obtaining approval of Relevant Authorities on all such
Contractor’s proposals shall be the responsibility of the Contractor.
The detailed proposal shall include:
(a) The width of the existing pedestrian route;
(b) Pedestrian volumes prior to diversion;
(c) The width of the diverted pedestrian route;
(d) The anticipated pedestrian volume along the diverted
pedestrian route; and
(e) Proposed temporary pedestrian direction signs.
(9) The Contractor shall ensure all existing or diverted pedestrian routes
within the Site are paved, protected, sign posted, illuminated, clean
and maintained in good condition to Engineer’s satisfaction.
(10) The Contractor shall be responsible for the relocation, installation,
traffic signal time adjustment, and traffic signal design of the
traffic signals affected by the TTM schemes. Traffic signals include
related posts, cables and equipment necessary for the proper operation
of the traffic signals.
1.3.1.2 Reinstatement
(1) The Contractor shall reinstate all signs, bollards, street furniture, street
lights, associated ducting, road markings, road, etc that have been
removed for the TTM. The reinstatement works shall be of at least
the original standards and to the satisfaction of the Relevant
Authorities and Engineer.
(2) Unless agreed with Relevant Authorities and Engineer, the
Contractor shall remove any traffic signals installed for TTM
schemes and reinstate area. The reinstatement works shall be to the
original standards and to the satisfaction of the Relevant Authorities
and Engineer.
(3) Unless agreed with Relevant Authorities and Engineer, the Contractor
shall reinstate any traffic signals removed for TTM schemes. The

reinstatement works shall be to the original standards and to the

satisfaction of the Relevant Authorities and Engineer.
1.3.1.3 Special Events

(1) For special public events such as festivals, and as ordered by Engineer
or relevant authorities, the roads or pedestrian routes being occupied
by the Contractor, or where the Contractor’s works are being carried
out, may have to be opened for public use for a short duration. The
Contractor shall proceed with all necessary measures or modify his
works to suit this purpose.
(2) The Contractor shall take all necessary and sufficiently adequate
precautions to protect against accidents, damages or the like that may
be deemed caused by construction equipment, tools, materials,
bitumen and bituminous material, or any other construction
materials, and shall be responsible for any claims arising from such
damage.
1.3.2 Technical Specifications for Road Work
(1) The Technical Specifications covering the materials and the
workmanship aspects for roadwork are included in this Sub-Section.
These specifications are not intended to cover the minute details. The
Works shall be executed in accordance with good practices followed
for achieving high standards of workmanship, thus ensuring safety
and durability of the Works. All codes and standards referred to in
these specifications shall be the latest thereof, unless otherwise stated.
(2) The attention of the Contractor is drawn to those clauses of
Codes/Standards which require supporting Specifications either by the
Engineer or by ‘Mutual' agreement between the Contractor and
Employer/Engineer. In such cases, it is the responsibility of the
Contractor to seek clarification on any uncertainty and obtain prior
approval of the Engineer before taking up the supply/construction. In
absence of such prior clarification, the Engineer’s choice/decision
shall be final and binding on the Contractor without any extra cost to
the Employer.
(3) All defective works are liable to be demolished and rebuilt and
defective materials replaced by the Contractor at his own cost. In
the event of such works being accepted after the repairs etc.,
have been done by the Contractor to the satisfaction of the
Engineer, the cost of such repairs shall be borne by the
Contractor.
(4) The Technical Specifications for Roadwork shall be the
"Specifications for Road and Bridge Works” (Fifth Revision April
2013), published by the Indian Roads Congress, on behalf of
Government of India, Ministry of Road Transport and Highways
and, called MORTH Specifications.
(5) Median Plantation, Avenue Plantation and Landscaping shall be
done as per “IRC: SP: 21-2009 Guidelines of Landscaping and Tree
Plantation”.

1.4 Piling and Diaphragm Walling
1.4.1 General
1.4.1.1 Piling plant and Methods
(1) Not less than 2 weeks before any piling work is commenced the
Contractor shall submit to the Engineer for Notice of No Objection
full details of his proposed piling plant, and detailed method
statements for carrying out the Works in the anticipated ground
conditions including boulders, soft ground, hard ground(soft/hard rock)
and below groundwater table . Such details shall include where
applicable a full description of the piling plant, drilling equipment ,
support systems and means to deal with hard ground conditions and
socketting the piles in rocks duly containing the noise and vibration
levels at sensitive locations. Details of casings and concreting
methods in respect of any driven or bored cast- in-place concrete piles
shall be included in the submission.
(2) The Contractor shall not commence any piling until the plant and
methods which he proposes to use have received a ‘Notice of No
Objection’ from the Engineer but such a notice shall not relieve the
Contractor from any of his obligations and responsibilities under the
Contract. If for any reason the Contractor wishes to make any
change in the plant and methods of working, he shall not make any
such change without having first obtained the Engineer's ‘Notice of No
Objection’ for such changes.
(3) Reference shall be made to the following documents regarding matters
relating to the safety of piling works.
BS8004 Code of Practice for Foundations
BS5573 Code of Practice for Safety Precautions in the
Construction of Large Diameter Boreholes for Piling and Other
Purposes
1.4.1.2 Records
The Contractor shall keep complete records of all data as required by the
Engineer covering the fabrication, driving and installation of each pile and
shall submit two signed copies of these records to the Engineer not later
than 24 hours after installation of the piles.
1.4.1.3 Program and Progress Report

(1) The Contractor shall inform the Engineer each day of the programme
of piling for the following day and shall give adequate notice of his
intention to work outside normal hours and at weekends.
(2) The Contractor shall submit to the Engineer on the first day of each
week, or on such other date as the Engineer may decide, a progress
report detailing the rate of progress to that date and progress during
the previous week and/or period of all main items of piling works.
1.4.1.4 Setting Out

(1) The Contractor shall establish and maintain permanent datum level
points, base lines and grid lines to the Notice of No Objection from the
Engineer and shall set out with a suitable identifiable pin or marker the

position of each pile.

(2) The setting out of each pile shall be given a Notice of No
Objection from the Engineer at least one day prior to commencing
work on a pile and adequate notice for checking shall be given by the
Contractor.
(3) Notwithstanding such notice, the Contractor shall be responsible for the
correct and proper setting out of the piles and for the correctness of the
positions, levels, dimensions, and alignment of the piles.
1.4.1.5 Tolerances
(1) Piles
a) Piles shall be driven or bored accurately vertical or to the specified
rake and the permitted deviation of the pile centre from the centre-point
shown on the setting out plan shall not exceed 25mm measured at the
working level of the piling rig, or other level with a Notice of No
Objection from the Engineer.
b) Deviation from specified cut-off level shall be plus/minus 25mm
c) The maximum permitted deviation of the finished pile shall be 1 in
200 from the vertical for vertical piles, and for raking piles 1 in 25
from the specified rake.
d) Forcible corrections shall not be made to piles.
e) The manufacturing tolerances for precast concrete piles shall comply
with the following requirements.
i) The external cross-sectional dimensions shall be within 0mm
and +50mm of the specified dimensions.
ii) The wall thickness of hollow spun concrete piles shall be within
0mm and +25mm of the specified thickness.
iii) There shall be no irregularity exceeding 6mm in a 3 meter
length along the face of the pile measured using a 3 meter straight
edge.
iv) The centroid of any cross-section of the pile shall not be more
than 12mm from the straight line connecting the centroids of
the end faces of the piles.
v) The centroid of any cross-section of a hollow pile shall be
determined by assuming that the pile has a solid section.
f) The diameter of cast-in-situ piles shall be at least 98% of
the specified diameter.
(2) Pile caps
a) Variation in dimensions shall be limited to +50mm and –10mm.
b) Misplacement in plan from specified position shall be limited to 15mm.
c) Surface irregularity measured with 3 meter straight edge shall be
limited to 5mm.
d) Variation of levels at the top shall not be beyond plus/minus 25mm.
1.4.1.6 Disturbances and Noise

(1) The Contractor shall carry out the piling work in such a manner and at
such times as to minimize noise and disturbance. The Contractor shall
employ suitable methods for boring/drilling /driving of piles,
particularly in rocky strata (boulders, soft rock and hard rock) so as to
limit the vibration (as specified in outline design Specifications) and

noise levels as acceptable to the residents of the area and Engineer.

The Contractor may have to change his pile boring/drilling/ driving
method, if so directed by the Engineer, in case the vibration and noise
levels generated are excessive and are objected to by the residents of
the area and the Relevant utility/services Authorities/Agencies.
(2) The Contractor shall take precautions adequate enough to avoid
damage to existing utilities and services and adjacent structures.
(3) The Contractor shall ensure that damage does not occur to any part of
completed piling works and shall submit to the Engineer for Notice of
No Objection his proposed sequence and timing for driving or boring
piles having regard to the avoidance of damage to adjacent piles.
1.4.1.7 Obstructions
If during the execution of the Works the Contractor encounters
obstructions in the ground, he shall immediately notify the Engineer
accordingly, submit to him details of proposed methods for overcoming the
obstruction for Notice of No Objection from the Engineer.
1.4.2 Concrete Piles

1.4.2.1 Materials - General
(1) Requirements of concrete and reinforcement for precast and cast in-
situ piles shall comply with Volume 4, Division H1, Clause 1.5 of this
Contract. Minimum grade of concrete for piles (other than secant piles
wall) shall be M40 subject to the provisions in Contractor’s DARR as
accepted by the Engineer. For Secant piles wall, the minimum grade of
concrete shall be M40.
(2) Precast piles shall be marked at the time of concreting with all relevant
information – egg, date, reference number, length and the like.
1.4.2.2 Reinforcement
(1) The reinforcement shall be assembled before placing in the moulds
and all hoops and links shall be of uniform length firmly wired into
position. Ends of helical reinforcement shall be firmly secured.
Diagonal fork spacers shall be of a Noticed pattern. In this respect
provisions pertaining to DAAR in Outline Design Specifications shall
be referred to and complied with by the Contractor.
(2) Joints in main longitudinal bars will be permitted only where each bar
cannot be practically supplied in one complete length. Where
permitted, joints shall be provided at agreed centre’s, designed to
develop the full strength of the bar across the joint, provided
with adequate links or stirrups and staggered in position from those of
adjacent longitudinal bars.
(3) Welding of cold worked high tensile requirement bars at joints in
main longitudinal bars will not be permitted without the agreement
of the Engineer in which case, the Contractor shall comply with the
requirements of IS 9417.
(4) Welding of hot-rolled high tensile steel bars shall be permitted
provided the method used for the same will not adversely affect the
properties of bars.

1.4.3 Precast Concrete Piles

1.4.3.1 Formwork
(1) Formwork shall comply with subsection 1.6 of this Specification
except as specified below. The head of each pile shall be square to
the longitudinal axis. The corners of the head and pile shaft for a
distance of 300mm f r o m the head shall be chamfered 25mm by
25mm. The method of forming hollow cores where required shall be
such that a continuous core is formed. The use of previously cast
piles as side forms will not be permitted holes for toggle bolts shall
be at right angles to the faces of the pile and lined with steel tubes
or other noticed material. Holes for lifting, handling and pitching
shall be formed in accordance with the agreed Drawings.
(2) Details of all pile shoes shall be submitted to the E n g i n e e r for
Notice of No Objection prior to fabrication or supply. All shoes shall
be fitted to the reinforcement as shown on the agreed Drawings.
1.4.3.3 Protection of Finished Piles

(1) Protection of finished piles against aggressive soil conditions shall be
provided by one of the following methods and as agreed in Contractor’s
DAAR.
a) Using sulphate-resistant cement - ASTM or TIS Type 5 or
Equivalent Indian Standards IS 12330.
b) Increasing concrete cover to the reinforcement
1.4.3.4 Lengthening of Concrete Piles
(1) Where it becomes necessary to lengthen a pile, the reinforcement at the
head of the pile shall be stripped of all surrounding concrete and
additional reinforcement added.
(2) The length stripped shall be not less than 40 times the maximum
diameter of the longitudinal reinforcement in the case of a spliced joint
or at least 300mm for a butt-welded joint. New binders of the same
size and spacing as in the original pile head and additional blinders
shall be fixed in the extension and the pile extended by concreting
between properly formed and supported moulds to the required
length. Prior to casting the extension, the existing concrete surface shall
be cut to sound concrete square to the pile axis and all loose particles
removed by wire brushing. This shall be followed by washing with
water and preparing and coating with a Noticed epoxy bonding agent
applied in accordance with the manufacturer's recommendation. Care
s h a l l b e taken to ensure that the alignment of the extended pile
across the joint is exactly maintained.
(3) Prior to carrying out any work for the lengthening of piles, the
Contractor shall submit a detailed method statement to the Engineer for
Notice of No Objection.
(4) After piles have been lengthened, driving shall not be resumed until the
specified characteristic strength of the added concrete has been
attained. Subject to the ‘Notice of No Objection’ from the Engineer
in writing, the Contractor may use rapid hardening Portland cement
conforming to IS 8041 for pile extensions in order to expedite the
Work.
(5) Driving or re-driving of concrete piles extended as described above

shall not be resumed until a Notice of No Objection is given by the

Engineer.
1.4.4 Cast-in-Place Piles

1.4.4.1 Bored Piles
(1) The Contractor shall check and agree with the Engineer the casing
position for each pile during and immediately after placing the casing.
Piles shall be constructed in a sequence submitted in advance to the
Engineer. During boring, the Contractor shall take soil, rock or
groundwater samples and transport them to a Noticed testing laboratory
or carry out in-place soil tests. A complete record of the construction of
each pile shall be kept by the Contractor and made available for
inspection by the Engineer.
(2) Diameters of the piles shall not be less than the diameters
specified by the Contractor’s Designer and given Notice by the
Engineer. Where enlarged bases are required, these shall be
mechanically formed and concentric with the pile shaft to within a
tolerance of 2% of the shaft diameter and shall not be smaller than
the required dimension. The sloping surface of the frustum forming the
enlargement shall make an angle not less than 55 degrees to the
horizontal. The diameters of piles shall be verified by Koden method or
other methods subject to the Notice of No Objection from the Engineer.
(3) Where polymer drilling fluid is used in boring for maintaining stability,
the level of the fluid in the excavation shall be kept at not less than
1.5 meters as per IS:2911 above the level of the external
groundwater or at such other level as will ensure that the fluid
pressure is at all times in excess of pressures exerted by the soils and
external groundwater.
(4) An adequate temporary casing shall be used where required for
ensuring stability of the strata near ground level until concrete has
been placed in the pile. A pile excavation shall be backfilled without
delay where a rapid loss of drilling fluid occurs and no further
excavation at the location of that pile shall be carried out until the
Contractor has obtained the Engineer's Notice of No Objection for
the proposed remedial work.
(5) Pumping from a boring shall not be permitted unless Notice of No
Objection is given by the Engineer.
(6) Where temporary casings or alternative methods for maintaining
stability of a boring are used, these shall be subject to the Notice of
No Objection from the Engineer.
(7) Temporary casings shall be free from distortion and of uniform
cross-section throughout each continuous length. During concreting,
all temporary casings shall be free from internal projections, encrusted
concrete or other materials. For minimum standards the length of such
casing shall be as per IS: 2911.
(8) Piles constructed in a stable cohesive soil without temporary casings
or other forms of support shall be bored and concreted without
prolonged delay which might allow collapse of any part of the pile
boring.
(9) On completion of boring, all loose, disturbed or remoulded soil shall be

removed from the base of the pile. Prior to placing concrete, the
Contractor shall inspect each and every pile boring and submit his
pile boring inspection records for Notice of No Objection from the
Engineer. After each pile has been cast, any empty bore which may
remain shall be protected and carefully backfilled as soon as possible.
1.4.4.2 Concreting
(1) The method of placing and the workability of the concrete shall be
such as to ensure that a continuous monolithic concrete shaft of the full
cross section is formed. The method of placing shall be subject to
the Notice of No Objection from the Engineer and shall be
carried out after inspection without such Interruption as would
allow the previously placed batch to have hardened. No
contamination of the concrete by spoil, liquid or other foreign matter
shall be allowed.
(2) The Contractor shall take all precautions to ensure that the concrete
mix and placing of the concrete does not result in arching of concrete in
a casing. Slump measured at the time of discharge into the pile boring
shall be in accordance with requirements as specified in IS 2911, Part I,
Section 2. Internal vibrators shall not be used to compact concrete
unless the Contractor is satisfied that no segregation or arching of the
concrete will result.
(3) Where concrete is placed in dry borings, measures shall be taken to
avoid segregation and bleeding and to ensure that the concrete at the
bottom of the pile is not deficient in cement.
(4) Concrete placed under water or drilling fluid shall be by means of a
tremie and shall satisfy requirements as per IS 2911, Part I, Section 2.
(5) Before concreting is commenced, the Contractor shall remove any
accumulation of silt or other material at the base of the pile or boring.
(6) The hopper and pipe of the tremie shall be clean and water-tight
throughout. The pipe shall extend to the base of the pipe or boring and a
sliding plug shall be placed in the pipe to prevent direct contact between
the first charge of concrete in the tremie pipe and the water or drilling
fluid. At all times during concreting, the tremie pipe shall penetrate the
previously placed concrete and shall not be withdrawn from the
concrete until completion of concreting. A sufficient quantity of
concrete within the pipe shall be maintained at all times to ensure that
the pressure within the tremie pipe always exceeds that from the
water or drilling fluid.
(7) The internal diameter of the tremie pipe shall not be less than
200mm for concrete made with 20mm aggregate, or as agreed with the
Engineer.
1.4.4.3 Drilling Fluid

(1) Drilling fluid shall comprise polymer complying with Specification
IS: 2720; IS:2911, Part I, Section 2, Appendix-A or DFCP 4 of the
Oil Companies Materials Association or given Notice by the
Engineer and thoroughly mixed with clean fresh water to form a
suspension meeting the specification requirements as submitted to and
a Notice of No Objection given by the Engineer.

(2) The Contractor shall obtain manufacturers' certificates of the

p o l y m e r powder consigned to the Site giving properties of each
consignment and shall submit them to the Engineer prior to
commencing the Work and whenever required.
(3) The temperature of the water used in mixing the suspension shall not be
lower than 5○C. Where saline or chemically contaminated groundwater
occurs, special precautions to the Notice of No Objection from the
Engineer shall be taken to modify the polymer suspension or pre-
hydrate the polymer in fresh water so as to make it suitable for pile
construction.
(4) The type and frequency of testing drilling fluid and the method and
procedure of sampling shall be proposed by the Contractor and subject
to Notice of No Objection from the Engineer prior to commencement of
piling work. Such control tests on the polymer suspension shall be
carried out during the course of the piling work.
(5) Before concreting a pile, the Contractor shall remove any heavily
contaminated polymer suspension which could impair the free flow of
concrete from the tremie pipe. A sample of the polymer suspension
shall be taken from the base of the boring using an Noticed slurry
sampling device and the specific gravity of the suspension should not
exceed 1.20 as per standard practice and also as per IS:2911.
Consistency of the mud suspension shall be controlled throughout the
pouring as well as concreting operations in order to keep the hole
stabilized as well as to avoid concrete mixing with the thicker mud
suspension.
(6) All reasonable steps shall be taken to prevent the spillage of polymer
suspension on the Site in areas outside the immediate vicinity of.
Discarded polymer shall be removed from the Site without delay and
any disposal thereof shall comply with the regulations of all appropriate
Relevant Authorities.
1.4.4.4 Extracting Temporary Casing

(1) The plant and methods of extraction of temporary casing shall be
subject to the Notice of No Objection from the Engineer. Temporary
casings for driven or bored cast-in-place piles shall be extracted
carefully while the concrete is sufficiently workable to ensure it is not
disturbed or lifted.
(2) During extraction, a sufficient quantity of concrete shall be
maintained inside the casing to overcome the pressure from external
water, soil or drilling fluid and to ensure that no reduction in section by
way of necking or shearing of concrete and contamination of the pile
takes place.
(3) Concrete shall be placed continuously as the casing is
extracted whilst maintaining the required head of concrete. The pile
should be formed at least 300mm above the cut-off level. Guidelines
in this regard as mentioned in IS:2911, shall be followed along with
other international standard practices. .

1.4.5 Pile Testing

1.4.5.1 General
Load testing of Piles shall conform to IS 2911, Part IV.
1.4.5.2 Safety Precautions

(1) General
When preparing for conducting a pile test the Contractor shall
comply with the requirements of the various acts, orders, regulations
and other statutory instruments that are applicable to the Work for the
provision and maintenance of safe working conditions, and shall in
addition make such other provision as may be necessary to safeguard
against any hazards that are involved in the testing or preparations for
testing.
(2) Personnel
All tests shall be carried out only under the direction and in presence of
an experienced and competent supervisor conversant with the test
equipment and test procedure. All personnel operating the test
equipment shall have been trained in its use.
(3) Kentledge
a) Where kentledge is used the Contractor shall construct the
foundations for the kentledge and any cribwork, beams or other
supporting structures in such a manner that there will not be
differential settlement, bending or deflection of an amount that
constitutes a hazard to safety or impairs the efficiency of the
operation.
b) The kentledge shall be adequately bonded, tied or otherwise held
together to prevent it collapsing, or becoming unstable due to
deflection of the supports.
c) The weight of kentledge shall be greater than the maximum test
load and if the weight is estimated from the density and volume
of the constituent materials an adequate factor of safety against
error shall be allowed.
d) No part of the kentledge support system shall be closer to the pile
centre-line than a distance of 2.5 times the shaft diameter of the
pile subject to the Notice of No Objection from the Engineer.
e) The weight of the kentledge shall be transferred in manner so that:
(i) The load is transferred symmetrically around the pile head;
(ii) the suitability of the kentledge is maintained at all time,
and;
(iii) any tendency of the kentledge to tilt or sway is minimized.
f) Loads shall not be allowed to be applied by supporting the
kentledge directly on the pile or pile cap.
(4) Tension piles and ground anchors
a) Where tension piles or ground anchors are used the Contractor
shall ensure that the load is correctly transmitted to all the tie rods
or bolts.
b) The extension of rods by welding shall not be permitted unless
it is known that the steel will not be reduced in strength by
welding.
c) The bond stresses of the rods in tension shall not exceed normal

permissible bond stresses for the type of steel and grade of

concrete used.
(5) Testing equipment
a) In all cases the Contractor shall ensure that when the hydraulic
jack and load measuring device are mounted on the pile head the
whole system will be stable up to the maximum load to be applied.
b) Means shall be provided to enable dial gauges to be read from
a position clear of the kentledge stack or test frame in
conditions where failure in any part of the system due to
overloading, buckling, loss of hydraulic pressure and so on
might constitute a hazard to personnel.
c) The hydraulic jack, pump, hoses, pipes, couplings and other
apparatus to be operated under hydraulic pressure shall be capable
of withstanding a test pressure of one and a half times the
maximum working pressure without leaking.
d) The maximum test load or test pressure expressed as a reading on
the gauge in use shall be displayed and all operators shall be made
aware of this limit.
e) General requirements for load test equipments shall be as follows.
i) Load capacity not less than the maximum required load in
the schedule of testing.
ii) Adequate enough to accommodate the maximum required
pile movement specified in the schedule plus the
displacement of the reaction system that occurs during
load test.
iii) Fully controlled increase or decrease in test load
iv) Fully capable of sustaining the applied load as
constant for specified period of time.
1.4.5.3 Presentation of Results

(1) Results to be submitted
Results shall be submitted as follows.
(a) Unless otherwise directed the Contractor shall submit a
summary of the pile test results in writing to the Engineer,
within 24 hours of the completion of the test. This summary
shall include as a minimum the following information.
(i) For a proof test with maintained load for each stage of
loading, the period for which the load was held, the load
and the maximum settlement or uplift recorded.
(ii) For Constant Rate of Penetration (CRP) or Constant Rate
of Uplift (CRU) test, the maximum load reached and a
graph showing applied load versus penetration
(movement) or applied load versus uplift - movement.
(b) Complete schedule of all recorded data shall be submitted to the
Engineer as both hard and soft copy in spreadsheet (Excel)
format within seven days of the completion of the pile test.
1.4.5.4 Completion of a Test

(1) Measuring equipment
On completion of a test all equipment and measuring devices

shall be dismantled, checked and either stored so that they are

available for use in further tests or removed from the Site.
(2) Kentledge
Kentledge and its supporting structure shall be removed from the test
pile and stored so that they are available for use in further tests or
removed from the Site.
(3) Ground anchors and temporary piles
On completion of a preliminary test, tension piles and ground anchors
shall be cut off below ground level, removed from the Site and the
ground made good with Noticed material.
(4) Preliminary test pile cap
a) The pile cap, if formed in concrete, shall be broken off and
the resulting material disposed off the Site. If the pile cap is made
of steel it shall be cut off and stored so that it is available for use
in further tests or removed from the Site.
b) For preliminary test piles which are not to be incorporated into
the Permanent Works, they shall be broken down to 2 metres
below ground level or as required and backfilled to the original
ground level with suitable material. For preliminary test piles
which are to be incorporated into the Permanent Works the pile
head shall be made good or extended to the cut-off level.
(5) Test pile cap
a) On completion of a test on a working pile, the test pile cap, if in
concrete, shall be stripped, the pile left in a state ready for
incorporation in the Permanent Works and the resulting material
disposed off the Site.
b) If the pile cap is made of steel it shall be cut off and stored
so that it is available for use in further tests or removed from the
Site as specified.
1.4.5.5 High Strain Dynamic Testing of Piles

Dynamic pile testing, which mobilizes all or part of the available pile static
capacity, shall be used where specified or required and shall be subject to
the Notice of No Objection from the Engineer.
1.4.5.6 Lateral Load Tests

Lateral load tests, where required shall be carried out using temporary plant
capable of providing an unyielding reaction of at least 1.5 times the
maximum lateral load to which the pile is to be tested. Alternatively, where
tension piles of the same size and type as the permanent piles are used for
providing the reaction system for vertical load tests these may be used for
the lateral load test by jacking apart. In this case the reaction piles shall be
provided with sufficient reinforcement to sustain the effects of maximum
lateral load.
1.4.5.7 Pile Integrity Tests

(1) General
a) Pile integrity testing shall be used where specified or required as
a method of proof-testing a pile as work proceeds with the aim of

indirectly assessing one or more of the following.

i) The structural integrity of the pile.
ii) The relative shape of the pile shaft and an estimate
of the physical dimensions of the pile or both.
iii) The continuity of the pile
b) Pile integrity testing, when specified/required, shall be performed
on a sufficient number of piles.
c) All testing shall be subject to the Notice of No Objection from the
Engineer.
(2) Test Procedure
a) Where integrity testing is required, the test to be adopted shall
be one of the following.
i) Sonic impact test (SIT)
ii) Sonic vibration test (SVT)
iii) Alternative test, as agreed
(3) Supervision and recording of results
Pile tests shall be carried out under the direction of a person
experienced in the supervision of pile integrity tests who shall record all
results in both hard and electronic form in preparation for submission to
the Engineer.
1.4.6 Diaphragm Wall

1.4.6.1 General
(1) The recommendations of BS 8004 ‘Code of Practice for
Foundation’ and DIN 4126 ‘Cast-in-situ concrete diaphragm walls;
design and construction’ shall be followed insofar as they are applicable
to diaphragm wall construction. Similar Indian Standards for guidance
or adoption are; IS 9556, IS 4651 and IS 456.
(2) The Contractor shall take full account of fact that in some locations the
walls may be close to existing structures and/or within a location where
headroom is limited.
(3) The Contractor shall pay particular attention to safety aspects of
the Work, employing barriers and covers as necessary.
1.4.6.2 Method Statement

(1) The Contractor shall submit a method statement giving the full
details of materials, plant and operations involved in the construction
of diaphragm walls at least 4 weeks prior to the commencement of
construction of diaphragm wall. This method statement shall include but
not be limited to the following details.
(a) Dimension of walls and lengths of panels.
(b) Design calculation, dimensions and details of guide walls.
(c) Formation of the joints between panels, including sealing the
joints and installation of water stop.
(d) Sequence of excavation and concreting of panels.
(e) Methods of monitoring and checking the stability of adjacent
buildings, structures properties, pavements, railways, services,
utilities road furniture and the like, all termed EBS.
(f) Methods of monitoring and checking the tolerances associated
with the diaphragm wall panels.

(g) Methods of monitoring and checking the stability of the

diaphragm wall trench.
(h) Mixing, transporting and placing equipment for the polymer
slurry.
(i) The cleaning and reuse of polymer slurry.
(j) Method of disposal of contaminated polymer slurry.
(k) Type, source, chemical and physical properties of the polymer to
be used.
(l) Calculations to show that the density of the polymer and lowest
head of slurry are sufficient to maintain the stability of the trench,
in the ground conditions envisaged, to its entire length.
(m) Methods of protection of any adjacent structure and utilities
existing close to the trench.
(2) Construction of diaphragm walls shall not commence until the
Contractor’s proposals have received a ‘Notice of No Objection’ from
the Engineer.
(3) Unless otherwise given Notice of No Objection by the Engineer, the
construction of panels shall be continuous once excavation has
commenced. Excavated panels or part panels shall not be left open at
night or during weekends.
1.4.6.3 Levels of Work

(1) Diaphragm walls shall be concreted to the levels shown on the
construction drawings.
(2) If the groundwater table is high, the effective trimmed final wall
levels shall normally be taken as 250mm below top of guide wall when
concrete is cast-up to top of trench. If the required cut-off is low and
the groundwater table is also at depth, concreting can be stopped at
lower level subject to the Notice of No Objection from the Engineer.
(3) Any remaining polymer within the trench shall be displaced off using
lean mix concrete, which shall be poured to the top of the guide walls.
1.4.6.4 Length of Panels

The length of the panels to be concreted shall be defined in the Contractor's
method statement and shall be subject to a ‘Notice of No Objection’ from the
Engineer.
1.4.6.5 Tolerances
(1) Construction shall be carried out in accordance with the following
normal tolerances, unless otherwise defined by the Contractor's
drawings or procedures.
a) For straight or other specified profile panels, the minimum clear
distance between the faces of the guide walls shall be the
specified diaphragm wall thickness plus 25mm, and the maximum
distance shall be the specified diaphragm wall thickness plus
50mm. The guide walls shall be propped as necessary, to
maintain these tolerances, and the inner guide wall shall be
constructed to the line as shown on the drawings.
b) The trench face of the guide wall on the side of the trench nearest
to the subsequent main excavation shall be vertical to within

1:200. The wall face shall not vary from a straight line or the
specified profile by more than plus 15mm in 3 meters and shall
be without ridges or abrupt irregularities.
c) The plane of the diaphragm wall face to be exposed shall be
vertical to within a tolerance of 1:200, relative to a vertical line
projected from the base of the guide wall. In addition to this
tolerance, 75mm shall be allowed for protuberances resulting
from irregularities in the ground excavated beyond the general
face of the wall.
d) The ends of panels shall be vertical to within a tolerance of 1:100.
e) Where recesses are to be formed by inserts in the wall,
they shall be positioned within a vertical tolerance of ±50mm, a
horizontal tolerance measured along the face of the wall of
±50mm, and a horizontal tolerance at right angles to the face of
the wall as constructed of ±20mm measured to the reinforcement
cage.
f) The tolerance in positioning reinforcement shall be as follows.
i) Longitudinal tolerance of cage head at the top of the
guide wall and measured along the trench: ±50mm.
ii) Vertical tolerance at cage head in relation to the top of
the guide wall: ±40mm.
iii) Lateral tolerance of reinforcement position in the
direction across the width of the wall; ±20mm.
g) The tolerance in positioning couplers and starter bars for
subsequent structural connections shall be as follows.
i) Longitudinal tolerance measured along the trench, ±50mm.
ii) Vertical tolerance, ±40mm.
iii) Lateral tolerance in the direction across the width of panel,
±20mm.
h) A minimum cover to main reinforcement shall be
80mm.Minimum clear distance between reinforcement bars shall
be 100mm.
i) Notwithstanding the requirements of this sub-section the
tolerances may be aggregated only to the extent that they do not
exceed 200mm.
(2) If, during the general excavation, it is detected that the above-stated
tolerances have been exceeded, the Contractor shall draw up
proposals for remedying or compensating for the defects.
1.4.6.6 Access
The Contractor shall note the restricted access to portions of the Works
and shall satisfy himself that his method of excavation, positioning of
equipment, spoil handling, placement of reinforcement cages, stop ends, and
concreting can be accommodated within these restrictions.
1.4.6.7 Adjacent EBS

(1) The Contractor shall be responsible for any movement, distortion or
damage resulting from his work to adjacent EBS.
(2) The Contractor shall be deemed to have made due allowance in his
rates and prices (The Contract Prices) for all ancillary treatment and

all work necessary to ensure the stability/protection of all EBS that

may be affected by his work.
1.4.6.8 Reinforcement
Refer Cl. 1.5.2.8 for reinforcement details.
1.4.6.9 Concrete
(1) Concrete shall comply with the Contract requirements/Specifications.
Structural concrete shall have minimum cement content for various
grades of concrete as agreed by the Engineer as part of the Contractor’s
DAAR keeping in view the durability and other requirements
(2) Minimum slump of the concrete shall be 150mm and the mix shall
flow easily within the tremie pipe and be designed to produce a dense
impervious concrete. Such structural concrete shall have a minimum
concrete grade of M40 and the water: binder ratio of the mix shall not
exceed 0.40 or as required by the design subject to fulfillment of the
provisions of DAAR.
(3) Lean mix concrete as per IS 456 clauses 5 to 8 shall be used as
backfill above any cut-off level for structural concrete and be taken to
the top level of the guide walls.
Cement content should not be less than 380 kg / cum of concrete for
Diaphragm wall.
For Diaphragm wall, OPC cement shall confirm to sulphate

concentration criteria as pe Sr .No (i) & (ii) of Table 4 of IS 456 and for
higher concentration sulphate content the type of cement shall be used
as per Sr. No. (iii), (iv) & (v) of Table 4 of IS 456. This condition shall
be followed wherever required in concrete of other part of Underground
structure.
1.4.6.10 Test Cubes

(1) Test cubes shall be made and tested in accordance with Volume 4,
Division H1 clause 1.5.2.
(2) Test cubes shall be taken for each panel constructed. Cubes shall be
marked with the wall panel numbers and shall be sub-marked within
each panel set to indicate a location within the panel.
1.4.6.11 Polymer
(1) Polymer for use in the wall support slurry shall be in accordance with
the requirements of this Contract.
(2) The Contractor shall institute a programme of regular sampling and
testing to ensure that the polymer fluid properties are suitable for use in
the Works. In this regard IS: 9556 shall be used for guidance.
1.4.6.12 Storage of Polymer

(1) Polymer shall be stored in dry cool conditions. Particular care shall
be taken with bulk storage to prevent balling of polymer powder due to
damp, or deterioration of properties due to damp and heat.
(2) A suitable design of hopper cone and polymer feeding device shall be

adopted. IS 4082 shall be used for guidance regarding stacking

and storage of construction materials and components at site.
1.4.6.13 Alternative Materials

(1) The Contractor may, subject to the requirements of the Contract,
consider and adopt suitable additional or alternative ingredients and
additives for the wall support slurry to that of the polymer specified
above. Samples and full details shall be obtained from the supplier and
manufacturer of such ingredients.
(2) Any such materials shall have no detrimental effect upon the stability
of the excavation or concreting, or formed concrete immediate as well
as long term.
(3) Ingredients to counteract the loss of slurry to the surrounding strata
shall be deemed covered by this Section.
1.4.6.14 Placing Concrete by Tremie

(1) Tremie pipes shall be clean, water-tight and with a minimum internal
diameter of 250mm.
(2) The tremie tube shall extend to the bottom of the trench excavation
prior to concreting and care shall be taken to ensure that all polymer
slurry is expelled from the pipe during the initial charging operation.
The tremie pipe shall be maintained with a minimum embedment of 2
meters into the concrete to prevent the re-entry of slurry into the pipe.
(3) The Contractor shall ensure that an adequate supply of concrete to the
tremie is available at all times so that placement is continuous until
completion of the panel.
(4) The number of tremie pipes per panel shall be in accordance with
the method statement. Where more than one tremie pipe is employed
during concrete pouring to any one panel, the charging of concrete
into the pipes shall be arranged so that it is evenly distributed
between the pipes and so that no differential head exists at the
concrete/slurry interface over the length of the panel. This level shall
be confirmed by soundings taken during the concrete pour.
1.4.6.15 Stop Ends

(1) Stop-ends, inserted before placement of concrete in the panel, shall be
clean and have a smooth regular surface. Any shutter release agent shall
have no detrimental effect on the finished works. Where stop-ends are
inserted in sections, adequate joint connections must be provided to
ensure verticality over the whole length.
(2) Extraction of stop-ends shall be carried out at such a time and in such
a manner that no damage is caused to the concrete placed against them,
or to the adjacent soil and structures.
(3) Stop-ends shall be adequately restrained to prevent movement during
concreting and not be permanently encased in the diaphragm wall.
(4) Stop end fixing arrangement shall be intact to hold water stopper and
should take NoNO from client.

1.4.6.16 Inserts
Inserts shall be formed at the locations shown in the Contractor's drawings
and in accordance with his method statements and procedures.
1.4.6.17 Checking and Monitoring

The Contractor shall provide all necessary monitoring instrumentation
including real time monitoring necessary for the close and continuous
checking of the movements and distortions of adjacent ground and EBS.
1.4.6.18 Safety and Emergency Procedures
(1) The Contractor shall take all necessary precautions to ensure stability
of his excavations and guide walls and shall take all necessary
precautions and be responsible for the safety of personnel in the area of
operation.
(2) The Contractor shall maintain, and make available for immediate use, a
sufficient quantity of slurry to allow for any sudden loss. Should the
loss continue despite the addition of the slurry and the stability of the
trench are placed at risk, the Contractor shall backfill with lean mix
concrete to preserve the stability of the trench and ensure the safety of
adjacent ground and EBS. The cause of the loss of slurry shall be
investigated and works shall not recommence until remedial measures
have been implemented.
1.4.6.19 Site Cleanliness

The Contractor shall ensure that the Site is cleared of slurry and that surplus
or displaced slurry is disposed of safely and without nuisance. All
operations shall be conducted in such a manner as to minimize any
spillage of slurry over the Site, or accesses thereto.
1.4.6.20 Obstructions
(1) An obstruction is defined as material, the excavation of which hinders
normal progress and the existence of which could not have been
foreseen.
(2) Upon encountering an obstruction, the Contractor shall determine the
method to be employed in removing the obstruction and such method
shall be subject to the Notice of No Objection from the Engineer.
1.4.6.21 Disposal of Spoil

(1) Spoil removed from the excavation shall be separated from the slurry
employed in the excavation process. It shall be disposed of as quickly
as possible to locations subject to the Notice of No Objection from the
Engineer and in such a manner that spillage and annoyance be
minimized.
(2) Contaminated slurry, not suitable for re-use, shall be removed from the
Site.
1.4.6.22 Joints
(1) All joints shall be fitted with a water-stop covering the full height of the
wall.
(2) Where concrete is cast against previously completed wall panels, the
previously formed concrete shall be cleaned so that solid substances

are removed before the joint is formed.

(3) When the joint is exposed upon subsequent excavation, the Contractor
shall immediately repair any joints which permit jetting or spraying of
water or within which solid foreign substances greater than 3mm
separate the concrete in adjacent panels.
(4) The walls and joints formed shall satisfy the water-tightness
requirements of this Contract.
1.4.6.23 Records
(1) The following records shall be maintained and kept for each wall panel
and such records shall be available for inspection by the Engineer.
a) Name of work.
b) Panel No and reference drawing number.
c) Date and time of start and finish of panel excavation.
d) Details of any obstructions encountered; time spent and
construction method adopted in overcoming such obstructions.
e) Date and time of completion of cage placement.
f) Date and time of start and completion of panel concreting;
g) Length of panel and width and depth of panel from top of guide
wall
h) Top of guide wall level ;
i) Top level of wall as cast, in relation to top of guide wall at the
edges and at the centre.
j) A log of soil/rock type encountered from start to finish of
excavation, and of slurry levels and densities.
k) Volume of concrete used and time of any interruptions in
concrete supply where these exceed 15 minutes.
l) Volumes of normal and lean mix concrete.
m) Cut-off level of concrete below top of guide wall level.
n) Date, place and time of slurry control tests and results recorded.
o) Concrete test cubes, w/c ratio, slump markings, date and results
obtained on testing.
p) Details of reinforcement and cage type.
q) Quantity of slurry removed from Site and spoil removed from Site
recorded by date.
r) A graph of theoretical and placed concrete volumes with depth.
1.4.6.24 Disposal of Slurry

Used polymer or contaminated slurry not suitable for re-use shall be disposed
of in water-tight containers. The Contractor may propose alternative means
of disposal which shall be subject to the Notice of No Objection from the
Engineer.

1.5 Structural Concrete: Plain, Reinforced & Pre-stressed
1.5.1 Concrete Materials

1.5.1.1 General
(1) This work shall comprise the construction of all or portions of structures
with Ordinary Portland Cement (OPC) concrete, of the required class
or classes, with or without reinforcement, with or without admixtures,
constructed in accordance with the Contract and the relevant
Standards to the lines, levels, grades and dimensions shown on the
Construction Drawings.
(2) Constituent materials for the concrete mix shall comply with the
requirements of IS: 456 or BS: 5328, unless otherwise given Notice of
No Objection by the Engineer. Additives such as fly ash, ground
granulated blast furnace slag and silica fume may be used in concrete to
improve its performance and workability etc., only after the Contractor
has obtained Notice of No Objection from the Engineer for the same, in
which case the Contractor shall demonstrate the quality control
procedure including source of these additives, their properties and
handling etc. as per the relevant BIS & International codes. The
performance of the concrete mix with additives shall be determined by
the field suitability tests.
(3) Ordinary Portland cement (OPC) of 43 grade and 53 grade
conforming to IS 269:2015 respectively shall be used. Portland
pozzolana cement (PPC) conforming to IS 1486 of grades 43 & 53
can also be used. The Engineer may direct the usage of sulphate
resistant Portland cement conforming to IS 12330 for structural
elements exposed to soil/ground. In all cases the cement shall meet the
28 day strength requirement of IS 8112 or IS12269.
(4) Testing and non-conformances affecting the standard of the concrete
shall be notified to the Engineer in-line with the Quality Assurance
(QA) procedure such that mitigation may be effected expeditiously
within the critically defined timeframes.
1.5.1.2 Cement
(1) General
a) If soil has soluble salts in excess of 0.5%, sulphate-resistant
cement shall be used conforming to IS12330 (or BS 4027), or total
chloride content in cement shall in no case exceed 0.05% by mass
of cement. Also, total sulphur content calculated as sulphuric
anhydride (SO3), shall in no case exceed 2.5%and 3.0% when
tri-calcium aluminate per cent by mass is up to 5% or greater than
5% (but less than 10%) respectively.
b) The cement used shall be as given in outline design specifications.
c) Whenever possible all cements of each type shall be obtained from
one constant source throughout the contract. Cement of different
types shall not be mixed together. Different brands of cement, or
the same brand of cement from different sources, shall not be used
without prior approval of the Engineer.
d) Supply/procurement of cement shall be through bulk carrier and
stored in silos of adequate capacity. Procurement of cement in
bags should be an exception with the specific approval of

Engineer-in-charge. Separate go-downs shall have to be provided

for different grades of cement. The fresh cement should be
used. The cement older than 3 months will not be allowed to use
at site. The cement should be stored in a water tight shed and on
wooden planks giving sufficient gaps between walls floors and
cement piles.
e) Cement obtained in bulk shall be stored in suitable silos of
adequate capacity. Each type of cement shall be stored in a
separate silo and it shall be ensured, that cements of different
quality are not mixed up.
f) All cement shall be fresh when delivered. Cement older than 3
months from the date of manufacture shall not be used.
g) In fair faced elements, the cement used in the concrete for any
complete element shall be from a single consignment. All cement
for exposed concrete shall be from the same approved source and
uniform in colour.
h) With each and every delivery of cement consignment, the
contractor shall provide manufacturer’s certificate that the cement
conforms to the relevant Indian standard. The contractor shall
provide complete facilities at site for carrying out the following
tests:
Setting time by Vicat's apparatus as per IS: 4031 and IS: 5513.
Compressive strength of cement as per IS: 4031, IS: 650, IS:
10080.
i) Total chloride content in cement shall in no case exceed 0.05
percent by mass of cement. Also, total sulphur content calculated
as sulphuric anhydride (SO3), shall in no case exceed 2.5 percent
and 3.0 percent when tri-calcium aluminate per cent by mass is
upto 5% or greater than 5% respectively.
(2) Testing
a) Cement shall be certified by the manufacturer as complying with
the requirements of the relevant Standard. The Contractor shall
submit to the Engineer the manufacturer's QA forms to
demonstrate that the cement complies with relevant standards.
b) Before ordering cement, the Contractor shall submit relevant
QA details on the proposed supplier and methods of transport,
storage and certification to the Engineer’s Notice of No Objection
to proceed (HOLD POINT). It must be proven that the quantity
and quality required can be attained and maintained throughout
the construction period.
c) Representative samples of the proposed cement may be required
to be taken and forwarded to an independent laboratory for
analyses before the source is Noticed. If cement is imported, fresh
tests as per the relevant Standards shall be conducted in a Noticed
laboratory.
d) Subsequent to obtaining the Engineer's Notice of No Objection,
the Contractor shall not change the agreed arrangements without
the Notice of No Objection by the Engineer. Each consignment of
cement shall be accompanied by a certificate which shall be

submitted to the Engineer immediately on delivery, substantiating

the place of manufacture and the results of required testing carried
out on the batch.
e) The Contractor may be required to sample cement and test such
samples in accordance with the relevant or equivalent Indian
Standards. The Contractor shall store the cement so that separate
consignments can be identified and used in order of delivery to
site (first-in, first-out process). In no circumstances shall cement
that has exceeded its ‘use-by’ date be allowed as part of the
concrete mix.
(3) Cement Delivery and Storage
a) Cement shall be delivered in bulk or in the original manufacturer's
sealed and marked bags, and shall be protected from the weather
by enclosed transfer systems or other Noticed coverings. The
Contractor shall provide silos to store sufficient bulk cement for
continuity of work, and cement shall be placed therein upon
delivery.
b) All necessary precautions shall be taken to prevent cement dust
causing a nuisance.
c) On receipt of a Notice from the Engineer cement that has been
damaged or does not comply with the Contract requirements
shall not be used in the Works and be removed from the Site
within 3 days of the Contractor's receipt of such notice.
1.5.1.3 Aggregate
(1) Aggregate Sources
Prior to commencing any concrete work, the Contractor shall
obtain the Engineer's Notice of No Objection for the proposed types
and sources of aggregate. Sampling of aggregates shall be as per IS
2430.
(2) Coarse Aggregates
a) Coarse aggregate for all classes of concrete shall
conform to the requirements of IS 383. It shall be furnished in
two separate sizes; either the 20mm down and or the 38mm down
to No. 4 as required by the Standard.
b) Physical tests for suitability shall be carried out in accordance
with IS 2386 Parts I to VIII.
c) Coarse aggregate shall be clean, free from dust and other
deleterious material. For reinforced and pre-stressed concrete
aggregate shall be well- graded and durable with nominal 20mm
sized stones.
d) Hand-broken stone may be used provided such complies with
the Contract requirements.
(3) Alkali-Silica Reactivity (ASR)
a) If aggregates contain materials which have been tested to show
chemical reactivity with alkalis found in any of the constituents of
the concrete mix, or in water which will be in contact with the
finished work, then the Contractor shall take samples of these
materials every week.
b) The Contractor shall ensure that the concrete mix complies with

Water absorption shall be less than 3% by weight (ASTM C 117)

(4) Fine Aggregate
a) Fine aggregate shall conform to the requirements of IS 383 or as
required to meet the design requirements.
The silt content by volume in fine aggregate shall neither exceed
8% nor more than 1% used in the trial mix.
b) Water absorption shall be less than 3% by weight the requirements
of this contract regarding "Minimizing Risk of Alkali-Silica
Reaction in Concrete",(Section 1.5.1.7)
c) The results of the Contractor's weekly ASR monitoring
tests shall be submitted in writing to the Engineer for Notice of
No Objection
(5) Chloride Content
a) The chloride content of aggregates shall be within the
recommended limits stated in IS 383 or BS 882.
b) The chloride content of the concrete mix shall be within the
recommended limit of IS 456 or BS 8110.
c) Chloride levels shall be determined daily in accordance with the
methods described in BS 812.
(6) Sulphate Content
The total acid soluble sulphate content of the concrete mix, expressed
as SO3, shall not exceed the recommended limits in IS 456 or BS 8110.
(7) Storage
a) All aggregates shall be stored in such a way that they shall be
kept free from contact with deleterious matter.
b) All aggregate shall be shaded from direct sunlight by means of a
roof of sufficient height to enable unimpeded access to plant.
Spraying of aggregate stockpiles with water shall be undertaken as
necessary.
c) Aggregate of different sizes shall be stored separately and shall
be stored in masonry or concrete-based bins or on stages to
prevent intermixing, segregation and the inclusion of dirt and
foreign materials. Storage bins shall be emptied and cleaned
regularly. All aggregate hoppers shall be painted white.
(8) Blending Of Aggregates

In order to obtain optimum workability, individual aggregates of
nominal size 20 mm, 10 mm, 4.75 mm and 2.36 mm will be blended
in such a way that the grading curve for all in aggregates will be a
smooth curve from size 0.15 mm to 20 mm falling within the
established envelope grading curve. Contractor shall establish
envelope grading curve for each grade of concrete for given
maximum size of aggregates and get it approved by Engineer before
finalising the mix design.
1.5.1.4 Reinforcement and Coupler specifications

Refer Cl. 1.5.2.8 for reinforcement details and Coupler specifications.

1.5.1.5 Water
(1) General
The Contractor shall make his own arrangements and procure fresh
potable water for the mixing and curing of concrete. Testing of such
water shall be in accordance with IS 3025.
(2) Quality
a) Water to be used for mixing and curing concrete and mortar shall be
fresh and free from dissolved or suspended matter which may be
harmful and shall comply with the requirements of IS 456.
However, chloride content in water shall not exceed 500 mg/litre and
Sulphate content shall not be more than 4 percent.
b) Water samples from the intended source of supply shall be taken for
analysis before any concrete work is commenced, and at intervals
throughout the duration of the Works.
c) Where potable water supply is not available the Contractor shall obtain
confirmation of quality and reliability of a proposed source
from the appropriate Water Authority and shall test the water for its
chemical and other impurities before its use in the Works. Cost of all
such tests shall be borne by the Contractor. No payment for this will be
done as it is included in the scope of work.
1.5.1.6 A. Admixtures
(1) General
a) The Engineer’s Notice of No Objection shall be obtained prior
to using any admixture in any concrete mix. The minimum
cement content specified shall not be reduced on account of use of
admixtures.
b) Admixtures shall conform to IS: 9103 or BS 5075 and BS 1014.
c) Admixtures containing chlorides or other potential corrosive
agents shall not be used.
(2) Quality
a) If admixtures are permitted these shall be used in the correct
quantities. Noticed equipment and methods shall be used for dispensing
and incorporating the admixture in the concrete; the dispensing unit
shall be designed so that the discharge of the admixture is visible.
b) The concrete tests described herein shall be conducted with the
admixture incorporated to establish that specified strengths are
achieved, and that densities are not reduced. If air-entraining agents
are used the density shall not be reduced by more than 5%.
c) Set-retarding and water-reducing admixtures shall comprise ligno-
sulphonate.
d) Air-entraining agents shall comprise neutralized vinsol resin.
e) The manufacturer's declared equivalent acid soluble alkali content and
the dosage rate of any admixture or pigment to be incorporated shall be
included with details of all concrete mixes
f) The alkali content of admixtures shall be taken into account when
determining the total equivalent alkali content of the concrete mix.
Only PC based admixtures are permitted to be used for the concrete.

1.5.1.6 B. Specification of Crystalline products
Product - Integral Crystalline Waterproofing/Durability Admixture,

CRYSTALLINE ADMIX
Dosage - minimum 0.75% by weight of cement + cementitious material (as
recommended by manufacturer)
Integral Waterproofing admixture should be single part cementitious powder

consisting of hydrophilic chemicals. When added to plastic mix, will permanently
create impermeable hardened concrete by developing insoluble needle like crystals to
seal the pores, capillaries, micro-cracks in the whole mass of concrete. The
crystalline admixture must be compatible with any other concrete admixture
confirming to ASTM D494 and IS 9103. It shall be used for all underground
structures (including shotcrete in tunnel lining). In addition, the waterproofing
admixture must confirm to the following requirements:
1. The crystalline admixture shall be compatible with any other concrete admixture
confirming to ASTM D494, the manufacturer should provide a 3rd party test
certificate.
2. At the manufacturer’s recommended dosage, material must fulfil the requirements of
American Concrete Institute Guidelines ACI-212-3R-10 Chapter 15 and fall under
PRAH (Permeability Reducing Admixtures for HYDROSTATIC conditions) and
must reduce Coefficient of Permeability of concrete by more than 90% (preferably
zero permeability) ,having Coefficient of water permeability of less than 0.5 X 10 -14
, when compared to control concrete and tested as per DIN 1048 Part 5 by carrying
out 4 cycles each of 5 bar Hydrostatic. Pressure for 72 hours and drying for 48 hours
between the cycles & Coefficient of Permeability calculated as per Darcy’s Formula/
Valenta equation by incorporating penetration values obtained at the end of fourth
cycle pressure. The manufacturer should provide a 3rd party test certificate.
3. At the manufacturer’s recommended dosage rate, the material must reduce Chloride
Diffusion Co-efficient by minimum 45% when tested as per ASTM C 1556 -4 / or its
equivalent and compared with the control concrete, thereby prolonging the durability
& service life of the treated concrete structure. The manufacturer should provide a 3rd
party test certificate.
4. The product shall be comply as per requirement of IS 9103 : 1999 for having
corrosion Effect on reinforcement zero to enhance durability enhancement
5. The product should have low risk of corrosion when tested as per ASTM C 876 for
minimum 180 days period.

6. At the manufacturer’s recommended dosage rate, the performance of the crystalline

admixture must not be restricted by water/cement ratio of the concrete mix. In other
words, the crystalline admixture must perform at any water / cement ratio of the
concrete mix as per IS 456 code of practice
7. It will not be affected by wear abrasion of the treated concrete surface and crystalline
treated concrete shall not require protection layer.
8. The recommended crystalline admixture must be non-toxic and must confirm to
CFTRI Tested, Nontoxic and suitable for use in potable water facilities.
9. The manufacturer must produce relevant test certificates from reputed laboratories,
confirming that the product when added at the recommended dosage rate, meets the
above requirements.
10. Manufacturer Qualifications: A firm with not less than 5 years in manufacturing
crystalline waterproofing of the type specified and should have manufacturing plant
in India under "Make in India" preference.
11. The manufacturer should have in house R&D lab equipped with all the necessary
equipment’s such as scanning electron microscope having capacity of 10000x times to
visualize and see the actual growth of crystals in concrete.
12. Storage / Shelf Life of material shall be as per the manufacturer’s data sheet or
relevant code
1.5.1.7 Minimizing the Risk of Alkali-Silica Reaction (ASR) in Concrete

(1) Concrete mixes for use in the Permanent Works shall comply with the
Contract.
The Contractor shall notify the Engineer of his proposals for complying
with this requirement.
(2) The materials shall satisfy one of the following requirements.
a) The reactive alkali content in cementitious material shall not
exceed a maximum value of 0.6% by mass when defined and
tested in accordance with this Contract.
b) The total mass of reactive alkali in the concrete mix shall not
exceed 3 kg/m3 of concrete when defined, tested and calculated in
accordance with this Contract.
c) The aggregate shall be classed as non-reactive in accordance
with this Contract.
(3) Cementitous Material (Hydraulic and Latent Hydraulic Binders):
a) The term alkali refers to the alkali metals sodium and potassium
expressed as their oxides. The reactive alkali content of Portland
cements shall be defined as the percentage by mass of
equivalent sodium oxide (Na2O) calculated from the following
relationship.

% equivalent Na2O = % acid soluble Na2O + 0.658 x (% acid

soluble K2O)
b) The method used in determining the acid soluble alkali
content of the materials shall be in accordance with BS 4550:
Part 2: Sub-section 16.2.
c) The Contractor shall make available the certified average acid
soluble alkali content of Portland cements on a weekly basis.
d) The Contractor shall give immediate notice of any change
which may increase the certified average acid soluble alkali
content above the level used in the mix design for the concrete.
A revised mix design for any concrete which would be affected
by the increased alkali content shall be submitted to the Engineer
for Notice of No Objection with notification of the change.
(4) Minimizing risk by use of cementitous material containing less
than 0.6% of reactive alkali.
a) These requirement shall be met provided the contribution of
alkalis from other source does not exceed 0.2 kg/m3.
b) The cementitous material shall be Ordinary Portland Cement
(OPC) complying with Indian Standards and shall have
additionally a certified maximum acid soluble alkali content not
exceeding 0.6%. The Contractor shall provide on request
weekly certificates which name the source of the cement and
confirm compliance with the Contract.
c) Minimizing risk by limiting the reactive alkali content of the
concrete to 3 kg/m3.
d) The reactive alkali content of the concrete contributed by OPC to
the concrete shall be calculated from:
A=Cxa,
100
Where,
A = reactive alkali content of the concrete to the nearest 0.1

(kg/m3)
C = target mean Portland cement content of the concrete (kg/m3)
a = certified average acid soluble alkali content of OPC (%).
e) Where reactive alkalis in excess of 0.2 kg/m3 are contributed to

the concrete from sources other than the cementitious material,
the limit of 3 kg/m3from the cementitious material shall be
reduced by the total amount so contributed. The reactive alkali
contributed by sodium chloride contamination of aggregates
shall be calculated from:
H = 0.76 x (NFxMF)+(NCxMC)per kg / 100m3
Where,

H= equivalent alkali contribution made to the concrete by the

sodium chloride
NF= chloride ion content of the fine aggregate as a percentage
by mass of dry aggregates and measured according to BS
812: Part 4
MF = fine aggregate content (kg/m3)
NC = chloride ion content of the coarse aggregate as a
percentage by mass of dry aggregate and measured
according to BS 812: Part 4: 1976 (now in draft as Part
117)
MC = coarse aggregate content (kg/m3).
The factor 0.76 is obtained from a consideration of the composition of

seawater. The chloride ion content of aggregate sources containing
0.01% of chloride ion by mass or more shall be determined
weekly in accordance with BS 812 or another noticed method.
When the chloride ion level is less than 0.01% it shall be regarded
as nil.
(5) The Contractor shall provide certificates on request confirming

compliance with the Contract which state the following.
a) The target means cementitious material content of the concrete.
b) The names of the Works manufacturing the cement.
c) A weekly report of the cement alkali determinations.
d) The certified average acid soluble alkali content of OPC.
(6) Minimizing the Risk by Using Selected Aggregates
a) Fine and coarse aggregate material shall comply with the
requirements of IS 383 and/or AASHTO Standard Specifications
M6 and M80 respectively.
(7) Water
a) Water for use in the manufacture of concrete shall be obtained
from a public utility supply or from a source Noticed by Engineer.
b) Water shall be potable and comply with the requirement of IS
456 and or BS 3148.
c) Where potable water supply is not available the Contractor shall
obtain confirmation of quality and reliability of a proposed source
from the appropriate water authority test the water for its chemical
and other impurities before using. Cost of all such tests shall be
borne by the Contractor.
1.5.2 Concrete Workmanship

1.5.2.1 Grade
(1) Mixes General
a) Concrete shall be provided in accordance with IS 456 or BS
5328 except where required otherwise by this Contract.
The trial mix shall be carried out as specified in the MORTH
specifications
(2) Concrete Mixes
a) The concrete mixes to be used in the Permanent Works shall be

tabulated in the form in a typical “Table of Concrete Mixes” as

given below.
TABLE OF CONCRETE MIXES

(Note: to be completed by the Contractor)
Description used on Drawings

Type of Mix
Type of Cement.
Type of Aggregate. Coarse –
Fine -
Nominal Aggregate maximum size (mm)
Grade
Minimum cement content (kg/m3)
Sampling rate (m3) - 28 day normal curing-
7 day normal curing
Workability - Slump (mm)
- VB(s)
Compacting
Maximum free water/cement ratio
Maximum cement content (kg/m3)
Special cement
Special aggregate. Coarse:
Fine:
Fine aggregate (%)
Admixtures. Specified:
Prohibited:
Amount:
Air content
Temperature of Fresh concrete (oC)
Maximum:
Minimum:
Density of Concrete (kg/m3)
Maximum:
Minimum:
(3) Chlorides
The total chloride content of the concrete mix shall be in
accordance with the limitations given in IS 456 or BS 8110
(4) Sulphates
The total water soluble sulphate content of the concrete mix shall not
exceed the limitations given in IS 456 or BS 8110.

1.5.2.2 Trial Mixes

(1) Laboratory Trials
a) Concrete shall be proportioned to provide an average
compressive strength; namely a specified characteristic strength
plus a standard deviation factor; in accordance with acceptance
criteria given in IS: 456 or relevant British Standard.
b) Not less than 35 days before commencement of concreting, the
Contractor shall carry out trials to determine the concrete mixes
which will satisfy the requirements of the Contract. The materials
and conditions used shall reflect those intended to be used for the
Works. A minimum six test cubes shall be made from each of
three consecutive batches with three cubes from each batch to be
tested at 7 days and three cubes at 28 days.
c) If the average 28 day strength (being defined as the measured
stress when the cube fails) exceeds the specified characteristic
strength by 20% or more, and the other requirements of IS 456
and IS 10262 or BS 5328 are met, then the trial mix proportions
may be used to commence the Permanent Works. Otherwise
further trials shall be carried out using re-designed mixes until the
minimum required strength is achieved.
d) Additional Requirements of trial mixes shall be tested to
determine the following properties of mixes proposed for initial
field tests.
i) Bleeding in accordance with ASTM C232.
ii) Drying shrinkage in accordance with BS 1881.
iii) Air content, if applicable.
iv) Free water/cement ratio.
v) Workability.
vi) Wet and dry densities.
vii) Indirect tensile strength in accordance with BS 1881
including cylinder - splitting and beam tests.
e) If the test results obtained do not satisfy the Contract or the design
requirements, the mixes shall be re-designed.
(2) Initial field tests
a) Trial mixes shall be prepared under full-scale site conditions and
tested in accordance with IS 10262 or BS 1881.
b) Samples of concrete incorporating the reinforcing details to be
used shall be cast and examined, before hardening using hand
tools, and after hardening by coring to assess the mixes. Cores
shall be 150 mm diameter by 200 mm long.
1.5.2.3 Quality Control

(1) Test Cubes
a) Cubes shall be manufactured in an on-site laboratory, specially
equipped for the purpose, in controlled conditions. They shall be
made, cured, stored, transported and tested in accordance with IS
516 and BS 1881.
b) The cube-testing machine shall be housed in a laboratory and
calibrated to BS 1610 when delivered. The machine calibration
shall be verified at 3- monthly minimum intervals by a testing

authority having National Accreditation Board for Testing and

Calibration Laboratories (NABL) Certification.
(2) Cubes Samples
a) A sample of concrete shall be taken at random on eight separate
occasions during each of the first five days of using a mix. The
standard deviation shall be calculated from at least 25 individual
cube results each representing separate batches of similar concrete
produced by the same batching plant under the same supervision.
The margin for the concrete batching plant shall be 1.64 times the
standard deviation.
b) Thereafter one sample shall be taken at random for each class
of concrete from every group of 25 batches made by each
concrete batching plant, and at least one sample shall be taken
each day that concrete of a particular grade is made. Samples
shall also be taken and two cylinders cast to determine the indirect
tensile strength of the concrete at 7 days and 28 days, as specified
in relevant IS code or BS 1881.
c) These samples shall be taken from every 100 batches, but at
least once a week during concreting operations, and shall coincide
with samples taken for test cubes. The frequency of sampling may
be required to be varied.
d) In addition to the above requirements, at least one sample shall be
taken from each individual structural unit, or part of a unit, when
the latter is the product of a single pour.
e) From each sample two cubes shall be made for testing at 28 days
and one for testing at 7 days for control purposes. The 28 day
Concrete Cube Strength (CCS) shall be the mean of two cubes.
The procedures shall be repeated when materials or design mixes
are changed.
f) 28 day concrete cube strength frequency:
i. 1 set for every 10m3 or part thereof of concrete for critical
structural elements like columns, precast element, segments,
larger cantilever, etc .
ii. 1 set for every 25m3 or part thereof for all other elements.
(3) Cube Strength Results
a) The results will be unacceptable if:
i) The average strength determined from any four
consecutive test cubes does not exceed the specified CCS by
0.5 times the current margin, or;
ii) One or more values in forty is less than 85% specified CCS,
or;
iii) Three or more values in forty are less than specified CCS; In
which case any of the following actions may be instructed.
Change the mix.
Improve quality control.
Cut and test cores from placed concrete.
Load-test relevant structural units.
Carry out non-destructive tests on as-placed concrete.
Cut-out and replace defective concrete.
b) If the range of individual cube strength made from the same

sample exceeds 15% of the mean then the method of making,

curing and testing cubes shall be checked.
c) In the event of a result having a range exceeding 20% the
Contractor shall submit his proposed corrective action for notice
of No Objection by the Engineer.
d) The Contractor shall cut concrete cores from as-built locations as
may be required by the Engineer and test them to BS 1881 as
modified by Concrete Society Report TR 11. If the values,
reduced by 0.69 Mega Pascal per week of age in excess of 28
days, are less than 75% CCS, the concrete shall be cut out and
replaced unless otherwise agreed with the Engineer.
• Acceptance criteria of concrete shall be finalize in accordance with IS

456:2000 or latest.
(4) Other Tests

a) Concrete shall be tested for drying shrinkage, water absorption
and moisture movement as directed for which 102 mm cubes and
76 mm by 76 mm prisms shall be prepared and tested in
accordance with BS 1881.
b) The acceptance limits are as follows.
i) Water absorption: 3% absorbed after 10 minutes;
(ii) 6.5% absorbed after 24 hours.
iii) Drying shrinkage: 0.05%
iv) Moisture movement 0.03%
c) Cubes may be required and trials carried out to determine
stripping times for formwork, the duration of curing and to
check-testing and sampling errors. The air content of air-
entrained concrete shall be determined for each batch produced
until consistency has been achieved, when fewer batches may be
tested.
d) During concreting of the Permanent Works six 150 mm diameter
by 200 mm long cores shall be cut through horizontal
reinforcement to assess plastic qualities. The qualities shall be
equal to those obtained in the initial field tests.
e) Compaction factor, slump, or other workability tests shall be
carried out as required during concreting of Permanent Works to
control workability at the batching plant and at the site of the
pour. The degree of workability shall be as for the trial mixes;
permitted tolerances shall be in accordance with IS 1199 or BS
5320.
f) Tests shall be carried out at least daily for the moisture content
and weekly for absorption value of the aggregate. The values for
the aggregate at the mixer shall be determined and changes made
to the mix to compensate for variations.
g) Additional Tests For Concrete

As frequently as the Engineer may require, additional tests shall
be carried out of concrete in addition to mandatory test specified
in MORTH Specifications, CPWD specifications relevant IS

Code.
Permeability test for Concrete :
The concrete will be verified for permeability by the following

procedure and shall confirm to IS:3085-1965 - ‘Permeability of
Cement Mortar & Concrete’. Section 1716.5 of MORTH
Specifications and DIN 1048.
The Engineer shall select random batches of concrete for

examination at his discretion and sampling will generally be done
at the point of discharge from the mixer and at placing point.
From the batches thus selected two concrete cylinders shall be

made in accordance DIN 1048.
At least two cylinders shall be made on each day’s concreting until

60 cylinders have been made for each grade of concrete.
All cylinders shall be made, cured, stored, transported and tested in

accordance with clause 1716.5 of MORTH Specifications. The
tests shall be carried out in a laboratory having NABL certification.
NT Build test shall also be conducted.
Test Procedure
The permeability of concrete will be verified by the following

procedure:
i. Prepare a cylindrical test specimen 150 mm dia and 160mm high.

ii. After 28 days of curing, test specimen will be fitted in a machine
such that the specimen can be placed in water under pressure up to
7 bars
iii. At first a pressure of one bar is applied for 48 hours, followed by 3
bars for 24 hours and 7 bars for next 24 hours.
iv. After the passage of the above period, the specimen is taken out
and split in the middle by compression applied on two round bars
on opposite sides above and below.
v. The water penetration in the broken core is measured with scale
and the depth of penetration assessed in mm (max permissible limit
25 mm).
h) Acceptability Criteria
The concrete shall pass the permeability test if it is properly

compacted and is not considered permeable when tested as above.
No extra payment shall be made for this test and cost of the same
should be included in the quoted rate for concrete work.

(5). Scheme for monitoring

a) Monitoring shall be carried out in accordance with the relevant
Standards, as implemented under the requirements of ISO 9002.
b) Compliance of the concrete and associated work to required levels
of performance shall be captured in the monitoring regime.
c) The scheme implemented shall be subject to the Notice of No
Objection of the Engineer and undergo regulatory QA checks to
ensure the levels of competence in monitoring are being
consistently adopted and undertaken in the Works.
1.5.2.4 Batching
(1) Machinery
Batching of Concrete Ingredients
Unless permitted by the Engineer, all concreting shall be produced in

computerized automatic weigh batching plant having printing facilities
to print out records of each batch and installed at site. Under
exceptional circumstances Ready Mixed Concrete (RMC) manufactured
in computerized automatic weigh batching plant (as per specifications
described above) by the approved agencies using the constituent
materials from approved sources and approved mix design may also be
used with prior approval from Engineer. Nothing extra shall be paid for
such RMC used in the work including transportation, placing in position
etc. However, in such cases the RMC production & transportation will
have to be directly supervised by the qualified personnel of the
contractor. (Contractor has to setup his own batching plant(s).RMC
from market will be permitted only in exceptional circumstances and to
be decided by the Engineer.)
(2) Accuracy of Batching
Batched materials shall be measured to the following tolerances and
discharged into the mixer without loss.
Cement ± 2% of the weight of the cement in the batch. Aggregate ±

2% of the weight of each aggregate in the batch. Water ± 2% of
the weight of water added to the batch. Admixture ± 5% of the
amount to be added to the batch.
(3) Calibration of Measuring Equipment
a) Measuring equipment shall be checked and calibrated at the start
of preliminary concrete tests and at weekly intervals. The
necessary test weights and the like shall be kept available on site.
Scales shall be checked over their complete range by a specialist
every three months.
b) A calibrated container shall be used to check the accuracy of
admixtures dispensers once each month. The results of these
checks shall be notified.
(4) Mixing
Concrete constituents shall be thoroughly mixed in batches. The
machines shall be capable of discharging while running.

(5) Ready-Mixed Concrete

a) Ready-mixed concrete shall not be used unless Noticed, and
shall comply with the requirements specified herein and those of
IS:4826 and BS 5328.
b) The supply and use of ready-mixed concrete shall be
subject to the Contractor's QA procedures.
c) Ready-mixed concrete shall be obtained from a depot subject to
the Notice of No Objection from the Engineer and transported
to the Site in truck type mixers which shall continuously agitate
the concrete mix.
d) The concrete shall be placed in its final position and
compacted within 2 hours of the introduction of cement to the
aggregates.
e) The ready-mixed concrete delivered to the Works shall comply
with this Specification. One cubic meter of each mix shall be
supplied to Site before it is required in the Works to allow the
Contractor to carry out workability tests.
f) For plant-mixed concrete the delivery note for each batch shall
state the time at which the concrete was mixed and the weight of
the constituents of each mix.
g) When truck-mixed concrete is used, water shall only be added
under the Contractor’s direct supervision either at the Site or at
the central batching plant in accordance with the standard Quality
Procedures. In no circumstances shall extra water be added to
the concrete after the original mixing is complete.
h) Samples for testing shall be taken as the concrete is placed
in its final position.
i) The Contractor shall arrange for the ready-mix concrete
supplier to provide the facilities stated in BS 5328, Clause 7.1 or
13.1.
(6) Records
a) Daily returns shall be provided showing the quantities of cement
and the total volume batched of each class of concrete for each
section of the Works.
b) The Contractor shall submit detailed records and test results for
all test cubes and specimens taken without delay to the Engineer
for his Notice of No Objection.
1.5.2.5 Control of Chlorides and Sulphates

(1) Chlorides in Concrete
a) The levels of equivalent acid-soluble chlorides as NaCl (Cl x
1.65 = NaCl) in the constituents of concrete as stated
elsewhere are indicative and are subject to the over-riding limits
for the mixes. The total estimated content as a percentage by
weight of the cement in the mix shall not exceed the following
limits.
(i) For reinforced concrete
0.5% if made with Ordinary Portland Cement (OPC)
0.1% if made with Sulphate-Resistant Portland Cement
(SRPC)

(ii) For mass concrete

1.0% if made with OPC
0.2% if made with SRPC
b) The Contractor shall test the constituents of the concrete to
establish these contents as provided for elsewhere in this Contract.
c) In addition, regular tests to BS 1881: Part 6 for chloride content
shall be made on the hardened concrete. The following values are
considered tolerable but shall be subjected to the Notice of No
(i) For reinforced concrete made with OPC 95% of the test
results less than 0.4% NaCl by weight of cement and no
result greater than 0.5% NaCl by weight of cement.
(ii) For reinforced concrete made with SRPC 95% of the test
results less than 0.1% NaCl by weight of cement and no
result greater than 0.14% NaCl by weight of cement.
(iii) For mass concrete made with OPC 95% of the test results
less than 1% NaCl by weight of cement, and no result
greater than 1.3% NaCl by weight of cement.
(iv) For mass concrete made with SRPC 95% of the test results
less than 0.2% NaCl by weight of cement and no result
greater than 0.25% NaCl by weight of cement.
d) In the event that the SRPC used contains a proportion by weight of
tri-calcium aluminate which approaches 4% to 8%, then Notice
shall be sought from the Engineer for an appropriate adjustment of
the relevant chloride content limits.
(2) Sulphates in Concrete
a) The level of acid-soluble sulphates (SO3) in the mix shall satisfy
all of the following requirements.
Coarse aggregate ≤ 0.4% by weight.
Fine aggregate ≤ 0.4% by weight.
Water ≤ 500 mg/l.
b) The total estimated sulphate content (SO3) of the mix including
that present in the cement shall not exceed 3.7% by weight of
cement in the mix.
c) In addition, regular tests in accordance with BS 1881: Part 6
shall be carried out on the hardened concrete to determine the
total sulphate content, which shall not exceed 4% by weight of
cement in the mix.
(3) Permissible Level of Chloride and Sulphates
The permissible level of chlorides and sulphates stated in this Contract
shall not be considered as mean values for the whole of the Works, but
shall apply to any concrete used in the Works.
(4) Concrete for water-retaining structures shall comply with IS 3370.
1.5.2.6 Placing
(1) General
a) Concrete shall be transported by means which prevent
contamination (by dust, rain and the like) segregation or loss of
ingredients, and shall be transported from the batching plant and
placed without delay.

b) Concrete shall be placed in the positions and in sequences

indicated on the Drawings. Placing shall not commence until the
fixing and condition of reinforcement and items to be embedded
and the condition of the containing surfaces or formwork have
been Noticed by the Engineer. The Contractor shall provide the
Engineer with written notification not less than 24 hours prior to
his intention to place concrete in the Works.
c) Concrete shall be placed directly in its final position without
segregation or displacement of the reinforcement, embedded
items and formwork. Where necessary concrete may be placed in
water in accordance with the Contract requirements.
d) Concrete shall not be dropped through a height greater than 1
meter.
(2) Extent of Pours
a) The limit of individual pours and the height of lifts shall be as
Noticed.
b) Floors, roofs and ground slabs shall be placed in a sequence of
pours to the approval of the Designer and the Notice of No
c) The sequence of pours shall be arranged to minimize thermal and
shrinkage strains.
(3) Placing Equipment
Concrete shall generally be placed without segregation by pumping or
bottom- opening skips. If chutes are used their slopes shall not cause
segregation and spouts or baffles shall be provided.
(4) Time for Placing
Concrete and mortar must be placed and compacted within 30 minutes
of water being added to the mix or otherwise included via damp
aggregates, unless admixtures are in use. Partially-set concrete shall not
be used in the Works.
(5) Compaction
a) Concrete shall be compacted during placing by Noticed
internal vibrators. The vibrators shall operate at a frequency of
not less than 10,000 cycles per minute, and shall be designed for
continuous operation.
b) The performance of vibrators shall suit the working
conditions, and depending on the thickness of layer to be
compacted; 25 mm, 40 mm, 60 mm and 75 mm diameter internal
vibrators may be used. The radius of influence of the vibrator
used shall ensure that the concrete mass being vibrated is
compacted at a speed commensurate with the rate of supply of
concrete.
c) Internal (needle) and surface (screed board) vibrators of approved
make shall be used for compaction of concrete.
Internal vibrators shall be used for compaction of concrete in
foundations, columns, buttresses arch section, slabs etc, and if
required surface vibrators shall also be used. Depending on the
thickness of layer to be compacted, 25 mm, 40 mm, 60 mm and 75
mm dia internal vibrators will be used. The concrete shall be
compacted by use of appropriate diameter vibrator by holding the

vibrator in position until:

i. Air bubbles cease to come to surface.
ii. Resumption of steady frequency of vibrator after the initial
short period of drop in the frequency, when the vibrator is
first inserted.
iii. The tone of the vibrated concrete becomes uniform.
iv. Flattened, glistening surface, with coarse aggregates particles
blended into it appears on the surface.
v. After the compaction is completed, the vibrator should be
withdrawn slowly from the concrete so that concrete can flow
in to the space previously occupied by the vibrator. To avoid
segregation during vibration the vibrator shall not be dragged
through the concrete nor used to spread the concrete. The
vibrator shall be made to penetrate, into the layer of fresh
concrete below if any for a depth of about 150 mm. The
vibrator shall be made to operate at a regular pattern of
spacing. The effective radii of action will overlap
approximately half a radius to ensure complete compaction.
vi. To secure even and dense surfaces free from aggregate
pockets, vibration shall be supplemented by tamping or
rodding by hand in the corners of forms and along the form
surfaces while the concrete is plastic.
vii. A sufficient number of standby vibrators shall be kept readily
accessible to the place of deposition of concrete to assure
adequate vibration in case of breakdown of those in use.
viii. Form vibrators whenever used shall be clamped to the sides
of formwork and shall not be fixed more than 450 mm above
the base of the new formwork and concrete shall be filled not
higher than 230mm above the vibrator. The formwork must
be made specially strong and watertight where this type of
vibrator is used.
Care must be taken to guard against over vibration especially
where the workability of the concrete mix is high since this
will encourage segregation of the concrete.
ix. Plain concrete in foundations shall be placed in direct contact
with the bottom of the excavation, the concrete being
deposited in such a manner as not to be mixed with the earth.
Plain concrete also shall be vibrated to achieve full
compaction.
x. Green concrete shall be protected from the direct sun light
and hot winds as per the methods approved by Engineer.
Such method should be got approved from the Engineer
before start of concreting operations.
Concrete placed below the ground shall be protected from
falling earth during and after placing. Concrete placed on
ground containing deleterious substances shall be kept free
from contact with such ground and with water draining there
from during placing and for a period of seven days or as
otherwise instructed thereafter. Approved means shall be
taken to protect immature concrete from damage by debris,

excessive loading, abrasion, vibrations, deleterious ground

water, mixing with earth or other materials, and other
influences that may impair the strength and durability of the
concrete.
(6) Vibrators
a) Vibrators shall penetrate the full depth of the layer of concrete
placed and just into the layer below, and be withdrawn slowly to
avoid the formation of voids.
b) Vibration shall not be applied directly or indirectly to concrete
after the initial set has taken place, nor shall it be used to make
concrete flow in formwork.
c) The Contractor shall have a minimum of two spare vibrators
available during each concrete pour in case of mechanical
breakdowns.
(7) Continuity of Placing
a) Placing in each section of work shall be continuous between
construction joints. The Contractor shall make provision for
standby equipment.
b) If the placing of concrete is delayed due to breakdown then the
Contractor shall erect vertical stop-ends and form a construction
joint or remove the concrete already placed and restart after repair
of the breakdown.
(8) Placing in Inclement Weather
a) Placing shall not take place in the open during rain or inclement
weather. If such conditions are likely to occur the Contractor shall
provide protection for the materials, plant and formwork so that
placing of concrete may proceed.
b) If strong winds are prevalent protection from driving rain and dust
shall be provided for.
c) During storms and heavy rain periods only underground or
enclosed concrete pours shall be permitted and this shall also be
subject to where there is a reasonable level of protection to the
concreting work.
(9) Placing in High or Low Temperatures
a) The temperature of fresh concrete shall not exceed 32 oC, nor
drop below 5oC, nor exceed the temperatures stated in the table
of mixes. The lowest of these shall be used at the time of placing
concrete.
b) The maximum concrete temperature after placement shall not
exceed 50oC nor be 30oC above the temperature at the time of
placement, whichever is the lower.
c) The Contractor shall comply with the document entitled "Concrete
in Hot Countries" published by the FIP congress at New Delhi
1986. The procedures the Contractor wishes to employ in this
regard shall be subject to Notice of No Objection from the
Engineer’s.
d) The Contractor shall supply suitable maximum and minimum
temperature thermometers and record the shade and open-air
temperatures at locations where concrete is being placed. A

recommendation for cold weather concreting is provided in IS:

7861 (Part 2).
In case of concreting in exceptionally hot weather the Engineer may at

his discretion specify the use of ice either flaked and used directly in the
mix or blocks used for chilling the mixing water. In either case, the
Contractor shall not be paid extra for cost of ice, additional labour
involved in weighing and mixing etc. All salt and saw dust shall be
removed from ice before use. Quality of water used for making ice
shall confirm to IS: 456.
Transporting
The method of transportation used should efficiently deliver the
concrete to the point of placement without significantly altering its
desired properties with regard to water-cement ratio, slump, segregation
and homogeneity.
The mix after discharging from the automatic computerized weigh

batching plant/mixer shall be transported by agitating transit mixers,
buckets, pumps etc. or as approved by the engineer without causing
segregation and loss of cement slurry and without altering its desired
properties with regard to water cement ratio, slump, air content,
cohesion and homogeneity. It should be ensured that the concrete is
moved to its final destination before it attains the initial set.
The revolving-drum truck bodies of approved make shall be used for

transporting the concrete. The number of revolutions at mixing speeds,
during transportation, and prior to discharge shall be specified and
agreed upon. Reliable counters shall be used on revolving-drum truck
units. Standard mixer uniformity tests, conforming to ASTM standards
C 94 “Standard Specifications for Ready Mix Concrete”, shall be
carried out to determine whether mixing is being accomplished
satisfactorily.
(10) Placement at Night

If Notice has been given for placing concrete at night or in dark
interiors, adequate lighting, ventilation and access shall be provided
when mixing, transportation and placing are in progress.
(11) Placement Underwater
a) Underwater concreting shall be carried out with minimum
disturbance of the water. Running water and wave wash shall be
controlled.
b) The specified concrete grade shall be used and the mix
design shall provide for good flowing ability.
c) Tremie pipes, bottom-dump skips or other Noticed placing
equipment shall be used.
d) Segregation shall be avoided.
e) Placing shall commence in sections and continue to completion
subject to Notice of No Objection from the Engineer. The
tremie pipe shall be buried in the concrete for at least 1.5m and

the tremie pipe must not be emptied until the pour is complete.
f) If a bottom-dump skip is used, the contents shall be covered by
canvas or similar before lowering into the water. The doors
shall be opened when the skip is resting on the bottom with no
tension in the support cable, and the skip shall be lifted gradually
so that the concrete flows out steadily.
(12) Preparation Before Placing

a) Before placing concrete for reinforced work on the ground, the
formation shall be compacted as specified and a screed of blinding
concrete shall be applied to form a surface for construction.
b) Before placing concrete on or against rock, masonry,
brickwork or old concrete, loose material shall be removed and
the surface washed down; water seepage shall be stopped or
channeled away from the Work.
c) For mass concrete placed against masonry or brickwork the
following shall apply.
The mortar joints in the face work shall have fully hardened.
The water-cement ratio of the concrete shall be increased to
compensate for absorption of moisture by the existing work.
The surface shall be soaked prior to placing.
The concrete shall be worked around ties and bond stones
and into open joints.
(13) Construction Joints
Construction joints in all concrete work shall be made as directed by the
Engineer. Where vertical joints are required, shuttering shall be fixed as
directed To ensure that the concrete does not take natural slope.
Before fresh concrete is placed against a vertical joint, the old concrete
shall be chipped, cleaned and moistened.
No separate payment shall be allowed to the Contractor for forming
joints or chipping and cleaning them. When a horizontal construction
joint is formed, provision shall be made for interlocking with the
succeeding layer by the embedment of saturated wooden blocks or
wooden strips beveled on four sides to facilitate their removal. Prior to
the next pour the wooden pieces shall be loosened and removed in such
a manner as to avoid injury to the concrete.
Construction joints in concrete walls and slabs for liquid retaining
structures shall be prepared in a similar manner to normal construction
joints. If use of metal, rubber or plastic water stops is specified, this
shall be cast into joints. Measures shall be taken by the Contractor to
ensure that no displacement or distortion of water stops takes place
during placing of concrete. The construction joints shall ensure proper
bond and leak proof joint.
(14) Cracks
If cracks, which in the opinion of the Engineer may be detrimental to
the strength of the construction, develop in concrete construction, the
Contractor at his own expense shall test the structure as specified in
clause 1.1.16 of ‘Loading Tests’ of these Specifications. If under such
test loads the cracks develop further, the Contractor shall dismantle the
construction, carry away the debris, replace the construction and carry

out all consequential work thereto.

If cracks develop in the concrete construction, which in the opinion of
the Engineer, are not detrimental to the stability of the construction, the
Contractor at his own expense shall grout the cracks with neat cement
grout or with other composition as directed by Engineer and also at his
own expense and risk shall make good to the satisfaction of the
Engineer all other works such as plaster, moulding, surface finish,
which in the opinion of the Engineer have suffered damage either in
appearance or stability owing to such cracks. The Engineer's decision as
to the extent of the liability of the Contractor in the above matter shall
be final and binding.
External crack width shall be restricted to 0.2mm on all viaduct
structures. If crack width is more than 0.2mm or in the opinion of
Engineer may be detrimental to concrete construction, the contractor
should test the structure at his own expense.
(15) Defective Concrete
Should any concrete be found honeycombed or in any way defective,
such concrete shall be cut out partially or wholly by the Contractor and
made good at his own expense. If Engineer feels that repaired structure
will not be having same strength or shape or uniformity with other
exposed surface as original desired structure / original structure, the
same shall be rejected by Engineer and required to be dismantled and
disposed off by contractor at his own cost, as instructed by Engineer.
Decision of the Engineer shall be final binding in this regard.
(16) Exposed Faces, Holes And Fixtures
On no account shall concrete surfaces be patched or covered up or
damaged concrete rectified or replaced until the Engineer or his
representative has inspected the works and issued written instructions
for rectification. Failure to observe this procedure will render that
portion of the works liable to rejection.
Holes for foundation or other bolts or for any other purposes shall be
moulded, and steel angles, holdfasts or other fixtures shall be
embedded, according to the drawing or as instructed by the Engineer.
1.5.2.8 Reinforcement and Coupler specifications
1.5.2.8.1 General
These specifications shall be read in conjunction with the MORTH
specifications and CPWD specifications with correction slips / amendments
upto date, and other relevant specifications described in the section 1 of these
specifications.
Any steel specified for reinforcement shall conform in every respect to the
latest relevant Indian Standard Specifications and shall be of tested quality
under the ISI Certification Scheme.
All reinforcement work shall be executed in conformity with the drawings

supplied and instructions given by the Engineer and shall generally be carried
out in accordance with the relevant Indian Standard Specifications IS:2502-
Bending and Fixing of Bars for Concrete Reinforcement.

Only TMT reinforcing bars of grade Fe500 D (0.2% proof stress / yield stress
not less than 500 Mpa) confirming to IS:1786 shall be supplied and used as
reinforcement steel for the permanent work
The reinforcement steel shall be from primary producers and no re-rolled

steel shall be supplied and used. The contractor will produce copy of original
challan / voucher as a proof of having purchased the steel reinforcement from
approved manufacturers or their authorised distributors.
The steel reinforcement shall be brought to the site in bulk supply of 10

tonnes or more as decided by the Engineer. All reinforcement shall be stored
horizontally above ground level on platforms, skids or other approved
supports, clear of any running or standing water. Proper drainage of platform
shall be provided. Steel reinforcement shall be stored in such a way as to
avoid distortion and prevent deterioration by corrosion. Bars of different
diameters shall be stored separately. A record shall be kept of the batch
numbers of reinforcement deliveries in such a form that the part of works in
which particular reinforcement is used can be readily identified.
1.5.2.8.2 Inspection & Testing

Every bar shall be inspected before assembling on the works and any
defective pitted, brittle, excessively rusted or burnt bars shall be removed.
Cracked ends of bars shall be cut out.
No work shall be commenced without the Engineer’s approval of the bar

bending schedule.
Manufacturer's test Certificate shall be supplied for each lot of supply brought
at site of work by the contractor.
Specimens sufficient for three Tensile Tests for each different size of bar,
bend and rebend physical tests for each consignment delivered shall be
sampled and tested by the Contractor before use at site. Test results shall be
duly supported by Graph. Batches shall be rejected if the average results of
each batch are not in accordance with the relevant specifications / codes and
the rejected steel shall be removed from the site of work by the contractor at
his own cost within a week’s time from the written order from the Engineer.
1.5.2.8.3 Bar Bending And Bar Bending Schedule

All bars will be carefully and accurately bent by approved means in
accordance with IS: 2502, and relevant drawings. It shall be ensured that
depth of crank is correct as per the bar cutting and bending schedule. Bent
bars are not straightened for use in any manner that will injure the material.
No laps should be allowed for Pre-cast segments and Piers, Pier caps.
However mechanical couplers are to be used without extra cost.
Prior to starting bar bending work, the Contractor shall prepare bar bending
schedule from the structural drawings supplied to him and get the same
approved by Engineer. Any discrepancies and inaccuracies found by the
Contractor in the drawings shall be immediately reported to the Engineer

whose interpretation and decision there to, shall be final.
1.5.2.8.3 Couplers for reinforcement above 20 mm in dia& Laps

As far as possible bars of the maximum length available shall be used.. For
bars having larger diameter more than 20 mm mechanical couplers shall be
provided at the locations approved by the Engineer and no lap shall be
permitted. No extra payment on account of providing mechanical couplers
shall be paid. Reinforcement Couplers for Mechanical Splices of Bars in
Concrete shall be of Class H and as confirm to IS 16172
Welding in lieu of lap is not permitted unless specified in the drawings or as

instructed by the Engineer.
1.5.2.8.4 Spacing, Supporting And Cleaning

All reinforcement shall be placed and maintained in the positions shown on
the drawings.
The Contractor shall provide approved types of supports for maintaining the
bars in position and ensuring required spacing and correct cover of concrete
to the reinforcement as specified on the drawings. Cover blocks of required
shape, size and strength M.S. Chairs and spacer bars shall be used to ensure
accurate positioning of reinforcement.
Cover blocks shall be cast well in advance with Concrete mix which shall be
approved by Engineer and shall have the strength same as that of concrete for
the member for which they are to be used. For Precasting works the cover
block shall be used of PVC make or shall have the precast with clip
arrangements, approved by Engineer. They shall be circular in shape for side
cover and square for bottom cover. Cover blocks shall be cast and compacted
using plate vibrator or any other approved method and shall be cured so as to
achieve the desired strength. The cost of cover blocks and chairs/spacers shall
be deemed to have been included in the rates.
Bars must be cleaned before concreting commences of all scale, rust or

partially set concrete which may have been deposited there during placing of
previous lift of concrete. Any reinforcement which is certified as corroded by
the Engineer shall be removed from the site.
The HYSD bars shall be provided using cement and inhibitor using following
procedure:
a) Cleaning of steel by wire brush for dust and rust.

b) Apply one coat of Cement slurry [1 kg cement & 600 cc of inhibitor
solution (Patent No. 109784/67)] by dipping or brushing. Allow it to dry
for 24 hours in shade. The water is not to be used. The inhibitor solution
is prepared in ionised water
No extra payment shall be made for the same.

18 Gauge G.I. wire shall be used for binding reinforcement as well as for
tying cover blocks with reinforcement.
1.5.2.8.5 Welding
Wherever specified all lap and butt welding of bars shall be carried in
accordance with IS:2571. Only qualified welders duly tested and certified by
the contractor shall be permitted to carry out such welding.
1 For cold twisted reinforcement welding operations must be controlled

to prevent supply of large amounts of heat larger than that can be
dissipated. The extreme non twisted end portion shall be cut off before
welding. Electrodes with rutile coating should be used.
2 Bars shall be free from rust at the joints to be welded.
3 Slag produced in welding after each run should be chipped and

removed by brush.
4 Electrode should not be lighted by touching the hot bar.
5 The welding procedure shall be approved by the Engineer and tests

shall be conducted to prove the soundness of the welded connection.
1.5.2.8.6 Provision of Future Cathodic Protection for Corrosion Control:

In order to provide Cathodic Protection in future, all reinforcement shall be
tack welded using electrodes compatible with the types of bars at the
specified intervals in the drawings. As a guideline, all reinforcing bars shall
be tack welded at each ends or at a distance not more than 6m along length to
the bars intersecting in other direction. The tack welding shall be checked for
the electrical continuity before concreting.
1.5.2.8.7 Coupler Specifications

Mechanical couplers of threaded type with enlargement at connection by cold
forging may be used at appropriate locations after prior approval of engineer
1. Introduction
Only cold-forged, parallel threaded mechanical coupler system are recommended.
All mechanical couplers shall be of Type 2 (or Class H as specified in IS-16172)
and should be simple to install and which can be confirmed by quick visual
inspection to have been correctly installed and to have achieved the required full
strength connection.
The couplers shall be of standard parallel thread type. Ends of the reinforcement
bars, which are to be joined, shall be enlarged by cold forging/upsetting, threaded
in such a way that root thread diameter is not lesser than the parent bar to be joined.
The coupler shall be of TYPE – II and qualified/Certified as per UK CARES, IS
code 16172:2014, ACI 318, ASME, Section III, and Div.2, Caltrans.
Couplers installed shall be strictly in accordance with the manufacturer’s
recommendations.

All the couplers shall undergo quality checks on uniformity of threads, dimensional
accuracy etc. Each coupler shall be clearly stamped indicating batch number and
diameter. This number shall be traceable to the original cast. The relevant material
mill certificate shall be submitted with supply of a particular lot. The certificate
shall give salient material properties. The coupler manufacturer shall satisfy the
below minimum criteria:
- operate at least an ISO 9000 approved quality assurance programme or
equivalent for the manufacture of couplers.
- have own manufacturing plant without outsourcing.
- Should have similar experience for supplying coupler and providing threading
services of atleast 10 years in similar underground metro project construction.
- must have completed at least three operational metro projects which is under
operation for more than 5 years.
2. Threading of ends of the reinforcing bars:

This threading activity shall preferably be done at Site. The various stages involved
in threading are as given below:
a. Cutting (Rebar End Préparation):
The ends of reinforcement bars shall be cut by mechanical means to get a

perfect plain and surface perpendicular to the axis of the bar.
b. Cold forging & threading:
After cutting the ends of the bar shall be enlarged by cold forging such that the area
of cross section after threading shall not be less than the area of cross section of the
parent bar. The length of cold forging shall be adequate for proposed thread length
as per manufacturer's design. Threading shall be done preferably on threading
machine. The threads shall be square parallel type to suit the couplers. The thread
length and depth shall be as per manufacturer's design. After threading is
completed, the threaded length of the bars shall be protected by providing plastic
end caps before taking the bars out of the shop.
3. Quality control in making of threads:

Double forging of bars is not permitted. In case of improper cold forging the forged
of the bar shall be square cut and fresh cold forging shall be undertaken. The
threading shall be checked with 'go' and “no go' gauges for the correctness of the
thread profile on the rebar.
4. Qualification tests
The coupler shall be qualified as per IS code 16172:2014, ACI 318, ASME -
Section III, and Div.2, Caltrans and must have conducted & qualified for the
following tests :
a. Static Tensile Test

Mechanical connections shall be tested for all reinforcing rebar sizes. For each
rebar size, a minimum of three connections (3 joints + 1 Parent bar) in each load
direction shall be tested in accordance with ASTM A370 test method to meet code
requirement. A tensile test on an unsliced specimen from the same bar used for the
spliced specimens shall be performed to establish actual tensile strength. The
tensile strength of an individual splice system shall not be less than the specified
ultimate tensile strength (UTS of rebar) of the spliced bar.
b. Cyclic Tension and Compression Test
Mechanical connections shall be tested in all reinforcing rebar sizes. For each rebar
size, a minimum of three connections shall be tested for cyclic tension &
compression test. Each specimen shall withstand cycles of stress variation of the
specified minimum yield strength of the reinforcing bar. Past certificates, however
these should not be more than 3 years old. The test should be carried out as per the
table mentioned below:
Loading Stages and Cycles per stage for cyclic load test
Stage Tension Compression Cycles

1 0.95 fy 0.5 fy 20cycles
2 2 εy 0.5 fy 4cycles
3 5 εy 0.5 fy 4cycles
Note:
fy is specified yield strength of the reinforcing bar.
εy is the strength of reinforcing bar at actual yield stress
c. Cyclic Tensile Test
Mechanical connections shall be tested in all reinforcing rebar sizes. For each rebar
size, a minimum of three connections shall be tested for low cyclic tensile test.
Each specimen shall withstand 100 cycles of stress variation from 5% to 90% of
the specified minimum yield strength (fy) of the reinforcing bar. One cycle is
defined as an increase from the lower load to the higher load & return. Past
certificates for low cycle fatigue test shall be accepted, however these should not
be more than 3 years old.
d. Low cycle fatigue test (for 10,000 cycles)
Fatigue test shall be conducted on splice sample from +173 Mpa to -173 Mpa for
10,000 cycles. A sine wave form @ 0.083 Hz shall be followed for bar dia 36 mm
& above and 0.35 Hz shall be followed for bar dia less than 36 mm. Test shall be
conducted confirming to IS 16172:2014. Past certificates for low cycle fatigue test
shall be accepted, however these should not be more than 3 years old.

e. High cycle fatigue test (for 2,000,000 cycles)
In high cycle fatigue test, the test specimen is subjected to an axial tensile load
which varies cyclically according to the sinusoidal wave form of constant
frequency in the elastic range, as accordance with IS-16172. Past certificates for
high cycle fatigue test shall be accepted, however these should not be more than 3
years old.
f. Slip test
Slip Test Shall be performed on each diameter coupler specimen as per ASTM A
370 section 10. Test shall be conducted confirming to IS 16172:2014 & Caltrans
specifications. Past certificates for low cycle fatigue test shall be accepted, however
these should not be more than 3 years old. Total slip shall not exceed the max value
of 0.1 mm. Refer table below for more details:
Bar diameter TOTAL Slip (µ m)

8 mm to 20 mm 250
25 mm to 28 mm 350
32 mm to 40 mm 450
45 mm 600
56 mm 750
g. Proof Loading Test
Every cold-forged, threaded bar end should undergo a proof load test prior to
leaving system supplier’s workshop. Every threaded bar must be subjected to proof
load testing to a minimum test loading of 75% of the characteristic strength
(theoretical fy). The system supplier should essentially install a proof load tester
equipment within its threading workshop premises and ensure to test each and
every threaded bar. A positive indication shall be marked on the rebar to indicate
that this operation has been carried out.
The proof load tester equipment should have LED display for automatic setting and
control of pressure and proof load imparted to each rebar. The equipment should be
compulsorily managed in automatic mode with display of setting pressure and
actual pressure applied and accepted if applied pressure is equal to or higher than
setting pressure.
Installation of couplers in the field:

The installation of couplers in the field, for joining reinforcing bars shall be
undertaken by trained manpower and as per manufacturer's instructions. Threads of
both the couplers and the bars shall be thoroughly cleaned just before installation.
Where couplers are cast-in the concrete, but connection is not to be completed
immediately, the couplers shall be internally greased and plastic capped to a
protection detail acceptable to the engineer. This cap shall be removed only when
next bar is to be attached, then the same to be cleaned before joining the next bar.

The contractor shall arrange for a suitably qualified manufacturer's representative

experienced in mechanically connecting reinforcement to be present at site before
the start of work for initial training of personnel, and also to demonstrate the
equipment and techniques as necessary. The threading workshop is to be fully
supervised by the manufacturer's representative.
The contractor shall submit to the Engineer, for his acceptance a method statement
for mechanically connecting the reinforcement and for the installation and
verification in the field. This shall take into account any special requirements
for horizontal, vertical and inclined couplers and shall include a rectification
procedure, if the connection is incorrectly made. It shall also cover the correct
methodology for handling of tools and equipment for mechanical connection on
site. The following information shall also be included:
a. Requirements for cleanliness

b. Equipment for threading bars
c. Method of locking the connections on both rebars
d. Method of verification of final rebars alignment and coupler integrity
Each coupler shall be visually examined prior to use to ensure the absence of rust
and of any foreign material on the inside surface. All completed couplers shall be
inspected and verified in accordance with the approved QAP. The Contractor shall
ensure the acceptance of the Engineer for a procedure for documenting the
inspection of the couplers. The contractor shall retain inspection records and shall
submit copies to the engineer within 7 days. The Couplers that do not meet the
acceptance shall be completely removed and the bars re-connected as required.
1.5.2.9 Joints
(1) Construction Joints
a) Construction joints shall be located and the sequence of placing
arranged as noticed, to minimize shrinkage and thermal strains in
the concrete.
b) Concrete placing shall not be interrupted except where joints
occur, and shall continue after normal hours if necessary to
achieve this.
c) Joints shall be formed square to the Work with keyways included.
d) Before placing is resumed at a joint the set surface shall be
roughened to remove laitance and expose the aggregate; the
aggregate shall not be damaged. If damaging materials have come
into contact with the surface of the joint the concrete shall be cut
back and the roughened surface cleaned by compressed air or
water jets and brushed and watered immediately before
placing. If required the surface shall be coated with a layer of
stiff cement grout prior to placing the new concrete.
e) Chemical surface-retarding agents shall not be used.
f) Construction joints shall be sealed with a noticed sealant at
external and liquid-contact faces.
g) Construction joints in water-retaining structures and in other

structures, wherever needed, shall incorporate a noticed water-stop

to comply with the water-tightness requirements as stipulated in
the Contract.
(2) Expansion, Contraction and Movement Joints
a) Expansion, contraction and other movement joints shall be
incorporated in the Works as shown on the Drawings, that have
Notice of no Objection from the Engineer.
b) Where shown on the Drawings, expansion joint fillers shall be
supplied and installed. Filler material shall be stored flat on a dry
surface adequately protected from rain or moisture in such a way
that the material does not deteriorate. Filler material which has
been damaged or has started to deteriorate shall not be
incorporated in the Works.
c) Movement joints shall be sealed with a noticed sealant applied in
strict accordance with the manufacturer's instructions to the
dimensions shown on the Drawings. The surface of the concrete
to which the sealant is to adhere shall be straight and cleaned of
all filler material, dirt, oil, grease and other matter. The sealant
shall be applied by methods recommended by the manufacturer so
that the sealant is brought flush to the surface of structure and a
smooth surface is achieved. Excess material and spillage shall be
properly cleaned off and removed.
d) Dowel bars shall be installed and cast-in across the movement
joint where shown on the Drawings. The bars shall be straight
with clean cut ends of the diameters and lengths as shown on
the Drawings or in the Schedules. Cutting and cleaning of the
dowel bars shall comply with the requirements of the Contract
e) The bars shall be firmly supported in the positions shown on the
Drawings so that they remain accurately parallel and are not
displaced during the casting of the concrete in the first part of the
structure. After the concrete has hardened and the formwork
removed, the projecting ends shall be cleaned of all concrete
spillage and painted with two coats of a noticed bituminous paint
and caps shall be fitted to the free ends of the bars. Dowel bar end
caps shall be of cardboard or other material, of correct diameter
for the dowel bar and of sufficient length to allow the specified
movement of the two adjacent concrete structures. They shall be
manufactured expressly for this purpose by a noticed
manufacturer.
f) The Contractor shall take care to protect the projecting ends of
dowel bars from bending or other damage prior to concreting
the succeeding bay. The bituminous paint shall be applied as
soon as practicable, but end caps shall not be fitted until
immediately prior to the succeeding concreting operations.
(3) Water-stops
The layout and installation of the water-stops shall be in accordance
with the manufacturer's recommendation and shall be subject to
(4) Bolts, Inserts and Openings
a) All fixing blocks, brackets, built in bolts, holes, chases, etc., shall

be accurately set out and formed and carefully sealed prior to the
concrete being placed. No cutting away of concrete for any of
these items shall be done.
b) Bolts and other inserts to be cast into the concrete shall be
securely fixed to the formwork in such a way that they are not
displaced during the concreting operations, and that there is no
loss of materials from the wet concrete through holes in the
formwork.
c) Unless shown otherwise on the Drawings reinforcement shall be
locally moved so that the minimum specified cover is maintained
at the locations of inserts, holes, chases, and the like.
d) Temporary plugs shall be removed and the threads of cast-in
bolts shall be proved to be free and shall be greased before
handing over any part of the Works.
1.5.2.10 Curing and Protection

(1) Curing and Protection
a) Concrete shall be protected from sunshine and drying winds
by noticed shading and wind-breaks, and from cold, rain or
running water, for a period of at least 7 days after placing. During
this period or for any extended period the following measures
shall be taken to prevent the loss of moisture and to minimize
thermal stresses caused by the difference in temperature between
the surface of the concrete and the core of the concrete mass.
b) Horizontal surfaces.
Polythene sheeting shall be placed immediately after finishing.
After final set has taken place, the polythene shall be replaced by
wet Hessian covered with polythene. The Hessian shall be kept
permanently damp. After 7 days the Hessian and polythene shall
be removed and a noticed curing compound of Acrylic Resin
based, Clear or translucent type shall be applied unless an
alternative method is used. The method of application shall be as
recommended by the manufacturer. Alternative methods of curing
shall be subject to the Notice of No Objection the Engineer
before use in the Works.
c) Vertical surfaces.
Polythene over wet Hessian shall be secured to the surfaces
immediately after removal of the formwork. The Hessian shall be
kept permanently damp. After 7days the Hessian and polythene
shall be removed and a noticed aluminized or white resin based
curing compound applied. Alternatively, the Hessian and
polythene to stay for a further 7 days. Water used during curing
operations shall be fresh water. Curing membranes shall be
compatible with waterproofing or other materials that may
subsequently be applied to the surface of the concrete.
(2) Contamination
Concrete shall be protected from contamination by sea or brackish
water, oil, fuel and other deleterious materials for a minimum period of
30 days after placing.
(3) Insulating Formwork

Insulating formwork shall be left in place for 72 hours after placing the
concrete or until the temperature peak of the concrete is reached. The
initial curing period defined above may then be reduced in proportion
subject to the Notice of No Objection from the Engineer
(4) Protection of Joints
Rebates formed to receive sealant and the surfaces of construction joints
shall be protected from curing compound by wet Hessian to ensure
proper curing of the joint surface and adjacent concrete. The protection
shall remain in place until the joint surface is sealed.
1.5.2.11 Finishes
(1) General
a) The finished faces of concrete shall be sound, even-coloured,
even-textured and free from defects. Arises shall have a 20mm by
20mm chamfer. Concrete faces shall not be rendered and defective
concrete shall be cut out and replaced or made good. A fine finish
shall be provided unless otherwise detailed on the Drawings.
b) Any concrete structure for the Platform Screen Doors shall be
cast with smooth surfaces, free of blowholes and any raised
blemishes. The Contractor shall take into account the
requirements of Architectural finishes to ensure that appropriate
finish of concrete surface is rendered to accommodate
requirements of various Architectural finishes in the stations.
(2) Fine Finish
Surfaces defined as having a fine finish shall be rubbed smooth by
carborundum stone small holes shall be stopped with noticed mortar of
the same final colour as adjacent concrete.
(3) Concrete Surfaces without Formwork
a) On upward-facing surfaces which do not require formwork or
special finish the finish shall be produced by proper placing and
compacting operations alone.
b) For a fair-finish screeding, this shall be carried out by sliding
and tamping a screed board running on the top edges of the
formwork, or on screeding guides, to give a dense concrete skin.
c) For a fine finish screeding as described, the surface shall be left
until the concrete has stiffened and the film of surface moisture
has disappeared. A steel or wooden float shall then be used for a
glossy or sandpaper surface as required. Working shall be the
minimum compatible with a good finish. The surface shall be
protected from water drops.
(4) Wire-Brushed Finish
After removal of the formwork the surface of the concrete shall be
abraded by stiff wire brushes and water to remove the cement
laitance and expose the aggregate.
(5) Bush-Hammered Finish
a) The surface shall be abraded by carborundum stones to remove
irregularities. Within 3 weeks, the surface shall be bush-
hammered to remove the cement laitance and expose the
aggregate. Noticed bush hammers shall be worked to within 12
millimeters of corners and arises; the remaining 12 millimeters

shall be hand-chiseled to match.

b) Bush hammers shall be operated perpendicularly to the surface,
and the remaining exposed aggregates shall not be loose or
fractured. The treated surface shall be washed with water and
stiffly brushed. The exposed aggregate shall be clean and free
from film.
(6) Chemical Retarders
Chemical surface retarders, may be used to produce an exposed
aggregate finish, and the Contractor shall demonstrate that the
durability of the concrete surface is not reduced.
(7) Carborundum Finish
a) Carborundum finish shall be achieved by sprinkling
carborundum grit on the unset surface and working-in by wooden
float.
b) The carborundum grit shall vary in size between BS 1.18
millimeters mesh and BS 0.6 millimeters mesh and shall be
distributed from a BS 1.18mm hand-screen at the rate of 2.15
kilograms per square meter.
(8) Specimen Panels of Concrete
If required, the Contractor shall produce specimen panels of finished
concrete for the Notice of No Objection from the Engineer.
1.5.2.12 Special Concrete

(1) No-Fines Concrete
a) The aggregate for no-fines concrete shall be coarse-graded
from 10mm to 20mm. A small percentage of fines from 10mm
to 5mm may be added to improve the strength if noticed.
b) Cement shall be mixed with the aggregate in the proportion
of 1 to 8 by volume.
c) Segregation of the cement grout shall be prevented.
(2) Granolithic Concrete
a) Granolithic concrete shall consist of one part by weight cement to
three parts of combined coarse and fine aggregate.
b) Granolithic concrete shall preferably be laid on top of the
unset base concrete, and compacted and worked to the correct
levels. The surface shall be floated with a steel float after
hardening until water sheen has disappeared. Cement or
cement-sand shall not be sprinkled onto the surface. The layer
shall be 12mm to 18mm thick.
c) If a granolithic layer is required to be placed on set concrete, the
latter shall be scabbled and cleaned to expose the aggregate, and
an noticed bonding agent applied. The layer shall not be less than
50mm thick.
d) If required, compounds shall be added or applied to give a
concrete with improved dust-proof and oil-proof qualities of any
desired colouring. The compounds shall be used in accordance
with the manufacturer's instructions.
e) Granolithic concrete paving shall be placed in panels not
exceeding 3 meter square. Contraction joints shall be provided
around the perimeter of each panel.

(3) Cement - Mortar, Grout, and Rendering

a) Cement-mortar shall consist of one part cement and four parts
fine sand by volume with just enough water to achieve work-
ability.
b) Cement-lime-mortar shall consist of three parts of sand to one
part of mixture comprising one part of cement to one part of
hydrated lime.
c) Grout shall consist of cement mixed with water in designed
proportions. Fine sand may be included in noticed quantities.
d) Rendering shall consist of three parts fine, sharp sand to one part
cement applied in two 10mm thick coats and one 5 mm thick
finishing coat. The colour of the finishing coat shall be subject to
e) Acid-resistant epoxy mortar shall be obtained from a noticed
manufacturer and applied in accordance with the manufacturer's
instructions.
f) Mortar, render and grout shall be used freshly mixed.
1.5.2.13 Protective Coatings
(1) External Sheet Tanking Membrane.
a) External protection to concrete substructures where required shall
be as noticed by the Engineer and fixed to the surface in
accordance with the manufacturer's instructions.
b) Materials and workmanship shall be in accordance with the
Contract waterproofing.
(2) External Brush-Applied Tanking Membrane.
a) Substructures shall be protected externally, where required with an
noticed membrane applied to the top of the blinding concrete and
to the outside surfaces of all buried concrete, and continued
where appropriate to 300mm above finished ground level.
b) The surfaces shall be cleaned and brought to a fine finish
before coating. Each coat shall be applied at the rate specified by
the manufacturer. Coatings shall be protected by a hard board or
similar materials during backfilling.
(3) Internal Protection to Concrete.
Protection to internal concrete faces shall be provided as required.
(4) Protection of Concrete Above Ground Level
a) All exposed concrete surfaces above tanking membrane tuck-in
level shall be coated with an noticed two-coat protection level
system, subsequently over- coated with an noticed compatible
two-coat smooth finish acrylic paint system.
b) Sample panels of minimum area 10 square meters shall be made
on finished concrete to prove the finish quality and enable the
colour to be selected. Only those panels finally noticed may be
included in the Works.
1.5.2.14 Tolerances
The tolerances of concrete surfaces shall be in accordance with the following.
Precast Concrete BS 8110 Members Subsection 6.11.3
Foundations and other BS 5606 in-situ buried concrete
Exposed concrete BS 5606 (including internal surfaces of sewer

culverts)
Other concrete surfaces: As shown on drawings/schedule of finishes
1.5.3 Precast Concrete

1.5.3.1 Manufacture Off-Site
(1) Casting of members shall not begin until a Notice of No Objection has
been given by Engineer to the shop drawings, required computation,
pre-stressing system (if required) and method of manufacture.
(2) When the drawings and method of manufacture have been noticed, no
changes shall be made without the Notice of No Objection from the
Engineer
(3) The Contractor shall inform the Engineer in advance of the
date of commencement of manufacture and casting of each type of
member. Concrete reinforcement and workmanship shall be as per IS
456.
(4) A copy of all cube test results for the precast concrete works shall be
sent to the Engineer as soon as these are available.
(5) No members to which the tests relate shall be dispatched to the Site
until the tests have been satisfactorily completed and noticed by the
Engineer.
(6) All members shall be indelibly marked to show the “member
mark” , the production line on which they were manufactured, the date
on which the concrete was cast and, if they are of symmetrical section,
the face that will be uppermost when the member is in its correct
position in the Works. The markings shall be so located that they
are not exposed to view when the member is in its permanent
position.
1.5.3.2 Forms
The design and engineering of the forms and false work as well as their
construction shall be the responsibility of the Contractor. All exposed
surfaces of each element of the structure shall be formed with similar
material to produce similar concrete surface textures, colour, and appearance.
Forms shall be inspected prior to authorizing casting operations. Details
shown on the Drawings shall be built into the forms. Worn, damaged, or
otherwise unacceptable forms shall be repaired before casting of any
member will be authorized. The forms may be made either of steel or of
plywood. If the Contractor elects to use plywood forms, it shall be high
quality plywood, 19mm minimum thickness marine grade subject to the
Notice of No Objection from the Engineer. Forms shall be structurally
adequate to support the members within permissible tolerances. The form
design shall incorporate the method and the necessary hardware to adjust and
maintain grade and alignment. Details of the hardware and adjustment
procedure shall be included in the required plans. Forms shall be coated with
an noticed form-release agent prior to use. Form release agents shall be of
commercial quality, of oil or other equivalent substances which permit the
ready release of forms and will not discolour the concrete. Excess form
release agents shall not be allowed to stand in puddles in the forms nor shall
coating be allowed to come in contact with reinforcing steel or hardened
concrete. Anchor devices may be cast into the concrete for later use in

supporting forms provided the arrangement has the Notice of No Objection

from the Engineer. The use of driven or drilled types of anchorages for
fastening forms or form supports to concrete shall not be permitted.
1.5.3.3 Curing
a) Curing of Precast member by water is preferable for 7 days with protection of
Hessian cloth and other method. However, use of Curing compounds can be
allowed as per method statement and procedure by Contractor with the approval of
Engineer. The compound material should be clear, water based, non toxic, non film
forming, reactive silicate treatment with indefinite shelf life suitable as a complete
replacement to any water curing procedures such as water soak, ponding, blankets
and plastic sheets for all horizontal and vertical surfaces. Manufacturer shall supply
written proof of completed, successful projects for upto 30 years. After completion
of curing process, there should not be any requirement of removal or special
preparation for surface applied adhesives, flooring, coatings, patching, concrete
stains, etc. Curing compound should have been successfully tested by CRRI as a
replacement for water curing and accredited by IRC also. Material test result
should be in compliance with ASTM C 309 and ASTM 1315.
b) Method of curing and their duration shall be such that the concrete will have
satisfactory durability and strength and members will suffer a minimum distortion,
be free from excessive efflorescence and will not cause undue cracking in the
works by shrinkage.
c) Steam curing with approved methodology can be adopted if required, for precast
components subject to the approval of Engineer-in-Charge. No extra payment will
be made for adopting steam curing. Before concrete products are subjected to any
accelerated method of curing, the cement to be used shall be tested in accordance
with accepted standards (relevant IS codes) especially for soundness, setting time
and suitability for steam curing. In the case of elements manufactured by
accelerated curing methods, concrete admixtures to reduce the water content may
be allowed to be as permitted by applicable codes of practice subject to the
approval of the Engineer-in- Charge. The normal aeration agents used to increase
the workability of concrete shall not be allowed. The steam curing of concrete
products shall take place under hoods, under chambers or in tunnels. Use of
insulated tarpaulin may be permitted. The steam shall have a uniform quality
throughout the length of the member. The precast elements shall be stacked with
sufficient clearance between each other and the bounding enclosure, so as to allow
proper circulation of steam. The surrounding walls, the top cover and the floor of
steam curing chamber or tunnel or hood shall be so designed as not to allow more
than 1 kcal/m2/h/ deg C. The inside face of the steam curing chamber, tunnel or
hood shall have a damp-proof layer to maintain the humidity of steam. Moreover,
proper slope shall be given to the floor and the roof to allow the condensed water
to be easily drained away. At first, when steam is let into the curing chambers, the
air inside shall be allowed to go out through openings provided in the hoods or side
walls which shall be closed soon after moist steam is seen jetting out. Preferably,
steam should be let in at the top of the chamber through perforated pipelines to
allow uniform entry of steam throughout the chamber. In no case shall steam
impinge directly on concrete products. The fresh concrete in the moulds shall be
allowed to get the initial set before allowing the concrete to come into contact with

steam. The regular heating up of fresh concrete product from 20 °C to 35 °C shall

start only after a waiting period ranging from 2 to 5 hours depending on the setting
time of cement used. The second stage in steam curing process shall be to heat up
the concrete elements, moulds and the surroundings in the chamber. The air-space
around the member shall be heated up to a temperature maximum to 70°C at a
gradual rate, not faster than 10° per hour. This process shall continue 1 1/2 to 2 1/2
hours depending upon the outside temperature. The third stage of steam curing
shall be to maintain the uniform temperature and pressure for a duration depending
upon thickness of the section. This may vary from 3 to 5 1/2 hours. The fourth
stage of steam curing shall be the gradual cooling down of concrete products and
surroundings in the chamber and normalization of the pressure to bring it at par
with the outside air. The maximum cooling rate, which is dependent on the
thickness of the member, shall not exceed 30° per hour. In all these cases, the
difference between the temperature of the concrete product and the outside
temperature shall not be more than 60°C for concrete up to M 30 and 75°C for
concrete greater than M 45. In the case of light weight concrete, the difference in
temperature shall not be more than 60°C for concrete less than M 25. For concrete
greater than M 50, the temperature differences may go up to 75°C. After the steam
curing is completed, the elements shall be further water cured for about 3 to 7 days
or Curing compound can be used with the approval of Engineer.
1.5.3.4 Storage
When members are stored, they shall be firmly supported only at the points
specified.
(1) The accumulation of trapped water and deleterious matter in the units
shall be prevented.
(2) Care shall be taken to avoid rust staining and efflorescence.
The pre-cast units shall be stored as directed by the Engineer. The area
intended for the storage of pre-cast units should be surfaced in such a
way that no unequal settlement can occur.
To prevent deformation of slender units, they should be provided with
supports at fairly close intervals and should also be safeguarded against
tilting. Lifting and handling positions should conform to the Engineer's
directions and drawings. In addition, location and orientation marks
should be put on the members, as and where necessary.
1.5.3.5 Handling and Transport

(1) Members shall be lifted or supported only at points specified or
otherwise given a Notice of No Objection from the Engineer and
shall be handled and placed without impact.
(2) The Contractor shall define the method of lifting, the type of
equipment and transport to be used, and the minimum age of the
members to be handled and shall be subject to the Notice of No
1.5.3.6 Assembly and Erection

(1) The method of assembly and erection described in the Contract
shall be as practicable and be strictly adhered to on site.
(2) Immediately after a unit is in position, and before the lifting
equipment is removed, temporary supports or connections between

members, as necessary, shall be provided.

(3) The final structural connections shall be completed as soon as possible.
During erection the precast units should be protected against damage
caused by local crushing and chafing effects of lifting and transport
equipment.
Temporary supports provided during erection should take into account
all construction loads likely to be encountered during the completion of
joints between any combination of precast and in-situ concrete
structural elements. The supports should be arranged in a manner that
will permit the proper finishing and curing of any in-situ concreting and
grouting associated with the precast member being supported when the
gaps of joints have to be filled with concrete or mortar. They should
first be cleaned and faces of the joints should be wetted. The mixing,
placing and compacting of cement and mortar should be done with
special care.
1.5.3.7 Forming Structural Connections

(1) No structural connections shall be made until the Engineer's Notice
has been received.
(2) Unless otherwise noticed by the Engineer, the composition and
water: cement ratio of the in-situ concrete or mortar used in any
connection and the packing of joints shall be in accordance with the
assembly instructions.
(3) Leveling devices shall only be released or removed subject to the
Notice of No Objection by the Engineer.
1.5.3.8 Epoxy Grout for Structural Connections (if required)

(1) Description
Epoxy shall be furnished as two components mixed together at the Site.
(2) Sampling and Testing
All tests will be conducted in accordance with the latest test methods of
the American Society for Testing and Materials, Federal Test Method
Standard No. 141 or equivalent British Standard.
(3) Packaging, Labeling and Storing
a) Each component shall be packaged in steel containers not larger
than 20 liters in volume. When the components are to be mixed at
a ratio of 2 parts A to one part B, by volume, the container
containing component B shall be one half the volume of the
container containing component A.
b) The containers shall have lug type crimp lids with ring seals, shall
be new, not less than 0.6mm nominal thickness and shall be of
such character as to resist any action by the components.
c) Each container shall be clearly labeled with the designation
(Component A or B), type (Standard or Rapid) if applicable,
manufacturer's name, date of manufacture, batch number (a batch
shall consist of a single charge of all components in a mixing
chamber), lot number, all directions for use specified elsewhere
and the following warning in Hindi and English:
"CAUTION” or Equivalent in Hindi
"This material will cause severe dermatitis if it is allowed to come

in contact with the skin or eyes. Use gloves and protective

creams on the hands. Should this material contact the skin,
wash thoroughly with soap and water. Do not attempt to remove
this material from the skin with solvents. If any gets in the eyes,
flush for 10 minutes with water and secure immediate medical
attention."
d) Attention is directed to the characteristic of some epoxy
components to crystallize or thicken excessively prior to use when
stored at temperatures below 2oC. Any material which shows
evidence of crystallization or a permanent increase in viscosity
or settling of pigments which cannot be readily re-dispersed
with a paddle shall not be used.
(4) Directions for Use
a) At the time of mixing, components A and B shall be at a
temperature between 16 degrees and 29oC unless otherwise
specified. Any heating of the adhesive components shall be done
by application of indirect heat. Immediately prior to mixing, each
component shall be thoroughly mixed with a paddle. Separate
paddles shall be used to stir each component. Immediately prior to
use, the two components shall be thoroughly mixed together in the
specified ratios. When mixed, all adhesives shall have a
uniformly grey colour without black or white streaks. No solvent
shall be added to any epoxy.
b) After mixing, all epoxies shall be placed in the work and any
overlaying or inserted be cleaned and it shall have moisture
content of not more than 0.5% when tested. The maximum size
of the aggregate shall not exceed that of material which is to be
bonded to the work by the epoxy. It shall also be placed before
thickening of the epoxy has begun. Surfaces upon which
epoxy is to be placed shall be free of rust, paint, grease, asphalt,
moisture and loose and deleterious material. When epoxy is
used as a binder to make epoxy concrete or grout, the two
components of epoxy shall be thoroughly mixed together before
the aggregate is added and, unless otherwise specified, the mix
proportions shall consist of one part of binder to approximately 4
parts of aggregate, by volume. Aggregate for use in epoxy
concrete and grout shall be one-fourth of the thickness of the joint
to be grouted. All surfaces against which epoxy concrete and
grout are to be placed shall be primed with a coat of the epoxy
used just prior to placing the grout.
c) No more material shall be mixed than can be used within 20
minutes from the time mixing operations are started. Pot life of
the epoxy mixture shall be 45 minutes.
(5) Epoxy Grout Strength Requirements
The compressive strength of 38mm cubes of epoxy grout tested in
accordance with ASTM C39 after 10 hours of curing at 20oC shall be
not less than the design strength of the pre-cast member.

1.5.3.9 Protection.
At all stages of construction, pre-cast concrete units and other concrete
associated therewith shall be properly protected to prevent damage to
permanently exposed concrete surfaces, especially arises and decorative
features.
1.5.3.10 Additional Specifications For Concrete

Any of the following shall be permitted to be used as part replacement of
Ordinary Portland Cement with the approval from Engineer.
• Microsilica / silica fume/ALCOFINE 1203
• Ground Granulated Blast Furnace Slag (GGBS)
However the cement content excluding any mineral admixtures shall not
exceed 450kg / cum except with the prior approval from Engineer or as limit
defined in IS 456 or other relevant code.
The water / (cement + binder) ratio should generally not exceed 0.33, but in
no case more than 0.40.
Minimum cement content in Precast Tunnel segment shall be 420 kg / cum of

concrete.
To combat the ASR, Micro silica shall be used in precast Tunnel segments
and other elements like OTE duct. Also Micro silica shall be used in in-situ
concrete for NATM and Cross passage tunnels. Micro silica shall be
minimum 5% cement and shall not exceed 10% by the wt of cement in order
to bind free alkalis early in plastic concrete and to reduce the permeability of
concrete to prevent the moisture and external alkalis penetration.
In order that the performance of the completed structure be consistent with the
requirements and assumptions made during planning and design, stringent
quality assurance measures shall be taken. The methods and procedures of
Quality System shall follow the guidelines contained in IRC:SP:47 - 1998. Q-
4 class of Quality Assurance shall be adopted for the ‘Materials’ and
‘Workmanship’ items.
The temperature of concrete at the time of placement shall not exceed 30 C.
The temperature of concrete at the mixing stage should be lower, to allow for
rise in temperature during transport. When considerable distance of transport
is involved, particular attention should be paid to ensure retention of slump as
targeted for placement.
Use of Microsilica / silica fume/ ALCCOFINE 1203 or equivalent
(a) Mineral admixture as mentioned above shall be permitted in the design

mix. It shall comply with ASTM C 1240 “Specifications for Silica Fume
for use in Hydraulic Cement Concrete and Mortar”. It shall be obtained
from proven, reliable and approved manufacturer/supplier to the
satisfaction of the Engineer.
(b) Adequate and complete dispersal of the mineral admixture during the

concrete mixing shall be ensured.
(c) When the mineral admixture is used in powder form the contractor shall
take all precautions against potential health hazards during handling of
the material.
(d) Chilled water and / or ice shall be used in the concrete mix depending on
the ambient temperature, dimensions of the concrete element, rate of
pouring and design mix constituents.
(e) Special profuse curing arrangements shall be made for dissipation of the
heat of hydration. The water curing shall be continued for a period of 14
days.
(f) The concrete design mix and arrangement for mixing, transportation, and
curing of concrete shall be subject to the approval of the Engineer.
Use of Ground Granulated Blast Furnace Slag (GGBS)
GGBS Conforming to IS : 12089 – 1987 (Reaffirmed 1999) will be used.
1.5.3.11 READY MIX CONCRETE AND PUMPING:
1.5.3.11.1 Ready-mixed concrete may be manufactured in a central automatic

weigh Batching plant and transported to the place of work in agitating
transit mixers.
The maximum size of coarse aggregate shall be limited to one-third
of the smallest inside diameter of the hose or pipe used for pumping.
Provision shall be made for elimination of over-sized particles by
screening or by careful selection of aggregates. To obtain proper
gradation it may be necessary to combine and blend certain fractional
sizes of aggregates. Uniformity of gradation throughout the entire job
shall be maintained.
The quantity of coarse aggregate shall be such that the concrete can be
pumped, compacted and finished without difficulty.
1.5.3.11.2. Fine aggregates:

The gradation of fine aggregate shall be such that 15 to 30 percent
should pass the 0.30 mm screen and 5 to 10 percent should pass 0.15
mm screen so as to obtain pumpable concrete. Sands, which are
deficient in either of these two sizes, should be blended with selected
finer sands to produce these desired percentages. With this gradation,
sands having a fineness modulus between 2.4 and 2.8 are generally
satisfactory. However, for uniformity, the fineness modulus of the sand
should not vary more than 0.2 from the average value used in
proportioning. Any presence of silt content to be removed from fine
aggregates as per relevant IS codes.

1.5.3.11.3 Water, Admixtures and Slump:

The amount of water required for proper concrete consistency shall take
into account the rate of mixing, length of haul, time of unloading, and
ambient temperature conditions.
Additions of water to compensate for slump loss should not be resorted

to nor should the design maximum water-cement ratio be exceeded.
Additional dose of retarder be used to compensate the loss of slump at
contractor’s cost, when permitted by Engineer. Retempering water shall
not be allowed to be added to mixed batches to obtain desired slump.
1.5.3.11.4 Transportation:
The method of transportation used should efficiently deliver the concrete
to the point of placement without significantly altering its desired
properties with regard to water-cement ratio, slump, and homogeneity.
The revolving-drum truck bodies of approved make shall be used for
transporting the concrete. The numbers of revolutions at mixing speed,
during transportation, and prior to discharge shall be specified and
agreed upon. Reliable counters shall be used on revolving-drum truck
units. Standard mixer uniformity tests, conforming to ASTM standards
C 94-69 “Standard Specifications for Ready Mix Concrete”, shall be
carried out to determine whether mixing is being accomplished
satisfactorily.
1.5.3.11.5 Pumping of concrete:

Only approved pumping equipment, in good working condition, shall be
used for pumping of concrete. Concrete shall be pumped through a
combination of rigid pipe and heavy-duty flexible hose of approved
size and make. The couplings used to connect both rigid and flexible
pipe sections shall be adequate in strength to withstand handling loads
during erection of pipe system, misalignment, and poor support along
the lines. They should be nominally rated for at least 3.5 MPa pressure
and greater for rising runs over 30 m. Couplings should be designed to
allow replacement of any section without moving other pipe sections,
and should provide full cross section with no construction or crevices to
disrupt the smooth flow of concrete.
All necessary accessories such as curved sections of rigid pipe, swivel

joints and rotary distributors, pin and gate valves to prevent backflow in
the pipe line, switch valves to direct the flow into another pipe line,
connection devices to fill forms from the bottom up, extra strong
couplings for vertical runs, transitions for connecting different sizes of
pipe, air vents for downhill pumping, clean-out equipment etc, shall be
provided as and where required. Suitable power controlled booms or
specialized crane shall be used for supporting the pipe line.

1.5.3.11.6 Field control:

Sampling at both truck discharge and point of final placement shall
be employed to determine if any changes in the slump and other
significant mix characteristics occur. However, for determining strength
of concrete, cubes shall be taken from the placement end of line.
1.5.3.11.7 Planning:
Proper planning of concrete supply, pump locations, line layout, placing
sequence, and the entire pumping operation shall be made and got
approved. The pump should be as near the placing area as practicable,
and the entire surrounding area shall have adequate bearing strength to
support concrete delivery pipes. Lines from pump to the placing area
should be laid out with a minimum of bends. For large placing
areas, alternate lines should be installed for rapid connection when
required. Standby power and pumping equipment should be provided to
replace initial equipment, should breakdown occur. The placing rate
should be estimated so that concrete can be ordered at an appropriate
delivery rate.
As a final check, the pump should be started and operated without
concrete to be certain that all moving parts are operating properly. A
grout mortar should be pumped into the lines to provide lubrication for
the concrete, but this mortar shall not be used in the placement. When
the form is nearly full, and there is enough concrete in the line to
complete the placement the pump shall be stopped and a go-devil
inserted and shall be forced through the line by water under pressure to
clean it out. The go-devil should be stopped at a safe distance from the
end of the line so that the water in the line will not spill into the
placement area. At the end of placing operation, the line shall be
cleaned in the reverse direction.
1.5.3.11.7 ADDITIONAL SPECIFICATIONS FOR CONCRETEM60

(a) Mineral admixture in the form of micro silica or condensed silica fume shall
be permitted in the design mix as specified in the IRS:CBC. It shall comply
with ASTMC 1240 “Specifications for Silica Fume for use in Hydraulic
Cement Concrete and Mortar”. It shall be obtained from proven and reliable
manufacturer/supplier to the satisfaction of the Engineer.
(b) Adequate and complete dispersal of the micro silica during the concrete
mixing shall be ensured.
(c) When micro silica is used in powder form the contractors hall take all
precautions against potential health hazards during handling of the material.
(d) Chilled water and/orice shall be used in the concrete mix depending on the
ambient temperature, dimensions of the concrete element, rate of pouring and
design mix constituents.
(e) Special profuse curing arrangements shall be made for dissipation of the heat
of hydration. The water curing shall be continued for a period of 21days.
(f) The concrete design mix and arrangement for mixing, transportation, and
curing of concrete shall be subject to the approval of the Engineer.

1.6 Formwork
1.6.1 General
These specifications shall be read in conjunction with the MORTH
specifications and CPWD/Gujarat PWD specifications with correction
slips/amendments up to date, and other relevant specifications described in
the Contract.
1.6.2 Materials
Formwork shall be of timber, plywood (including marine plywood), steel or
any other suitable material capable of resisting damage to the contact faces
under normal conditions of erecting forms, fixing steel and placing concrete.
The selection of materials suitable for formwork shall be made by the
Contractor based on the quality consistent with the specified finishes and
safety. The entire responsibility of planning, designing, erecting, dismantling,
shifting and safety of false work lies with the Contractor. All formwork and
formwork supports (centering, props, scaffolds, ladders etc.) shall be in
structural steel only and preferably of pipes conforming to IS:806, IS:1161,
IS:1239, IS:2750. Wooden ballies shall not be permitted as props/formwork
supports. All props shall be properly braced using x & k bracings. Ladders to
be used at site should have treads and shall be fabricated from structural
steel. Wooden/ bamboo/aluminum/pipe ladders shall not be permitted.
1.6.2.1 Timber
Timber used for formwork shall be easily workable with nails without
splitting. It shall be stable and not liable to warp when exposed to sun and
rain or wetted during concreting.
1.6.2.2 Plywood
Plywood used for formwork shall be minimum 12mm thick. Shuttering
quality plywood complying with IS:4990. Suitable stiffeners and walers shall
be provided depending on the shuttering design.
1.6.2.3 Steel
Steel formwork shall be made of minimum 4mm thick black sheets
stiffened with angle iron frame made out of M.S. angles 40mm x 6 mm
supported at suitable spacing.
1.6.3 Design & Drawings

(1) The permissible stresses in materials in all Temporary Works such as
formwork, falsework, staging, launching and the like shall be the
same as for the Permanent Works. The Contractor’s checked and
verified calculations and drawings of the same including construction
sequence (along with soft copy in CD ROM) shall be submitted to the
Engineer for Notice of No Objection.
(2) All constructed Temporary Works shall be also inspected by the
Contractor’s Design Checker and an inspection report shall be
submitted to Engineer. All Temporary Works shall be robust, safe and
constructed in such a way that the concrete can be properly placed
and thoroughly compacted to obtain the required shape, position and

level subject to specified tolerances. It is the responsibility of the

Contractor to obtain the results required by the Engineer, whether or
not some of the Work is sub-contracted. Agreement of the temporary
works by the Engineer shall not diminish the Contractor's responsibility
for the satisfactory performance of the same, nor for the safety and co-
ordination of all operations.
(3) The design of false work should be such as to facilitate easy and safe
access to all parts for proper inspection.
(4) Methodology for removal of form should be planned as a part of total
formwork design process.
(5) In case of pre-stressed concrete work, careful consideration shall be
given to re- distribution of loads due to pre-stressing.
1.6.4 Formwork for Exposed Concrete Surfaces

The facing formwork, unless indicated otherwise in drawings, shall
generally be made with materials not less than the thickness mentioned
below for different elements of the structure:
1. Plain slab soffit, and sides of beams, joists and ribs and side of walls,
parapets, etc shall be made with:
a. Steel plates not less than 4mm thick of specified sizes stiffened
with a suitable structural framework and fabricated true to plane
b. Timber planks of 20mm actual thickness and of specified surface
finish, width and reasonable length,
c. Plywood not less than 12mm thick (IS:4990 - Specification
for Plywood for Concrete Shuttering Work) stiffened with a
suitable timber frame work or 3mm thick plywood with a 20mm
timber plank backing, of specified sizes stiffened with a suitable
timber framework and bracing. At joints 6mm/10mm sponge to
be provided.
2. Bottoms of beams, sides of columns shall be formed using the following
materials.
a. Steel plates not less than 5mm thick of specified sizes
stiffened with a suitable structural framework, and fabricated true
to plane.
b. Timber planks of 35mm actual thickness and of specified surface
finish, width and reasonable length.
c. Plywood not less than 12mm thick (IS:4990), of specified sizes
stiffened with a suitable timber framework.
3. For precast segments, portals, tunnel connections and the like, suitable
steel formwork shall be used.
1.6.5 Formwork for Sloped Surfaces

1 Forms for sloped surfaces shall be built so that the formwork can
be placed board-by-board immediately ahead of concrete placement so
as to enable ready access for placement, vibration, inspection and
finishing of the concrete.
2 The formwork shall be built in such a way so that the boards can be
removed one by one from the bottom up as soon as the concrete
has attained sufficient stiffness to prevent sagging. Surfaces of

construction joints and finished surfaces with slopes steeper than 2

horizontal:1 vertical shall be formed as required herein.
1.6.6 Formwork for Curved Surfaces

1 The Contractor shall interpolate intermediate sections as necessary and
shall construct the forms so that the curvature will be continuous
between sections. Where necessary to meet requirements for curvature,
the form lumber shall be built up of laminated splices cut to make tight,
smooth form surfaces.
2 After the forms have been constructed, all surface imperfections
shall be corrected and all surface irregularities at matching faces of
form material shall be dressed to the specified curvature.
1.6.7 Erection of Formwork

The following shall apply to all formwork:
1 Before fabricating the forms the Contractor shall submit for seeking
Engineer’s Notice of No Objection, the design of forms and the types of
material to be used. (Ref. ACI 347 Formwork for Concrete or
equivalent I.S. Code).
2 All shuttering planks and plates shall be adequately backed by a
sufficient number and size of walers or framework to ensure rigidity
during concreting. All shutters shall be adequately strutted, braced and
propped to prevent deflection under deadweight of concrete and
superimposed live load of workmen, materials and plant, and to
withstand pouring rate and vibration.
3 Vertical props shall be supported on wedges or other measures shall be
taken so that the props can be gently lowered vertically during removal
of the formwork. Props for an upper level shall be placed directly over
those in the level immediately below, and the lowest props shall bear on
a sufficiently strong area. Care shall be taken that all formwork is set
plumb and true to line and level or camber or batter where required.
4 Provision shall be made for adjustment of supporting struts where
necessary.
When reinforcement passes through the formwork care shall be taken
to ensure close fitting joints against the steel bars so as to avoid loss
of fines during the compaction of concrete.
5 If the formwork is held together by bolts, these shall be so fixed that
no iron will be exposed on surfaces against which concrete is to be laid
and within the concrete cover to the steel reinforcement. In any case
wires shall not be used with exposed concrete formwork. If the
Contractor elects to use tie-bolts running through the concrete then the
Contractor shall define the location and size of such tie-bolts and
submit his proposals for Notice of No Objection from the Engineer. The
tie-bolts shall be so designed that their removal on de-shuttering does
not leave any embedment within the concrete cover to steel
reinforcement. Holes left in the concrete by these tie-bolts shall be filled
by the concrete repair material and the methodology set out in the
Contractor’s noticed proposal.
6 Provision shall be made in the shuttering for beams, columns, and
walls for a port hole of convenient size so that all extraneous

materials that may be collected could be removed just prior to

concreting.
7 Formwork shall be so arranged as to permit removal of forms without
jarring the concrete. Wedges, clamps and bolts shall be used wherever
practicable instead of nails.
8 The formwork for beams and slabs shall be so erected that forms on the
sides of the beams and the soffit of slabs can be removed without
disturbing the beam bottoms or props under beams.
9 Surfaces of forms in contact with concrete shall be oiled with a
mould oil of noticed quality form releasing agent. The use of mould oil
which results in blemishes of the surface of the concrete including
diesel, burnt oil and any other lubricating oil shall not be allowed.
Mould oil shall be applied before reinforcement has been placed and
care shall be taken that no oil comes in contact with the reinforcement
while it is being placed in position. The formwork shall be kept
thoroughly wet during concreting and the whole time that is left in
place.
10 Immediately before concreting is commenced, the formwork and other
related arrangements shall be carefully examined to ensure the
following.
a. Removal of all dirt, shavings, sawdust and other refuse by
brushing, washing and compressed air/vacuum cleaning.
b. The tightness of joints between panels of sheathing and between
these and any hardened core.
c. The correct location of tie bars, bracing and spacers, and
especially connections of bracing.
d. Adequate cover blocks are in place
e. Straightness and plumbness of the form work
f. Side supports/restraints for the form work are enough and robust.
g. Construction joint (wherever applicable) is properly prepared.
h. That all wedges are secured and firm in position.
i. That provision is made for traffic on formwork not to bear
directly on reinforcing steel.
j. Pouring platform along with its approach from ground is robust
and safe for workers movement.
k. Arrangement for vibrators for compaction of concrete
l. Sequence of concrete pouring is well defined and is agreed
upon by the Engineer and is explained to concrete pouring team
m. The Pouring area is well lit.
n. Curing arrangements are well planned and agreed upon by the
Engineer.
o. The concrete protection measures in accordance with this
Specification are in place.
11 The Contractor shall ensure dimensional accuracies of the Work and for
the general arrangement of propping and bracing. (IS:3696 - Safety
Code of Scaffolds and Ladders, IS:4014 Steel Tubular Scaffolding I &
II). All scaffolding and staging shall be either of steel tubes or built up
section of rolled steel with adequate bracing at several levels in each
perpendicular direction connecting each prop. In addition to this
diagonal bracing should be provided in elevation ideally at 45

degrees or between 30 degrees and 60 degrees. The Contractor shall

be entirely responsible for the adequacy of propping, and for keeping
the wedges and other locking arrangements undisturbed through the de-
centering period. (IS:8989 Safety code for erection of concrete framed
structures)
12 Formwork shall be continuously watched during the process of
concreting. If during concreting any weakness develops and formwork
shows any distress the Work shall be stopped and remedial action shall
be taken.
1.6.8 Concrete Finishes

This section deals with the surface of concrete on which forms had been
fixed while concreting.
1.6.8.1 Formed Surface

(1) Allowable deviation from plumb or level and from the alignment
profile, grades and dimensions shown on the drawings is defined as
"tolerance" and is to be distinguished from irregularities in finishes as
described herein. Tolerances in concrete construction are specified
elsewhere.
(2) The classes of finish and requirements for finishing of concrete surface
shall be as shown on the drawings or as hereinafter specified.
(3) Completed concrete surface shall be tested, where necessary to
determine whether surface irregularities are within the limits specified
hereinafter.
(4) Surface irregularities are classified as "Abrupt" or "Gradual". Offsets
caused by displaced or misplaced form sheathing, or form sections or
by loose knots or otherwise defective timber form will be considered as
abrupt irregularities, and shall be tested by direct measurements. All
other irregularities shall be considered as gradual irregularities and will
be tested by use of template, consisting of a straight edge or the
equivalent thereof for curved surfaces. The length of the template shall
be 150 cm for testing of formed surfaces and 300 cm for testing of
unformed surfaces.
(5) The classes of finish for formed concrete surfaces are designated by
one of the symbols F1, F2, F3 and F4. Unless otherwise specified or
indicated on drawings, these classes of finish shall apply as follows:
(a) Finish F1 : This finish applies to surfaces where roughness is not
objectionable, or surface that will otherwise be permanently
concealed. Surface treatment shall be the repair of defective
concrete, correction of surface depressions deeper than 25 mm and
filling of tie rod holes. Form sheathing will not leak mortar when
concrete is vibrated. Forms may be manufactured with a minimum
of refinement.
(b) Finish F2 : This finish is required on surfaces permanently
but not prominently exposed to public view for which
other finishes are not specified except F1. Forms shall be
manufactured in a workmanlike manner to the required offsets
or bulges. Surface irregularities shall not exceed 5mm for
abrupt and 8mm for gradual irregularities measured with a 1.5 m

template.
(c) Finish F3 : This finish is required for coarse textured concrete
surfaces Intended to receive plaster, stucco or wainscoting.
Surface irregularities shall not exceed 5mm for both abrupt and
gradual irregularities.
(d) Finish F4 : This finish is designated for surfaces prominently
exposed to public view where appearance is also of special
importance.. To meet with requirements for F4 finish, forms shall
be manufactured in a skilful, workmanlike manner, accurately to
dimensions. There should be no visible offsets, bulges or
misalignment of concrete. At construction joints, the forms shall
be rightly set and securely anchored close to the joint. Abrupt and
gradual irregularities shall not exceed 3mm. Irregularities
exceeding this limit shall be reduced by grinding to a level of 1:20
ratio of height to length. Jute bag subbing or sand blasting shall
not be used.
1.6.8.2 Unformed Surfaces

(1) The classes of finish for unformed surfaces are designated by symbols
U1, U2, U3 and U4. Unless otherwise specified or indicated on
drawings, these classes of finish shall apply as follows:
(a) Finish U1: This finish applies to unformed surfaces that will be
concealed permanently or otherwise where a screeded surface finish
meets the functional requirements. Finish U1 is also used as the stage of
finishes for U2 and U3. Finishing operations shall consist of sufficient
leveling and screeding to produce an even uniform surface. Surface
irregularities shall not exceed 10mm.
(b) Finish U2 : This is floated finish, and used on all outdoor,
unformed surfaces. Finish U2 is also used as the second stage of finish
for U3. Floating to be performed manually or mechanically on stiffened
screed surface shall be minimum to produce textured surface. If finish
U3 is to be applied, floating shall be continued till a small amount of
mortar without excess water is brought to the surfaces so as to permit
effective trowelling. Surface irregularities shall be removed.
(c) Finish U3 : This is a trowelled finish and shall be used for tops of
parapets, etc prominently exposed to view. When the floated surface
has hardened sufficiently, steel trowelling shall be started. Steel
trowelling on hardened, floated surface shall be performed with firm
pressure to produce a dense uniform surface free from blemishes and
trowel marks and having slightly glossy appearance. Surface
irregularities shall not exceed 5mm.
(d) Finish U4 : This is a steel-trowelled finish, similar to finish U3,
except that light surface pitting and light trowel marks such as obtained
from the use of machine trowelling will be acceptable, provided that
surface irregularities do not exceed the limits specified for finish U3.
(2) Unformed surfaces which are nominally level shall be sloped for
drainage as shown on drawings unless the use of other slopes or level
surface is indicated on drawings. Narrow surface such as tops of
parapets, walls and kerbs shall be sloped approximately 10mm per
300mm of width. Broader surface such as roadways platform shall be

sloped approximately 5mm per 300mm of width. Finishes of floor and

roof slabs shall be sloped Exposed Concrete Work.
(3) Exposed concrete surfaces shall be smooth and even, originally as
stripped without any finishing or rendering. The surface shall
be rubbed with carborundum stone immediately on striking the
forms. The Contractor shall exercise special care and supervision of
formwork and concreting to ensure that the cast members are made true
to their sizes, shapes and positions and to produce the surface patterns
desired. No honeycombing shall be allowed. Honeycombed parts of the
concrete including the other surface defects in the concrete shall be
removed by the Contractor as per the methods, which do not affect the
strength of adjoining concrete.
(4) Part of defective concrete thus removed shall be re-cast using fresh
concrete of same grade or noticed quality concrete repair material
depending upon the size, location, thickness of the defective concrete
and structural behavior of the member having defective concrete.
Contractor shall ensure that no air bubbles are formed on the exposed
surface. Concrete pouring sequence, vibration methodology etc shall be
planned to avoid air bubbles.
1.6.9 Age of Concrete at Removal of Formwork

In accordance with CPWD/Gujrat PWD Specifications or IS:456.
Immediately after the forms are removed, they shall be cleaned with a jet
of water and a soft brush.
1.6.10 Stripping of Formwork

The work of formwork removal should be planned and a definite scheme of
operation worked out. Formwork shall be removed carefully without jarring
the concrete, and curing of the concrete shall be commenced immediately.
Concrete surfaces to be exposed shall be rubbed down with carborundum
stone or bush-hammer to obtain a smooth and even finish. Where the
concrete requires plastering or other finish later the concrete surface shall be
immediately hacked lightly all over using noticed methods.
1.6.11 Reuse of Forms

The Contractor shall not be permitted reuse of timber facing formwork
brought new on the works for more than 5 times for exposed concrete
formwork and 8 times for ordinary formwork. 5 or 8 uses shall be permitted
only if forms are properly cared for, stored and repaired after each use. Use of
different quality boards or the use of old and new boards in the same
formwork shall not be allowed. If any other type of special or proprietary
form work is used, the number of times they can be used shall be given a
Notice of No Objection from the Engineer.
1.6.12 Formwork for Precast / Pre-stressed Concrete

(1) The provisions in this section shall be considered supplementary to the
general provisions stated above and additional Technical Specifications
for pre-cast segments. Pre-cast concrete members and panels shall be
made in accurately constructed moulds, on a properly prepared casting

bed. The Contractor shall submit detailed drawings of formwork to

the Engineer for Notice of No Objection. Finishing with cement mortar
shall not be allowed.
(2) The formwork should be so designed that it does not restrain the
shrinkage movements and possible shortening due to pre-stress of the
concrete. The formwork shall be of sturdy construction with special
considerations to shutter vibrators when used. All edges and joints of
the formwork should be designed and sealed so that no cement grout
can escape and there is no wedging or keying to the concrete. The
effect of curing on the formwork should be given special
consideration. Depending on care, curing, erection and maintenance of
the formwork after stripping, the number of uses that can be made with
different types of formwork shall be such that the quality of structural
element is maintained to the required standards.
(3) Stripping
As soon as the pre-cast units have attained sufficient strength, the
formwork shall be stripped. The pre-cast unit shall be lifted uniformly
out of the formwork without being subjected to tilting or restraint
effects.
1.6.13 Special Architectural Finishes

Special noticed architectural finishes like grooves, logos,
engravings/projections in inset and out set as per the noticed design shall be
provided by fixing monolithic rubber forms or any other noticed material
fixed on the entire surface of the formwork. The shore hardness of the
rubber shall be appropriate to ensure strength, flexibility and elasticity. The
rubber shall be cold-cured (preferably polyurethane based) and fixed to the
formwork under controlled conditions in shade and air temperature not
exceeding 28oC. The form liners shall be shrinkage free, solvent free and
shall be impervious to abrasion by Concrete, resistant to concrete pressure
and heat resistant up to 70oC dry heat. Formwork liner fixation shall be
factory made under close tolerances and stage inspections. If proprietary
system of formwork is used, detailed information as given in Appendix A
herein shall be furnished to Engineer for Notice of No Objection before use.
Appendix A
Information to be supplied by Manufacturers of Proprietary Systems of form Work
1. General
1.1 The information which the manufacturer is required to supply shall be in
such detail as to obviate unsafe erection and use of equipment due to the
intention of the manufacturer not having been made clear or due to wrong
assumptions on the part of the user.
1.2 The user shall refer unusual problems of erection/assembly not in
keeping with intended use of equipment, to the manufacturer of the
equipment.
2. Information Required
2.1 The manufacturers of proprietary systems shall supply the following

information;
a. Description of basic functions of equipment.
b. List of items of equipment available, giving range of sizes, spans and
such like, with manufacturer’s identification number or other
references.
c. The basis on which safe working loads have been determined and
whether the factor of safety given applies to collapse or yield.
d. Whether the supplier’s data are based on calculations or tests. This
shall be clearly stated as there may be wide variations between results
obtained by either method.
e. Instructions for use and maintenance, including any points which
require special attention during erection, especially where safety is
concerned.
f. Detailed dimensional information, as follows :
i. Overall dimensions, depths and widths of members.
ii. Line drawings including perspectives and photographs showing
normal uses.
iii. S e l f -weight.
iv. Full dimensions of connections and any special positioning and
supporting arrangements.
v. Sizes of members, including tube diameters and thicknesses of
material.
vi. Any permanent camber built into the equipment.
vii. Sizes of holes and dimensions giving their positions.
viii. Manner of fixing including arrangements for sealing joints.
ix. Method of de-stripping, storing & shifting.
g. Data relating to strength of equipment as follows:
i. Average failure loads as determined by tests.
ii. Recommended maximum working loads for various conditions of
use.
iii. Working resistance moments derived from tests.
iv. Working shear capacities derived from tests.
v. Recommended factors of safety used in assessing recommended
loads and deflections based on test results.
vi. Deflections under load together with recommended pre-camber
and limiting deflections.
vii. If working loads depend on calculations, working stresses should
be tested. If deflections depend on theoretical moments of inertia
or equivalent moments of inertia rather than tests, this should be
noted.
viii. Information on the design of sway bracing against wind and
other horizontal loadings.
ix. Allowable loading relating maximum extension of bases and/or
heads.
xi. Any restrictions regarding usage of any component or full
assembly with regard to spans, heights and loading conditions.

1.7 Prestressed Members
Structural concrete containing prestressed steel reinforcement to introduce pre-

compression is termed as prestressed concrete.
1.7.1 General
The prestressed concrete work shall generally conform to IS:1343 “Code of Practice
for Prestressed Concrete” and Section 1800 of MOST Specifications. The Concrete,
Formwork and Non- tensioned reinforcement shall conform to relevant clauses in
Section 3, 4, and 5 of this specification. The work shall be carried out in accordance
with the drawing and these specifications or as approved by the Engineer.
The pre-stressing steel shall be un-coated stress relieved low relaxation seven-ply
strand conforming to IS: 14268. All pre-stressing steel shall be free from splits,
harmful scratches, surface flaws, piping and other surface defects likely to impair its
use in pre-stressed concrete. The pre-stressing steel shall be stored in a manner such
that they do no come in contact with dirt, water, greasy and other harmful materials.
The contractor shall furnish the test certificate for each bundle of strands bought if
required by the Engineer, he shall get tested at his cost samples of strands in
specified bundles in an approved laboratory.
The land for setting up casting yard /Construction Depot as required shall be
arranged by the contractor at his own cost.
The precast pre-tensioned elements shall be cast by the Contractor in the pre-casting
yard. After 28 days of casting, the girders shall be transported to site and erected at
appropriate position by the Contractor. The Tenderers are advised to visit the station
sites as well as site of proposed pre-casting yard and assess the physical condition of
the route for transportation of the elements. The Department shall allocate the
premises of pre-casting yard for a specific period to the successful bidder on “as is
where is” basis.
Concrete and un tensioned steel for the construction of prestressed concrete members
shall conform to the requirements of sections respectively in so far as the
requirements of these Sections apply and are not specifically modified by
requirements set forth herein.
Contractor shall ensure that different components of prestressing such as jacks,

bearing plates, wedges, anchorages, strands and HDPE ducts are compatible to one
another and the same shall be exchanged in between all the suppliers to ensure the
same.
1.7.2 Pre-stressing Tendons

1.7.2.1 Materials
(1) Steel Wire
Steel wire shall comply with BS 5896.
(2) Cold worked high tensile alloy bar
Cold worked high tensile alloy steel bars for prestressing shall
comply with the requirements of BS 4486.
(3) Stress-relieved seven-wire strand Stress relieved seven-wire strand
shall comply with the requirements in TIS 420, Grade 1860, nominal

diameter 12.7 millimeters or 15.2 millimeters, or have properties that

are not inferior. The characteristic breaking load shall not be less than
that specified by the Contractor.
Sheathing:
The joints of all sheathings shall be water-tight. Special attention shall be
paid to the junction at the anchorage end, where the sheathing must
tightly fit on the protruding trumpet end of anchorage and thereafter
sealed preferably with adhesive water proof tape as per approved
manufacturer.
The sheathing and all joints shall be water-tight. Any temporary opening
in the sheathing shall be satisfactorily plugged and all joints between
sheathing and any other part of the prestressing system shall be
effectively sealed to prevent entry of mortar, dust, water or other
deleterious matter. Sheathing shall be neatly fitted at joints without
internal projection or reduction of diameter.
Enlarged portions of the sheathing at couplings or anchorages shall be of
sufficient length to provide for the extension of the tendons.
All pre stressing sheathing ducts shall be in the form of corrugated
HDPE ducts conforming to IRS Concrete Bridge Code and relevant
codes.
Grout Vents
Grout vents of at least 20 mm diameter shall be provided at both ends of
the sheathing and at all valleys and crests along its length. Additional
vents with plugs shall also be provided along the length of sheathing
such that the spacing of consecutive vents do not exceed 20m. Each of
the grout vents shall be provided with a plug or similar device capable of
withstanding a pressure of 1.0 MPa without the loss of water, air
pressure or grout.
Anchorages:
Anchorages shall be procured from authorised manufacturers only.
Anchorages shall conform to BS:4447.
(4) Sampling and Testing
a) When it is proposed to use super strand complying with BS 5896
Table 6 or other than the lowest strength 3,4,5,6 or 7 mm diameter
wire complying with BS 5896 Tables 4 or 5 the following shall
apply:
(i) A sample shall be taken from each reel of material proposed for
use in the Works
(ii) A reel shall only be accepted if both the breaking load and the
0.1% proof load of the sample exceeds the specified characteristic
loads given in Tables 4 or 6 of B5 5896. In the case of Table 5
this requirement shall apply to the breaking load and the load at
1% elongation.
(iii) These requirements shall be additional to any other requirements
of the Contract.
c) The Contractor shall arrange for samples of the steel intended for
use in the Works to be tested at a noticed laboratory.
a. All materials specified for testing shall be furnished free of
cost and shall be delivered in time for tests to be made well in
advance of anticipated time of use.

b. All strand to be transported to the site shall be assigned a lot

number and tagged for identification purposes. Anchorage
assemblies to be transported shall be like-wise identified.
c. All samples submitted shall be representative of the lot to be
furnished and in the case of strand, shall be taken from the
same master roll. The Contractor shall furnish samples of at
least 5.0m length selected from each lot for testing. Also, two
anchorage assemblies, complete with distribution plates of
each size or type to be used, shall be furnished along with
short lengths of strands as required.
d. All equipment must be used in accordance with the
specification of the manufacturer and must at all times be
maintained in good condition.
e. The type of jack used should correspond with the type of
strand used. It must also be checked that the jacks have the
necessary stroke for the stressing of the strands/wires on the
particular job. Pressure tests on jacks must be executed with
pressures 10% higher than the maximum operating pressure.
The combined jack and pump system should be checked for
correct behavior.
1.7.2.2 Handling and Storage

(1) Care shall be taken to avoid mechanically damaging, work-hardening or
heating pre-stressing tendons while handling. All pre-stressing
tendons shall be stored clear of the ground and protected from the
weather, from splashes from any other materials, and from splashes
from the cutting operation of an oxy-acetylene torch, or arc-welding
processes in the vicinity.
(2) In no circumstances shall pre-stressing tendons after manufacture be
subjected to any welding operation, or 'on-site' heat treatment or
metallic coating such as galvanising. This does not preclude cutting as
specified in this Contract.
(3) All wires, strands or bars stressed in one operation shall be taken,
where possible, from the same parcel. Each cable shall be tagged with
its number from which the coil numbers of the steel used can be
identified. Cables shall not be kinked or twisted. Individual wires
and strands for which extensions are to be measured shall be readily
identifiable at each end of the member. No strand that has become
unraveled shall be used.
1.7.2.3 Surface Condition

Pre-stressing tendons anchorages, blocking devices and internal and external
surfaces of ducts shall be clean and free from pitting, loose rust, loose scale and
chloride contamination at the time of incorporation in the Work. If any
surface cleaning is required it shall not heat, damage or polish the surface, or coat
it with oil, grease or any other material.
1.7.2.4 Straightness
(1) Pre stressing Wire

Unless otherwise agreed with the Engineer, low relaxation and normal
relaxation wire shall be in coils of sufficiently large diameter to ensure that
wire pays off straight.
(2) Strand
Pre-stressing strand, however manufactured, shall be in coils of sufficiently
large diameter to ensure that the strand pays off reasonably straight.
(3) Bars
Pre-stressing bars as delivered shall be straight. Bars bent in the threaded
portion shall be rejected. Any straightening of bars shall be carried out
cold but at a temperature of not less than 5oC. Any necessary heating shall
be by means of steam or hot water.
(4) Reinforcement mesh or wire
Mesh or wire shall be delivered in sheets or coils. Any straightening
shall be carried out cold but at a temperature of not less than 5oC. Any
necessary heating shall be by means of steam or hot water.
(5) Cutting
All cutting of wire, strand or bar shall be carried out using either:
a) A high-speed abrasive cutting wheel, friction saw at not less than
one diameter from the anchor or any other mechanical method noticed
by the Engineer, or
b) An oxy-acetylene cutting flame, using excess oxygen to ensure a
cutting rather than a melting action not less than 75 millimeters
from the anchor whilst the temperature of the tendon adjacent to
the anchor shall not be greater than 200oC. Care shall be taken that
neither the flame nor splashes come into contact with either the
anchorage or other tendons or reinforcement.
1.7.3 Pre-cast / Prestressed Construction

Care shall be exercised in the set-up of each member. All materials to be
encased within the concrete of the member shall be properly positioned and
supported. Provisions for all projections, recesses, notches, openings,
blackouts and the like shall be made in accordance with the Drawings.
1.7.3.1 Stressing Tendons

1.7.3.1.1 General
(1) It shall be the obligation of the Contractor to provide a technician
skilled in pre- stressing systems to supervise or provide appropriate
surveillance of the Work and give the Engineer such pertinent
information as he may require for inspecting the Work. Such a
representative shall be available full-time on all days during which
the stressing and grouting of tendons is in progress.
(2) All post-tensioning steel shall be tensioned by means of hydraulic
jacks so that the force of the pre-stressing steel shall not be less than
the value shown on the noticed working drawings. The maximum
temporary tensile stress (stressing stress) in pre-stressing steel shall not
exceed 80% of the specified minimum ultimate tensile strength of the
pre-stressing steel.

1.7.3.1.2 Tensioning Apparatus

The tensioning apparatus shall meet the following general requirements:-
a) The means of attachment of the tendon to the jack or tensioning
device shall be safe and secure.
b) Where two or more wires or strands are stressed simultaneously, they
shall be approximately of equal length between anchorage points at
the datum of load and extension measurement. The degree of
variation shall be small compared with the expected extension.
c) The tensioning apparatus shall be such that a controlled total force is
imposed gradually and not dangerous secondary stresses are induced in
the tendons, anchorage or concrete.
d) The force in the tendons during tensioning shall be measured by
direct-reading load cells or obtained indirectly from gauges fitted in the
hydraulic system to determine the pressure in the jacks. Facilities shall
be provided for the measurement of the extension of the tendon and of
any movement of the tendon in the gripping devices. The load-
measuring device shall be calibrated to accuracy within ± 2% and
checked at intervals. Elongation of the tendon shall be measured to
accuracy within 2% or ±2 millimeters, whichever is the more accurate.
e) The tensioning equipment shall be calibrated before the tensioning
operation and at intervals of months or as noticed by the Engineer.
f) Any indication in the loss of strength in tendons during the tensioning
operation shall be brought to the attention of the Engineer. Any
corrective measures which may be required in procedures and/or
material shall be subjected to the Notice of No Objection from the
Engineer.
g) When friction must be reduced, water-soluble oil may be used to the
Notice of No Objection from the Engineer. This oil may be flushed
from the duct as soon as possible after stressing is completed by use of
water pressure. These ducts shall be flushed again just prior to the
grouting operations. Each time the ducts are flushed, they shall be
immediately blown dry with oil-free air.
h) Loss in strength of tendons may occur from wedge pull-in, bond
failure tendon slippage or concrete elastic shortening, and these shall
be separately identified by methods agreed with the Engineer.
Immediate loss in strength must also be identified from relaxation loss
for the purposes of design and testing.
1.7.3.1.3 Testing by Contractor

(1) For the purpose of accurately determining the tendon elongations while
stressing, the Contractor shall bench-test two samples of each size
and type of strand tendon to determine the modulus of elasticity prior
to stressing the initial tendon. The bench should be at least 6 meters
long, with concrete anchorage blocks having a constant area end section
of at least four times that of the anchorage assembly area. The tendon
shall be straight and centered on the cross-sectional area of the bench.
(2) The test procedure shall consist of stressing the tendon at an anchor
assembly with the dead end consisting of a load cell. The test specimen
shall be tensioned to 80% of ultimate in a minimum of 10 increments.

(3) For each increment, the gauge pressure, elongation and load cell force
shall be recorded. The data shall be furnished to the Engineer. The
theoretical elongations shown on the post-tensioning working drawings
shall be re-evaluated by the Contractor using the results of the tests and
corrected as necessary.
(4) Revisions to the theoretical elongations shall be noticed to the
Engineer. Apparatus and methods used to perform the tests shall
be proposed by the Contractor. After the initial testing, five more
tests shall be performed. These tests shall be spaced evenly throughout
the duration of the Contract.
1.7.3.1.4 Pre-tensioning
Where pre-tensioning methods are used, the tension shall be fully
maintained by some positive means during the period between tensioning
and transfer. The transfer of stress shall take place slowly to minimize shock.
It is important to identify the different modes of stress transfer between and
un grouted tendons and allow for the test system to behave in the appropriate
manner for each setup.
1.7.3.1.5 Straight Tendons

(1) In the long-line method of pre-tensioning, sufficient locator plates shall
be distributed throughout the length of the bed to ensure that the
wires or strands are maintained in their proper position during
concreting.
(2) Where a number of units are made in the line, they shall be free to slide
in the direction of their length and thus permit transfer of the pre-
stressing force to the concrete along the whole line for grouted tendons.
In the individual mould system, the moulds shall be sufficiently rigid to
provide the reaction to the pre-stressing force without distortion. In
ungrouted tendons the locator plates must be fashioned so that load
transfer is not incorrectly carried out at these plate locations but
only at the external concrete faces by bearing.
1.7.3.1.6 Deflected Tendons

(1) Where possible the mechanisms for holding down or holding up
tendons shall ensure that the part in contact with the tendon is free to
move in the line of the tendon so that frictional losses are nullified. If,
however, a system is used that develops a frictional force, this force
shall be determined by test and due allowance made as agreed with the
Engineer.
(2) For single tendons the deflector in contact with the tendon shall have a
radius of not less than 5 times the tendon diameter for wire or 10
times the tendon diameter for a strand, and the total angle of deflection
shall not exceed 15 degrees. Where the radius is less than 5 times the
diameter of the tendon and the angle of deflection exceeds 15
degrees, the loss of strength of the tendon shall be determined by test
and due allowance made.
(3) The transfer of the pre-stressing force to the concrete shall be
effected in conjunction with the release of hold-down and hold-up
forces as noticed by the Engineer.

1.7.3.1.7 Post-tensioning
Tensioning force shall be applied in gradual and steady steps and carried out
in such a manner that the applied tensions and elongations can be measured at
all times. The sequence of stressing, applied tensions and elongations shall be
in accordance with the approved drawing or as directed by the Engineer.
1.7.3.1.8 Arrangement of Tendons
Where wires, strands or bars in a tendon are not stressed simultaneously, the
use of spacers shall be in accordance with the recommendations of the system
manufacturer.
1.7.3.1.9 Anchorages
(1) Anchorages shall be tested in accordance with the requirements of BS
4447
(2) For each anchorage system used in the Works, the characteristic
value for anchorage efficiency shall be not less than 90%.
(3) Proprietary anchorages shall be handled and used strictly in accordance
with the manufacturer's instructions and recommendations.
1.7.3.1.10 Deflected Tendons

The deflector in contact with the tendon shall, have a radius of not less than
50 times the diameter of the tendon, and the total angle of deflection shall not
exceed 15 degrees unless otherwise agreed with the Engineer.
1.7.3.1.11 Tensioning Procedure

(1) Before tensioning, the Contractor shall demonstrate that all tendons
are free to move in the ducts unless the geometry of the ducts makes
this impracticable as agreed with the Engineer. Tensioning shall be
carried out in such a manner that the stress in the tendons increases at a
gradual and steady rate.
(2) Unless otherwise described in the Contract, concrete shall not be
stressed until it has reached at least the age at which 2 test cubes
taken from it attain the specified transfer strength. The test cubes
shall be made and tested as described in BS 1881. They shall be cured
in similar conditions to the concrete to which they relate in a manner
noticed by the Engineer.
(3) The Contractor shall cast sufficient cubes to demonstrate that the
required strength of the concrete at transfer has been reached.
(4) The Contractor shall ensure that those carrying out the stressing are
provided with particulars of the required tendon loads, order of stressing
and extensions. Allowance shall be made during stressing for the
friction in the jack and in the anchorage, although the former is not
necessary when using load cells.
(5) Any allowance for draw-in of the tendon during anchoring shall be
subjected to the Notice of No Objection from the Engineer.
(6) Stressing shall continue until the required extension and tendon load are
reached or are noticed by the Engineer.
(7) The extension shall allow for any draw-in of the tendon occurring
at the non- jacking end, but measurement shall not commence until any
slack in the tendon has been taken up.
(8) Immediately after anchoring, the forces in the pre-stressing tendons
shall not exceed 70% of their characteristic strength. During stressing

the value may exceed 70% of their characteristic strength, with Notice
of No Objection from the Engineer, but shall not exceed 80%.
(9) After the tendons have been anchored, the force exerted by the
tensioning apparatus shall be decreased gradually and steadily so as to
avoid shock to the tendon or the anchorage. Full records shall be kept
of all tensioning operations, including the measured extensions,
pressure-gauge or load-cell readings, and the amount of draw-in at
each anchorage. Copies of these records shall be supplied to the
Engineer within 24 hours of each tensioning operation.
(10) Unless otherwise agreed with the Engineer tendons shall not be cut
less than 3 days after grouting.
1.7.4 Pre-stressing Tendons - Protection and Bond
(1) The pre-stressing tendons shall be protected in their permanent
positions from both mechanical damage and corrosion. The tendon
protection compound shall be applied to all unbonded pre-stressing
tendons within 28 days of installation of the tendon in the duct. The
tendon protection compound shall be applied to the ends to avoid
corrosion as described in the Contract and the following sub- clauses.
(2) The exposed tendons at the anchorages and the anchorages themselves
shall be sealed within a closed box and protected from both mechanical
damage and corrosion. Suitable access shall be left for jacking
equipment for the later removal of the strands of unbonded tendons.
The means of protection shall be designed by the pre-stressed steel
supplier and noticed by the Engineer.
(3) A tendon protection compound shall be a micro-crystalline wax
(petrolatum) base material containing additives to enhance the corrosion
inhibiting, wetting, and moisture displacing properties, as well as the
ability to form a polar bond with the tendon steel.
(4) The compound manufacturer shall provide test data verifying that the
following properties are met for the service life of 120 years
and temperature range of 0 degrees to 50oC
(a) Freedom from cracking and brittleness;
(b) Continuous self-healing film over the coated surfaces;
(c) Chemical and physical stability;
(d) Non reactivity with the surrounding and adjacent materials
such as concrete, tendons, and ducts;
(e) Moisture displacing characteristics.
(5) Additionally it shall remain flexible to allow removal and
replacement of the tendons. The tendon protection compound and its
method of installation shall be noticed by the Engineer.
(6) Provision shall be made for expansion of the tendon protection
compound during the lifetime of the structure.
(7) Before installing the tendon protection compound it shall be
demonstrated that the ducts, U-bend anchorage and anchorages are
clean and free of water and chlorides.
(8) The tendons, internal face of the steel u-bend anchorage, stressing
anchorages and any other metallic components of the pre-stressing
system shall additionally be pre-treated with a protection compound
before delivery to site. The protection compound shall be applied to
each strand of the tendon and shall be compatible with the tendon
protection compound injected into the ducts. The protection compound

shall be noticed by the Engineer.
(9) The Contractor shall notice the Engineer on tendon protection
compound suppliers proposals which shall describe how the tendon
protection compound can be removed and re-injected into ducts,
including buried ducts, within the permanent works.
(10) All materials used in the pre-stressing systems shall not give off toxic
fumes at temperatures below 50oC and shall not support combustion.
1.7.5 Ducts for Bonded Tendons

1.7.5.1 Ducts
(1) Ducts for longitudinal, transverse or vertical tendons embedded into the
concrete may be of flexible, semi-rigid, or rigid galvanized, ferrous
metal capable of withstanding concrete pressures without deforming or
permitting the entrance of cement paste during casting of the member.
(2) Ducts shall retain their shape and be capable of transferring bond
stresses. The semi-rigid duct must be rigid enough to remain straight
when supported at 1200 millimeters maximum intervals but flexible
enough to allow 3600 millimeters radius curves. Flexible duct shall be
secured or supported at not more than 300 millimeters intervals.
1.7.5.2 Grouting of Pre-stressing Tendons

(1) General
The Contractor shall undertake grouting trials when required by the
Engineer.
(2) Materials
a) Unless otherwise directed or agreed by the Engineer as a result
of grouting trials, the grout shall consist only of Ordinary Portland
Cement.
b) Cement and water. The water/cement ratio shall be as low as
possible consistent with the necessary workability, and under no
circumstances shall the water: cement ratio exceed 0.45 by weight.
c) The grout shall not be subject to bleeding in excess of 2% after 3
hours or 4% maximum when measured at 25oC or such other
temperature as may be noticed by the Engineer, in a covered
cylinder approximately 100 millimeters diameter with a height of
grout of approximately 100 millimeters and the water shall be
reabsorbed by the grout during the 24 hours after mixing.
d) Admixtures may be used with the written permission of the
Engineer and shall be applied strictly in accordance with the
manufacturer's instructions. Admixtures shall not contain chloride
ions in excess of 0.25 % by weight.
e) Dry materials shall be measured by weight.
(3) Ducts
a) Air vents shall be provided at any crests in the duct profile and
elsewhere as specified.
b) All ducts shall be thoroughly cleaned before grouting. Ducts
formed without metal sheathing shall be provided with effective
drainage and, unless otherwise directed by the Engineer, shall

be flushed with water before grouting.

c) All surplus water shall be removed by compressed air injection.
d) All anchorages shall be sealed or fitted with grouting connections.
(4) Grouting Equipment
a) The mixing equipment shall produce a grout of homogeneous
consistency and shall be capable of providing a continuous supply
to the injection equipment.
b) The injection equipment shall be capable of continuous operation
with little variation of pressure and shall include a system for
recirculating the grout while actual grouting is not in progress.
Compressed air shall not be used.
c) The equipment shall have a sensibly constant delivery pressure not
exceeding 1 Mega Pascal. All piping to the grout pumps shall have
a minimum of bends, valves and changes in diameter. All baffles
to the pump shall be fitted with 1.18 millimeter sieve strainers.
All equipment, especially piping, shall be thoroughly washed
through with clean water after every series of operations and at the
end of use for each day. The interval between washing shall not
exceed 3 hours.
d) The equipment shall be capable of maintaining pressure on
completely grouted ducts and shall be fitted with a valve that
can be locked off without loss of pressure in the duct.
(5) Mixing
Water shall be added to the mixer first, then the cement. When these are
thoroughly mixed, the admixture, if any, shall be added. Mixing
shall continue until a uniform consistency is obtained. Mixing shall not
be by hand.
(6) Injecting Grout
a) Grouting shall be carried out as soon as is practicable after the
tendons in them have been stressed and anchors trimmed and the
Engineer's permission to commence has been obtained.
b) Injection of grout shall be continuous, and it shall be slow
enough to avoid producing segregation of the grout. The method
of injecting grout shall ensure complete filling of the ducts an
complete surrounding of the steel. Grout shall be allowed to
flow from the free end of the duct until its consistency is
equivalent to that of the grout injected. The opening shall then be
firmly closed. Any vents or bleed holes shall be closed in a
similar manner one after another in the direction of the flow.
After an appropriate time, further injections shall be carried
out to fill any possible cavities.
c) The injection tubes shall then be sealed off under pressure until
the grout has set.
d) The filled ducts shall not be subjected to shock or vibration
within 1 day of grouting.
e) Not less than 2 days after grouting, the level of grout in the
injection and vent tubes shall be inspected and made good as
necessary.
f) The Contractor shall keep full records of grouting including the
date each duct was grouted, the proportion of the grout and any

admixtures used, the pressure, details of any interruptions and

topping up required. Copies of these records shall be supplied
to the Engineer within 3 days of grouting.
f) The Contractor shall provide facilities and attendance for the
radiographic testing of the grouted duct.
(7) Strength of Grout
The compressive strength of 100 millimeters cubes made of the grout
shall exceed 17 MPa at 7 days. Cubes shall be cured in a moist
atmosphere for the first 24 hours and subsequently in water.
1.7.6 Ducts for Unbonded Tendons

(1) Unless shown otherwise on the Drawings, ducts and injection
tubes in the superstructure and substructure shall be formed from
high density polyethylene (HDPE) which shall incorporate a stabilizing
agent to prevent Ultra Violet Light (UVL) degradation.
(2) The minimum wall thickness of the ducts shall be such that the ducts
are capable of resisting the pressures developed during installation of
the protection compound. The ducts shall be smooth bore.
(3) Ducts with external diameters greater than 70 millimeters shall be
transported and stored in straight lengths without stacking. The
distance between supports shall be limited to 3 meters and the height of
storage to 1.5 meters. Alternatively ducts may be transported and
stored in coils provided that they are fixed to the designed tolerances.
Damaged ducts shall not be used in the Works.
(4) No boring of any holes in the ducts shall be permitted once the
tendons are installed.
(5) U-bend anchorages shall be formed from smooth-bore unwelded steel
tubes and shall comply with the requirements of BS 4360.
(6) Joints between ducts, ducts and anchorages and ducts and U-bend
anchorages shall be formed by a coupling device using thermo-fusion
techniques which shall provide a water-tight seal to the ducts and shall
be capable of resisting the pressure developed during installation of the
tendon protection compound. The inner surfaces of the joints shall
form a smooth transition between ducts and U- bend anchorages to
allow satisfactory installation of the tendons. All coupling devices shall
be noticed by the Engineer.
(7) Injection tubes shall be provided at the U-bend anchorages, the stressing
anchorages and at any other positions on the length of the ducts which
are required to achieve satisfactory installation of the tendon
protection compound. The injection tubes at the U-bend anchorages
shall also be used as drainage points for the U-bend. The connection
between the ducts and the injection tubes shall be water-tight and
capable of resisting the pressure developed during installation of the
tendon protection compound.
(8) All injection tubes shall be sealed after use to prevent the ingress of
water.
(9) After completion of all duct joints and before completion of the
in-situ joints between pre-cast segments and before installation of the
tendons, all ducts shall be air tested to an equivalent 100 millimeters
water gauge. The test shall be performed in accordance with BS 8301

Section 5.
(10) Any ducts which do not contain tendons shall remain empty and shall
be sealed at each end to prevent the ingress of water.
1.7.7 Pre-stressing Tendons - Trial Construction-Unbonded Tendons

(1) Before commencing construction of the pre-cast segments a trial shall
be carried out which shall demonstrate the satisfactory installation,
removal and replacement of a pre-stressing strand together with the
proposed techniques for duct jointing, duct testing and installation of the
tendon protection compound.
(2) The tendons shall be stressed in accordance with this Contract.
(3) The ducts shall be filled with a tendon protection compound in
accordance with this Contract and the tendon extension and
anchorage shall be protected as if they were to be included in the
permanent works.
(4) The trial shall demonstrate that any one strand may be destressed,
removed, inspected, replaced and restressed and that no voids are
created within the tendon protection compound.
(5) The trial shall also demonstrate that all of the strands in a duct may be
removed and that the tendon protection compound can be removed from
the ducts and U- bend anchorage
(6) The trial shall be undertaken using the pre-stressing system to be
used in the Permanent Works and shall be noticed by the Engineer.
1.7.8 Pre-stressing Tendons - Temporary Tendons

(1) Temporary tendons may be re-used as temporary tendons elsewhere
provided special precautions are incorporated at the anchorages to
ensure tendons are not damaged. These precautions shall be noticed by
the Engineer.
(2) The tendons shall be enclosed within a duct throughout their length.
(3) The tendons shall be pre-treated in accordance with the Contract
and the protection compound shall be applied to the outer surfaces of
the tendon after each use.
(4) The maximum jacking force for the re-usable temporary tendons shall
not exceed 70% of their guaranteed minimum breaking load.
(5) After removal of the tendons the ducts shall be sealed at each end to
prevent the ingress of water.
1.7.9 Preparation for Casting

(1) The Contractor shall submit for Notice of No Objection, in
accordance with the provisions of the Employer's Requirements,
working drawings of the pre-stressing system proposed for use. For
initial notice, 3 sets of such drawings shall be submitted.
(2) After notice, between 6 sets, shall be submitted. The working drawings
of the pre- stressing system shall show complete details and be
accompanied by substantiating calculations of the method and
materials the Contractor proposes to use in the pre-stressing
operations, including any additions or rearrangement of reinforcing

steel from that shown on the Drawings. Such details shall outline the
method and sequence of stressing and shall include complete
specifications and details of the pre-stressing steel and anchoring
devices, working stresses, anchoring stresses, type of ducts, and all
other data pertaining to the pre- stressing operation, including the
proposed arrangement of the pre-stressing steel in the members.
(3) Working drawings shall be A1 size and each drawing and calculation
sheet shall include the job site, name of the structure as shown on the
Contract Drawings and Contract name.
(4) Working drawings shall be submitted sufficiently in advance of the
start of the affected work to allow time for notice by the Engineer and
correction by the Contractor of the drawings without delaying the
Work. Such time shall be proportional to the complexity of the Work
but in no case shall such time be less than eight (8) weeks.
(5) At the completion of each structure, one set of reproducible Mylar of the
corrected original tracing of all working drawings for said structure
shall be furnished to the Engineer. Drawings which are common to
more than one structure shall be provided for each structure. An index
prepared specifically for the working drawings for each structure
containing sheet numbers and titles shall be included.
(6) Reinforcing steel shall be fabricated and placed in accordance with the
Drawings and as required herein. No reinforcing steel shall be cut and
removed to permit proper alignment of stressing ducts. Any bar that
cannot be fabricated to clear the conduits shall be replaced by
additional bars with adequate lap lengths and shall be submitted to the
Engineer. In the plane of the steel parallel to the nearest surface
of concrete, bars shall not vary from plan placement by more than
12 millimeters or one-tenth (1/10) of the spacing between bars,
whichever is less.
(7) All pre-stressing steel shall be protected against physical damage
and rust or other results of corrosion at all times from manufacture to
grouting or encasing in concrete. Pre-stressing steel that has
sustained physical damage at any time shall be rejected. The
development of visible rust or other results of corrosion shall be
cause for rejection, Pre-stressing steel shall be packaged in containers
or shipping forms for the protection of the steel against physical damage
and corrosion during shipping and storage. A corrosion inhibitor
which prevents rust or other results of corrosion shall be placed in the
package or form, or shall be incorporated in a corrosion inhibitor carrier
type packaging material, may be applied directly to the steel, with
notice to the Engineer. The corrosion inhibitor shall have no
deleterious effect on the steel or concrete or bond strength of steel to
concrete. Packaging or forms damaged from any cause shall be
immediately replaced or restored to original condition.
(8) The shipping package or form shall be clearly marked with a statement
that the package contains high-strength pre-stressing steel, and the care
to be used in handling; and the type, kind and amount of corrosion
inhibitor used, including the date when placed, safety orders and
instructions for use.
(9) Pre-stressing steel for post-tensioning which is installed in

members prior to placing and curing of the concrete, shall be

continuously protected against rust or other corrosion, until grouted,
by means of a corrosion inhibitor placed in the ducts or applied to
the steel in the duct. The corrosion inhibitor shall conform to the
requirements specified herein.
(10) When steam curing is used, pre-stressing steel for post-tensioning
shall not be installed until the steam curing is completed.
(11) All water used for flushing ducts shall contain either quick lime
(calcium oxide) or slaked lime (calcium hydroxide) in the amount of 13
grams per liter. All compressed air used to blow out ducts shall be oil
free.
(12) When acceptable pre-stressing steel for post-tensioning is installed in
the ducts after completion of concrete curing, and if stressing and
grouting are completed within 10 calendar days after the installation of
the pre-stressing steel, rust which may form during said 10 days will
not be cause for rejection of the steel. Pre- stressing steel installed,
tensioned and grouted in this manner, all within 10 calendar days, will
not require the use of a corrosion inhibitor in the duct following
installation of the pre-stressing steel. Pre-stressing steel installed as
above but not grouted within 10 calendar days shall be subject to all the
requirements in this section pertaining to corrosion protection and
rejection because of rust.
(13) Any time acceptable pre-stressing steel for pre-tensioning is
placed in the stressing bed and is exposed to the elements for more
than 36 hours prior to encasement in concrete, adequate measures shall
be taken by the Contractor, as noticed by the Engineer, to protect said
steel from contamination or corrosion.
(14) All ducts shall be located within 5 millimeters of the locations given
on noticed fabrication plans. Method and spacing of supports for
ducts shall be shown on the working drawings. After installation in
the forms, the end of the ducts shall at all times be sealed to prevent
entry of water and debris. Following each pour of concrete, the
Contractor will be required to demonstrate that all empty ducts are free
of water and are unobstructed and undamaged. Immediately prior to
installation of the pre-stressing steel, the Contractor shall again
demonstrate that all ducts are unobstructed and that they are free of
water and debris.
(15) Where tendons are described in the Contract as deboned from the
concrete they shall be covered with sleeves noticed by the Engineer.
The ends of the sleeves shall be taped to the tendon to prevent the
ingress of grout.
(16) Concrete shall not be deposited into forms until the entire set-up of
the forms, reinforcement, ducts, and anchorage has been thoroughly
inspected and checked. The Contractor shall submit a proposal to the
effect that the rate of producing and placing concrete will be sufficient
to complete the proposed pour and finishing operations within the
scheduled time, that experienced concrete finishers are available where
required for finish work and all necessary finishing tools and equipment
are on hand at the site of the Work and are in satisfactory condition for
use.

(17) Concrete on sloped forms shall be placed on the lowest end or edge
and worked to the higher end or edge to avoid loss of water and
compaction. Self-levelling concrete may be used where access is
limited, however vibration is still necessary.
(18) Conveying equipment shall be of a size and design that will permit the
placing of concrete within the time limits specified. Conveying
equipment shall be cleaned at the end of each operation or work day
and just prior to reuse shall again be checked and cleaned of hardened
concrete and foreign materials.
(19) Belt conveyors shall be horizontal or at a slope which will not cause
excessive segregation of loss of ingredients. Concrete shall be
protected against undue drying or rise in temperature. A noticed
arrangement shall be used at the discharge end to prevent aggregate
segregation. Mortar shall not be allowed to adhere to the return
length of the belt. Concrete shall be discharged into a hopper or
through a baffle.
(20) The concrete shall be first placed in the web forms followed by
placement at the bottom slab and then in the top form. Any alternate
sequence shall be submitted to the Engineer for notice.
(21) For pours conducted in stages, the concrete from the first stage
interfacing with the newer pour should be clean and moistened. Older
concrete surfaces should be scabbled to allow aggregates to be partially
visible or else scarified and roughened if the first pour is fairly recent.
(22) All concrete shall be consolidated by means of noticed vibrators
together with any other equipment necessary to perform the Work as
specified. Internal vibrators shall have a minimum frequency of
8,000 vibrations per minute and sufficient amplitude to consolidate
the concrete effectively.
(23) Vibrators should be of sufficient size but not oversized for the
particular pour – eg, the vibrators should be able to fit between
reinforcement cages, rebar spacings and into corners. Vibration
time shall be controlled such that segregation is not caused by keeping
the vibrator in one place for prolonged periods. Typical diameters range
from ½” to ¾” (12 to 18 millimeters) for standard pours and to be
determined by trial pours prior to use on actual works. Honeycombing
from air-entrainment is also reduced by proper vibration, especially
between the reinforcement and form faces.
(24) At least two (2) stand-by vibrators in working condition shall be
provided for emergency use in case of malfunction. The use of
external vibrators or vibrating forms for consolidating concrete will be
permitted and may be required when the concrete is inaccessible for
adequate consolidation. When external vibration is used, the forms
shall be constructed sufficiently rigid to resist displacement or damage.
Vibrating of concrete shall be done with care and in such a manner as
to avoid displacement of reinforcing, conduits, and other items to be
fixed in place.
1.7.10 Tests And Standards Of Acceptance
The materials shall be tested in accordance with codal Specifications and shall

meet the prescribed criteria.
The work shall conform to the Specifications and shall meet the prescribed
standards of acceptance.
1.7.11 Quality Control and Testing Materials
The contractor shall carry out all tests of materials in order to guarantee the
specified quality in accordance with the relevant clauses of this specification.
Tests of Precast and/or Pretensioned Elements
One unit of each type of precast element shall be load tested upto to failure but
its quantity shall not be paid as it is included in scope of work of contract.
Prior to carrying out load tests, the contractor shall submit arrangement of
testing, loading etc. and shall carry out any modifications, if needed, on the
existing testing arrangement to the satisfaction of Engineer-in-Charge at no
extra cost. The contractor shall submit a report containing test results and
observations etc. to the department.
Shop drawings and design calculations for construction procedures
The contractor shall submit according to a schedule, complete details and

information concerning the method, materials, equipment and procedures he
proposes to use. These shall be called “Method statements”. Method
Statements shall be submitted sufficiently in advance of the start of
superstructure filed construction operations, so as to allow the Employer’s
Representative adequate review period, which shall not be less than 30 days.
The submittals shall invariably include step-by-step casting, lifting, curing,
stacking, transportation and erection procedure. The contractor’s Method
Statements shall also include all design calculations, drawings and information
as may be relevant. The following points are specifically highlighted.
- Accommodating block-outs, openings and protrusions. Protruding re-bars

may be needed (track starter rebars, for example). Anchorages and inserts
for OHE poles, Signalling equipment and cable routing supports shall also
be included where needed in precast structures.
- Adjusting to changes in structure length, curve, inclination and camber as
shown in Detailed Design Drawings issued by Engineer.
- Adjusting the profile to take into account design camber values
- Stripping without damage to the concrete
- The from design shall provide a tapered portion at both end for bearing of
electrometric bearing.
- Forms shall not be removed until the concrete has attained adequate
strength. Care should be exercised in removing the forms to prevent
spalling and chipping of the concrete.
- All side, bottom and end forms for precast beams shall be constructed of
steel.
- Forms shall be of sufficient thickness, with an adequate external bracing

and stiffeners, and shall be sufficiently anchored to withstand the forces

due to placement and vibration of concrete.
No tie bolt is permitted for casting of precast beam. Joints in the forms shall
be designed and maintained for mortar tightness. The grade and alignment of
forms shall be checked each time they are set and shall be maintained during
the casting of concrete.

1.8 Structural Steelwork
1.8.1 General
Workmanship and materials shall be generally in accordance with relevant
Indian Standards or where alternatively noticed by the Engineer, in
accordance with BS-EN or ASTM standards.
The work shall include furnishing, fabricating, transporting, assembling,
erecting and painting of structural steel and other incidental metal
construction, size and quantity in conformity with the drawings and these
specifications or as desired by the Engineer.
Technical Drawings, to be submitted by the Contractor and approved by the

Engineer, shall show as appropriate the salient dimensions, design loads,
sizes of members, location of openings at various levels and other necessary
information required for the preparation of shop drawings, fabrication
drawings and erection details.
General requirements relating to the supply of material shall conform to the

codal specifications.
Finished rolled material shall be procured from primary manufacturers and
shall be free from cracks, flaws, injurious seams, laps, blisters, ragged and
imperfect edges and other defects. They shall also be free from loose mill
scale, rust, pits or other defects affecting its strength and durability.
The acceptance of any material on inspection at the mill, shall not be a bar to
its subsequent rejection, if found defective.
Unless specified otherwise, high tensile steel rivet conforming to IS: 1149
shall be used for members of high tensile steel conforming to IS: 961 and
shall not be used for mild steel members. Unless specified otherwise, bolted
connection of structural joints using high tensile friction grip bolts shall
comply with requirements of IS: 4000. Cast iron shall not be used in any
portion of the structure.
1.8.2 Scope of Work

The scope of work for the contractor in respect of structural steel work shall
cover, but shall not be limited to the following:
A. Preparation of complete detailed fabrication drawings and erection
marking drawing based on the design drawings, required for all the
permanent and temporary structures
B. Submittal of revised design, with calculations and detailed fabrication
drawings, in case any substitution of the designed sections is required.
C. Submittal of design calculations for joints and connections to be
developed by the contractor along with detailed fabrication drawings.
D. Supply of all raw steel materials for fabrication, taking into account
wastage margin, including storage and upkeep of the materials.
E. Furnishing of all materials, labour, tools and plant and all consumable
required for fabrication and supply of all necessary bolts, nuts, washers,
tie roads and welding electrodes for field connections, with necessary
wastage margins.

F. Fabrication of the steel works in accordance with the approved

fabrication drawings, including all shop assembling, matching and
marking. Design, manufacture / fabrication and provision of all jigs,
fixings, manipulators etc. required for the fabrication.
G. Provision of shop painting and requisite site painting to all fabricated
steelwork, as per requirements of the related specification of the
painting.
H. Suitability marking, bundling and packing for transport of all fabricated
materials.
I. Preparing and furnishing materials, drawing Office dispatch lists, Bolts
Lists and any other lists of bought out items required in connection with
the fabrication and erection of the structural steelwork.
J. Loading and transporting all fabricated steelwork and field connection
materials to site.
K. The contractor shall submit, for examination by the Engineer, detailed
particulars of his proposed methods of erection of the superstructure
steelwork, together with complete calculations relating to strength and
deflection. If the erection scheme necessitates the attachment of strength
steelwork to the permanent steel work, the contractor shall submit, for
approval of the Engineer, the methods he proposes for making good the
permanent steelwork after removing the temporary work. The contractor
shall also submit the design and fabrication drawings of all temporary
support, staging, braces etc. required for safe erection, for approval of
the Engineer.
L. The contractor shall provide all construction and transport equipment,
tools, tackle, and consumables, materials, labour and supervision
required for the erection of the structural steelwork.
M. Receiving , unloading, checking and moving to storage yard, storage,
guarding and upkeep of fabricated steelwork and other consumable
materials and fasteners at site.
N. Transportation of all fabricated structural steel materials from site
storage yard, handling, assembling, bolting, welding and satisfactory
installation of all fabricated structural steel materials in proper location,
according to approved erection drawings and/or as directed by the
Engineer.
O. Setting out, aligning, plumbing, leveling, bolting, welding and securely
fixing the fabricated steel structures in accordance with the erection
scheme, or as directed by the Engineer.
P. Providing protective treatment to the erected steel structures, as per

Specification.
Q. All major modifications of the fabricated steel structures, as directed by
the Engineer, including but not limited to the following:
i) Removal of bends, kinks, twists etc. for parts damaged during
transport and handling.
ii) Cutting, chipping, filling, grinding etc. if required or preparation
and finishing of site connections.
iii) Reaming of holes for use of higher size bolt if required.
iv) Re-fabrication of parts damaged beyond repair during transport and
handling or refabrication of parts which are incorrectly fabricated.

v) Fabrication of parts omitted during fabrications by error, or

subsequently found necessary.
vi) Drilling of holes which are either not drilled at all or are drilled in
incorrect location during fabrication.
vii) Carry out tests in accordance with the related Specification.
1.8.3 Submittals
A. On commencement of the Project, the Contractor shall submit the
following:
i) Prior to the technical submittals, the contractor shall submit the
proposed overall schedule for documentation such as calculations,
shop/ working drawings, plan/ procedures and records. Submission
of samples, process of fabrication / delivery / erection for the
approval of the Engineer.
ii) Complete fabrication drawings, materials lists, cutting lists, bolt
lists, welding schedules and QC schedules, based on the design
drawing furnished to him and in accordance with the approved
schedule. It is highlighted that structural steel members dimensions
indicated in tender drawings are tentative only, and may be
modified during final design stage.
iii) Results of any tests, as and when conducted and as required by
thecodal provisions and Engineer.
iv) Manufacturers mill test reports in respect of steel materials, bolts,
nuts and electrodes, as may be applicable.
v) A detailed list of all constructional Plant & Equipment, such as
cranes, derricks, winches, welding sets, erection tools etc. their
make, model, present condition and location, available to the
contractor and the ones he will employ on the job to maintain the
progress of work in accordance with the contract.
vi) The total number of experienced personnel of each category, like
fitters, welders, riggers etc., which he intends to deploy on the
project.
B. The contractor shall submit a detailed erection program for completion
of the work in time and in accordance with contract. This will show, in a
Performa approved by the Engineer, the target program, with details of
erection proposed to be carried out in each week, details of major
equipment required and an assessment of required strength of various
categories of workers.
C. The contractor shall submit complete design calculations for any
alternative sections proposed by him, for approval of the Engineer. Use
of any alternative section shall be subject to approval of the Engineer.
1.8.4 Furnishing of Information

A. Detailed design and drawings shall be furnished by the contractor and
all such drawings shall form part of these works
B. The Engineer reserves the right to make changes in the design drawings
even after release for preparation of shop drawings to reflect addition,
omission & modifications in data/details and requirements. Contractor
shall consider such changes as part of these Specifications and the
contract, and no extra claims shall be entertained on this account.

C. Design drawings, approved by the Engineer, will show as appropriate the

salient dimensions, design loads, sizes of members, location of openings
at various levels and other necessary information required for the
preparation of fabrication drawings, designs and erection details.
D. It shall be clearly understood that the drawings provided are for tender
purpose. The typical details of connection, cuts, notches, bends, etc.
where shown in the design drawings are only for general guidance of the
contractor. The contractor shall design and develop all such detail
drawings based on the design forces and functional requirements of
metro rail system as per codal provisions.
E. In case of variations in design drawings and specifications, the decision
of the Engineer shall be final. Should the contractor, find any
discrepancy in the information furnished by the Engineer, same shall be
immediately brought to the notice of Engineer for resolution. The
contractor shall obtain clarifications on discrepancies from Engineer
before proceeding with the work.
F. No detailed shop drawings will be accepted for examination by the
Engineer unless the same, have first been completely checked by the
contractor's qualified structural engineer (independent agency to be
appointed by contractor) and are accompanied by an erection plan
showing the location of all pieces detailed. The contractor shall check
and ensure that detailing of connections is carefully planned to obtain
ease in erection of structures, including field-welded connections and/or
bolting.
G. No fabrication work shall be started by the contractor without having
obtained approval of Engineer on the relevant drawings. Approval by the
Engineer of any of the drawings shall not relive the contractor of his
responsibility to provide correct design of connections, workmanship, fit
of parts, details, materials and errors or omissions of all work shown
thereon. The approval of Engineer shall constitute approval of the size of
members, dimensions and general arrangement, but shall not constitute
approval of the connections between members and other details.
H. Drawings, for approval, shall be submitted by the contractor in an
orderly manner commensurate with erection sequence and approved
construction programme.
I. The contractor shall furnish ten prints of all approved final drawings for
field use and record purpose.
J. The drawings prepared by the Contractor, and all subsequent revisions
thereof shall be at the cost of the Contractor, and no separate payments
shall be made for the same. Revisions shall incorporate all modifications,
field changes, substitutions etc. effected.
K. The Contractor shall give due consideration to the need of trial
assemblage at shop, weight and size limitation of elements for
transportation from shop to construction site, temperature variation of 25
degree centigrade between the fabrication shop and site, site
measurements of the as-built dimensions and avoidance of site welding
except for fixtures. All the drawings shall be prepared in metric units.
The drawings should preferably be of A-1 standard size, and the details
shown therein shall be clear and legible. These drawings shall include
but shall not be limited to the following:

i) Assembly drawings, giving exact sizes of the sections to be used

and identification marks of the various sections.
ii) Dimensional drawings of base plans, anchorages details in
foundation, foundation bolts location etc.
iii) Complete specifications of Materials and detailed drawings of all
sections including their billing weights.
iv) Shop details of temporary structures together with detailed
calculations.
v) Detailed shop drawings for proper co-ordination with the concrete
components to which the steel members shall be connected, as
required.
vi) Any other drawings or calculations that may be required for proper
completion of the works and clarification of the works or
substituted parts thereof.
1.8.5 Applicable Codes of Practice
The following specifications, standards and codes are included as part of this
Specification. All Standards, specifications, codes of practice current on the
date of signing of agreement and referred to herein shall be applicable
1. IS: 800 (1984) Code of Practice for General Construction in Steel.

2. IS: 808 (1989) Dimensions for Hot Rolled Steel Beam, Column, Channel
and Angle Sections.
3. IS: 814 (1991) Covered Electrodes for Manual Metal Arc Welding of
Carbon & Carbon - Manganese Steel.
4. IS: 816 (1969) Code of Practice for Use of Metal Arc Welding for
General Construction in Mild Steel.
5. IS: 817 (1969) Code of Practice for Training and Testing of Metal Arc
Welders.
6. IS: 919 (1993) ISO System of Limits & Fits (Part 1 & Part 2)
7. IS: 1148 (1982) Hot Rolled Rivet Bars (upto 40mm) for Structural
Purposes.
8. IS: 1182 (1983) Recommended Practice for Radio Graphic Examination
of Fusion Welded Butt Joints in Steel Plates.
9. IS: 1363 (1992 Hexagon Head Bolts, Screws and Nuts of Product grade
C. (Part 1 to Part 3)
10. IS: 1364 (1992) Hexagon Head Bolts, Screws and Nuts of Product
Grades A &B (Part 1 to 5)
11. IS: 1367 (1991) Technical Supply Conditions for Threaded Steel
Fasteners.
12. IS: 1852 (1985) Rolling & Cutting Tolerances for Hot-Rolled Steel
Product.
13. IS: 1977 (1975) Structural Steel (Ordinary Quality).
14. IS: 2016 (1967) Plain Washers.
15. IS: 2062 (2011) Steel for General Structural Purposes.
16. IS: 2595 (1978) Code of Practice for Radio Graphic Testing.
17. IS: 3600 (1985) Methods of Testing Fusion Welding Joints. (Part 1 to
Part 9)

18. IS: 3613 (1974) Acceptance Tests for Wire Flux Combinations for
Submerged Arc Welding.
19. IS: 3658 ( 1981) Code of Practice for Liquid Penetrant Flow, Detection.
20. IS: 3757 ( 1985) High Strength Structural Bolts.
21. IS:4000 (1992) High Strength Bolts In Steel Structures-Code of Practice
22. IS: 4353 (1967) Recommendations for Submerged Arc Welding of Mild
Steel and Low Alloy Steel.
23. IS: 4943 (1968) Assessment of Butt and Fillet Fusion Welds in Steel
Sheet, Plate and Pipe.
24. IS: 5334 (1981) Code of Practice for Magnetic Particle Flow Detection
of Welds
25. IS: 5369 (1975) General Requirements for Plain Washers and Lock
Washers.
26. IS: 5372 (1975) Taper Washers for Channels
27. IS: 5374 (1975) Taper Washers for I Beams.
28. IS: 6623 (1985) Specification for High Strength Structural nuts
29. IS:6649 (1985) Specifications for hardening and tempering washers for
high strength structural nuts
30. IS: 6755 (1980) Double Coil Helical Spring Washers.
31. IS: 7215 (1974) Tolerances for Fabrication of Steel Structure.
32. IS: 7318 (1974) (Part I)Approval Tests for Welders When Welding
Procedure Approval is not required -fusion Welding of Steel.
33. IS:8500 (1991) Structural steel -Micro alloyed (Medium and High
Strength Qualities) .
34. IS:891O (1978) General requirements of Supply of Weldable Structural
Steel.
35. IS: 9595 (1980) Recommendations for Metal Arc Welding of Carbon &
Carbon-Magnese Steels.
36. IRS: Steel Bridge Code.
37. IRS: Welded Bridge Code.
38. IRS: Code of Practice For Electric Welding Of Mild Steel Structures
39. IRS: Fabrication & Erection of Steel Girder Bridges & Locomotive Turn
Tables (B1-2001).
40. IRS: Standard Specification for Classification, Testing And Approval of
Metal-Arc Welding Electrodes, Serial No M.28-76.
41. IRS: Standard Specification for Classification, Testing And Approval of
Submerged Arc Welding Wire-Flux Combinations for Use On Indian
Railways Serial No M.39-68.
42. IRC: 22 (2008) Standard specifications and code of practice for road
bridges – Section VI (Composite Construction). BS: 5400-6 (1999)
Steel, concrete and composite bridges- Specifications of material and
workmanship, Steel.
1.8.6 Material Properties

All materials to be supplied by the Contractor shall conform to relevant Indian
Standards or equivalent, as approved by the Engineer.
Steel materials required for the work shall be procured from primary
manufacturers, free from imperfections, mill scales, slag intrusions,
laminations, pittings, rusts etc. that may impair strength, durability and
appearance. All materials shall be of tested quality only. If desired by the

Engineer test Certificates in respect of each consignment shall be submitted

in triplicate. Whenever the materials are permitted for procurement from
identified stocks, a random sample shall be tested at an approved laboratory,
as directed by the Engineer.
(1) Structural steel of E450BR conforming to IS:2062 (with latest
amendment) may be used on roof portals (curved) including its splicing
plates over entry exit structure. For other miscellaneous structures
structural steel of E250 BR OR E350 BR conforming to IS:2062 shall
be used..
(2) Dimensional properties, tolerances and rolling margins shall
comply with the relevant Standards.
(3) The condition of steel for fabrication shall be to IS 2062 or Swedish
Standard 05 5900, Grade C unless otherwise detailed.
(4) Bolts and nuts shall comply with design requirement. For splicing of
any structural member wherever required HSFG bolts and nuts of
property class- 8.8 conforming to IS:3757, IS:4000-1992 and IS:6623
(1985) respectively shall be used. Unless specified otherwise, the bolts
shall be hexagonal.
All anchor bolts shall be of property class of 8.8 and nuts shall conform
to IS:1363 (1992), IS:1364 (1992) and IS:1367, as applicable, and
unless specified otherwise, shall be hexagonal. All nuts shall conform to
property class compatible with the property class of the bolt used.
(5) Washers shall comply with BS 4320. For HSFG bolts , washer shall be
conforming to IS:6649 (1985).
Plain washers shall be conforming to IS:5369 ( 1975), unless otherwise
specified. One washer shall be supplied with each bolt and, in case of
special types of bolts, more than one washer as needed for the purpose
shall be supplied. An additional double coil helical spring washer,
conforming to IS:6755 (1980), shall be provided for bolts carrying
dynamic or fluctuating loads and those in direct tension. Tapered
washers, conforming to IS:5372 (1975) and IS:5374 (1975), shall be
used for channels and beams respectively wherever required
(6) Stainless steel shall be grade 316 S31 to BS 970: Part 1, unless detailed
otherwise.
(7) Stud Shear Connectors

The stud shear connectors shall be high tensile steel and the testing
procedure shall be as per BS: 5400-6-1999. The headed studs for shear
connection shall have minimum properties i) Ultimate strength fu= 495
MPa, ii) Yield strength fy= 385 MPa and iii) Elongation = 18%.
1.8.7 Testing
(1) The Contractor shall perform tests and submit test certificates for the
materials to be used in the Work. The tests shall include the following
in accordance with IS: 226/IS: 2062 or BS-EN 1993 or applicable
Indian Standard.
a) Chemical analysis
b) Tensile tests
c) Bend tests
d) Flattening tests

(2) The tests shall be carried out by a noticed testing authority and notice
shall be given of the intended execution of any such test. The specimens
for testing shall be a random sampling of steelwork to be used for the
project.
(3) If any sample fails a test, the consignment it represents may be rejected
in part or in whole. Alternatively it may be possible to either:
a) Retest the consignment using another sampling set or;
b) Notice the criteria for acceptance of this particular
consignment, should the Engineer allow an acceptance for a
particular use justified by the design requirements
(4) In no way do these specific qualifications provide a precedent for future
acceptance of any failed consignment.
1.8.7.1 Storage of Materials
General
All materials shall be so stored as to prevent deterioration, and to ensure the
preservation of their quality and fitness for the work. If required by the
Engineer, the materials shall be stored under cover and suitably painted for
the protection against weather. Any material, which has deteriorated or has
been damaged shall be removed from site and replaced by new members, as
directed by the Engineer at no extra cost and time.
The steel to be used in fabrication shall be a stored in separate stack clear of
the ground section wise and lengthwise.
The storage area shall be kept clean and properly drained. Structural steel
shall be so stored and handled in such a manner that members are not
subjected to excessive stresses and damage. Girders and beams shall be
placed in upright position. Long members shall be supported on closely
spaced skids to avoid unacceptable deflection.
Yard
The Contractor shall be required to establish a suitable yard, in an approved
location at site for storing the fabricated steel structures and other materials
which will be delivered to site. The yard shall have proper facilities such as
drainage and. lighting including access for cranes, trailers and other heavy
equipments.
The Contractor shall have been deemed to have visited the site, prior to
submission of his tender, to acquaint himself with the availability of land and
the development necessary by way of filling, drainage, access roads, fences,
sheds etc., all of which shall be carried out by the Contractor at his own cost
and as directed by the Engineer.
Covered Store
All field connection materials, paints etc. shall be stored on racks and
platforms, off the ground. In a properly covered building by the contractor.
1.8.7.2 STRUCTURAL STEELWORK SPECIFICATION -WELDED

STRUCTURE
General

Fabrication drawings shall be prepared by the Contractor after approval of the

camber sheets duly incorporating the camber and nominal lengths of
members.
The truss members shall be plotted accurately in the template shop of the
Contractor to full scale or all the joints, gussets, splices etc. shall be drawn on
AutoCAD drawing and precise dimensions plotted.
No detailed shop drawings will be accepted for examination by the Engineer

unless the same, have first been completely checked by the Contractor's
qualified structural engineer. The Contractor shall check and ensure that
detailing of connections is carefully planned to obtain ease in erection of
structures, including field bolting or field connection of temporary structure
to permanent structure. Any temporary structure which is used for erection or
launching purpose and required to be welded to permanent structural works
will be supplied by the Contractor and the same will be required to be shop
welded by the Contractor. In case of field bolted connection between
temporary structure and permanent structural works, all necessary holes
provision shall be left.
No fabrication work shall be started by the Contractor without having

obtained approval of Engineer on the relevant drawings. Approval by the
Engineer of any of the drawings shall not relieve the contractor of his
responsibility of workmanship, fit of parts, details, materials and errors or
omissions of any work.
The Contractor shall give due consideration to the need of trial assemblage at
shop, weight and size limitation of elements for transportation from shop to
site storage yard, temperature variation of 25 degree centigrade between the
fabrication shop and site, site measurements of the as-built dimensions and
avoidance of site welding except for fixtures. All the drawings shall be
prepared in metric units.
Scope of Specification
This Specification covers the supply, fabrication and delivery to Site of

welded structural Steelwork, including the supply of all consumables,
electrodes and other materials required for fabrication and field connections
of all structural steelwork covered under the scope of the Specification.
Products
Ref. Specification for Structural Steel
General Workmanship
All workmanship shall be in accordance with the best practices in modern

structural shops. Greatest accuracy shall be maintained in the manufacture of
every part of the work and similar parts shall be strictly interchangeable. The

contractor shall not proceed with any welding until the Engineer has
approved his welding plan, which shall include.
- Weld joint description, welding process, welding position

- Base metal preparation including sketch of joint showing arrangement
of parts, welding groove details, weld passes and their sequence and
joint preparation required
- Welders qualification
- Welding current: Type and polarity. The welding parameters shall be
recorded as below:
Welds Electro wire Current Arc ge Wireed Travel Electric Gaslow

no. dia. (mm) Amps (m/min) (m/Min (mm) (L/min)
1 2 3 4 5 6 7 8
- All information’s on welding procedures, equipment, additives and

preheating during welding operation.
- Details of non-destructive testing methods
- Precautions with regard to welding shrinkage
- Possible treatment of completed welds by grinding
- Procedure and programme of welding sequence
- Procedure for heat control and minimizing warp age of base material
Templates
Templates used throughout the work shall be of steel In cases where actual
materials have been used as templates for drilling similar pieces, the Engineer
shall decide whether such materials are fit to be used as parts of the finished
structure.
Straightening
All materials shall be straight and free from twists, and if necessary, before
being worked, shall be straightened and/or flattened by pressure, unless
required to be of curvilinear form. Heating the member element shall not be
resorted for straightening.
Clearance
The clearance between fraying surface of bolted connections shall not be
greater than 1mm at each end. If separation is between 1 to 3mm, the surface
should be tapered to eliminate the separation. Over 3mm separation shall be
filled with filler plates.
Shearing, Cutting and Planning

Cutting shall be done automatically. Cutting by shearing machine may be
used for plates not exceeding 10 mm in thickness provided that the plate
edges be fully enclosed in a weld. Oxygen cutting may be used provided a
smooth and regular surface free from cracks and notches is secured.
1. Chipping of angle flanges and edges of plates, wherever necessary, shall

be done without damaging the parent metal. Chipped edges shall be

ground to a neat finish and sharp corners and hammered rough faces
shall be rounded off.
2. The edges and ends of all cut/sheared plates members, flange plates,
web plates of plate girders, and all cover plates, and the ends of all
angles, tees, channels and other sections forming the flanges of plate
girders, shall be planed/ground. Edge preparation for welding may be
done by machine controlled flame cutting, with edges free from burrs
should be clean and straight.
3. The butting surfaces at all joints of girders shall be planed so as to butt

in close contact throughout the finished joint.
1.8.8 Fabrication
(1) The work of fabrication shall comply with the requirements of IS:
800 or other relevant codes of practice noticed to the Engineer, in
accordance with BS-EN 1993 or ASTM. Fabrication accuracy shall be
within the limits detailed in BS-EN1993 .
(2) All parts assembled for bolting shall be in close contact over the
whole surface and all bearing stiffeners shall bear tightly at top and
bottom without being drawn or caulked. The component parts shall be
so assembled that they are neither twisted nor otherwise damaged. As
specified cambers if any shall be provided. Drilling done during
assembling shall not distort the metal or enlarge holes. The butting
surfaces at all joints shall be so cut and milled so as to butt in
close contact throughout the finished joints.
(3) Cutting shall be done automatically. Hand flame cutting will not be
permitted.
(4) The edges and ends of all cut/sheared flange plates, web plates of plate
girders, and all cover plates, and the ends of all angles, tees,
channels and other sections forming the flanges of plate girders, shall
be planed/ground.
(5) Holes for bolts shall be drilled to conform to clause 10 of IS:7215 .
Punching of holes will not be permitted. All drilling shall be free from
burrs. No holes shall be made by gas cutting process.
(6) All welding for the works shall be carried out by first class welders and
shall be in accordance with IS:816, IS:819, IS:1024, IS:1261, IS:1323
and IS:9595. The Engineer may at his discretion order periodic tests
of the welder and/or of the welds produced by them. All such tests
shall be carried out by the Contractor at his cost.
(7) Safety requirements shall conform to IS:7205, IS:7273 and
IS:7269 as applicable and shall conform to safety, economy and
rapidity.
(8) As much work as possible shall be welded in shops. The pieces
shall be manipulated to ensure down hand welding for all shop joints
as far as possible. All parts to be welded shall be arranged so as to fit
properly on assembly. After assembly and before the general welding
is to commence the parts are to be tack welded with small fillet or
butt welds as the case may be. The tack welding must be strong enough

to hold the parts together but small enough to be covered by the general
welding. The welding procedure shall be so arranged that the distortion
and shrinkage stresses are reduced to a minimum.
(9) All joints required in structure to facilitate transport or erection shall be
shown on the drawings. The lengths of structural members shall be the
maximum normally available in the market and the jointing of shorter
length in order to make up lengths required shall not be permitted.
(10) Each piece of steel work shall be marked distinctly before delivery,
indicating the position and direction in which it is to be fixed.
Three copies of a complete marking plan shall be supplied to the
Engineer before erection commences.
(11) In the case of welded fabrication any distortion remaining in the
member after welding operations are completed shall be rectified by
the Contractor.
(12) All members of trusses and lattice girders shall be straight
throughout their length, unless shown otherwise on the drawings, and
shall be accurately set to the lines shown on the drawings. Sheared
edges of gussets or other members to be straightened and dressed where
necessary.
(13) Templates and jigs used throughout the work shall be all steel. In
cases where actual materials have been used as templates for drilling
similar pieces, the Engineer’s notice shall be obtained to use as parts of
the finished structure.
(14) Apart from the requirements of welding specified under the above sub
clauses, sections above, the Contractor shall ensure the following
requirements in the welded joints.
a. Strength-quality with parent metal.
b. Absence of defects
c. Corrosion resistance of the weld shall not be less than that of
parent material in an aggressive environment.
(15) No gasket or other flexible material shall be placed between the holes.
The holes in parts to be joined shall be sufficiently well aligned to
permit bolts to be freely placed in position. Driving of bolts is not
permitted. The nuts shall be placed so that the identification marks
are clearly visible after tightening. Nuts and bolts shall always be
tightened in a staggered pattern and, where there are more than four
bolts in any one joint, they shall be tightened from the centre of the joint
outwards
1.8.9 Detailing of Connections

(1) Detailing of connections shall ensure that inaccessible pockets/gaps are
avoided.
In this respect, back-to-back angles with spacers and similar details
which would prevent full accessibility for painting are not acceptable.
(2) Where cope holes are required to allow completion of butt welding
they shall be of adequate size to allow fillet welding to seal the
connection, while still allowing full accessibility for subsequent
painting.
(3) Snipping of stiffeners at the root radii of rolled members is not
acceptable.

Stiffeners shall be cut to the required profile to fit closely into all
such radii, and seal welded.
(4) High-strength friction grip (HSFG) bolts shall be used only on mating
surfaces as specified herein.
(5) HSFG bolted connections, slip-bolted connections and welded
connections shall not be used interchangeably or in tandem with each
other. The use of each of these types of connections shall be separate
and distinct.
1.8.10 Submissions
(1) The Contractor shall submit to the Engineer two initial copies of
each shop drawing and subsequently four copies of the final shop
drawings for retention by the Engineer.
(2) The Contractor shall submit for notice, the details of erection
procedures. The procedure should contain details of safety precautions
to be taken during erection - refer IS 7205.
1.8.11 Welding
General
Only Automatic submerged arc welding will be used for fabrication of
railway bridges.The welding and the welded work shall conform to IS:816
(1969) and 1S:9595 (1980), unless otherwise specified. As much work as
possible shall be welded in shops and the layout and sequence of operations
shall be so arranged as to eliminate distortion and shrinkage stresses
1.8.12 Electrodes
All electrodes shall be kept under dry conditions. Any electrode damaged by
moisture shall not be used unless it is guaranteed by the manufacturer that,
when it is properly dried, there will be no detrimental effect. Any electrode,
which has part of its flux coating broken away or is otherwise damaged, shall
be rejected. Any electrode older than six (6) months from the date of
manufacture shall not be used. Batch certificates for electrodes shall be
submitted by the Contractor. Welding consumables for Manual metal arc
welding shall conform to IRS-M-28, Wire and Flux combination for
Submerged Arc welding to IRS-M-39 and filler wires for CO2 welding to
RDSO/ M & C / Specification issued vide letter No-M & C/ W/111/24 dated
1.1.1994/ 7.2.1994.
1.8.13 Preparation of Joints

1. The edges shall be prepared, with an automatically controlled flame
cutting torch, correctly to the shape, size and dimensions of the groove,
prescribed in the design and fabrication drawings. In case of U-groove
joints, the edges shall be prepared with an automatic false cutting torch
in two phases, following a bevel out with a gouging pass, or by
machining.
2. The welding surfaces shall be smooth, uniform and free from fins, tears,
notches or any other defects, which may adversely affect welding, and
shall be free of loose scale, slag, rust, grease, paint, moisture or any
other foreign material.

1.8.14 Welding Procedure

1. All welding procedures shall be submitted to the Engineer for approval,
well before starting fabrication.
2. The welding procedures shall be arranged by the Contractor to suit the
details of the joints, as indicated in the drawings, and the position at
which welding has to be carried out. Welding procedure shall cover the
following:
a. Type and size of electrodes
b. Current and (for automatic welding) arc voltage
c. Length of run per electrode; or (for automatic welding) speed of
travel
d. Number and arrangement of runs in multirun welds
e. Position of welding
f. Preparation and set-up of parts
g. Welding sequence
h. Pre or post heating
i. Any other relevant information.
3. The welding procedures shall be so arranged that distortion and
shrinkage stresses are reduced to the minimum, and that the welds meet
the requirement of quality specified.
4. Any weld found defective shall be removed, by using either chipping
hammer or gouging torch, in such a manner that parent material is not
injured in any way.
1.8.15 Fusion Faces and Surrounding Surfaces
1. Fusion faces and the surrounding surfaces within 50mm of the welds
shall be free from all mill scale and free from oil, paint or any substance
which might affect the quality of the welds or impede the
quality/progress of welding. These shall be free from irregularities,
which would interfere with the deposition of the specified size of weld
or be the cause of defects.
2. All mill scale within 50mm of welds shall be removed prior to welding,
either by pickling followed by thorough power wire brushing, or by
other approved methods.
3 If preparation or cutting of the fusion faces is necessary, the same
shall be carried out by shearing, chipping, gas cutting or flame gouging.
4 Where hand gas cutting or hand gouging is employed, the blowpipe or
gouging blowpipe shall be properly guided.
1.8.17 Assembly for Welding

Parts to be welded shall be properly assembled and held firmly in position by
means of jigs and clamps prior to and during welding. The assembly is to be
done on firm hard bed where components shall be held in position using
suitable fixtures so that once the measurements are taken to set a component
at proper location, these cannot move till tack assembly is made. The jigs for
drilling holes shall also be mounted where ever required. Tack welding using
MMAW or CO2 welding is used for tack welding.
Quality of tack welds:

a) Tack weld shall not be less than the throat thickness of the root run of
the weld to be used in the joint.
b) Length of tack weld shall not be less than four times the thickness of the
thicker part or 50 mm whichever is smaller.
c) Tack welds shall not be made at extreme ends of the joint.
d) Where tack welds are to be incorporated in the joint weld, the shape,
size and quality should be same as for main welding joint.
1.8.18 Welded Girders and Other Plate Construction
Automatic submerged arc welding shall be employed for fabrication of

welded girders and other plate construction, wherever specified. Metal inert
gas welding (CO2) may be done for short length where access to the location
of the weld does not permit submerged arc welding subject to approval of
Engineer.
1.8.19 Accuracy of Fit-Up

Parts to be fillet welded shall be brought into as close contact as practicable,
and the gap due to faulty workmanship or incorrect fit-up shall not exceed
1.5mm. If greater separation occurs at any position, the size of fillet weld
shall be increased at such positions by the amount of the gap.
1.8.20 Jigs and Manipulators

Jigs and manipulators shall be used, where practicable, and shall be designed
to facilitate welding and to ensure that all welds are easily accessible to the
operators.
1.8.21 Ends of Butt Welded Joints

The ends of butt joints shall be welded so as to provide full throat thickness.
This may be done by the use of extension pieces, cross-runs or other
approved means.
1.8.22 Weld Face and Reinforcement of Butt welds

The weld face shall, at all places, be deposited projecting the surface of the
parent metal. Where a flush surface is required, the surplus metal shall be
dressed off.
1.8.23 Testing of Butt Welds

Butt-welded joints are to be 25% radiographically tested by the Contractor at
his own cost. If such tests indicate the joints to be defective, the cost of
rectification of defective welds shall also be borne by the Contractor.
1.8.24 Minimum Leg Length & Throat Thickness in Fillet Welds

The minimum leg length of a fillet weld as deposited shall be not less than the
specified size. In no case shall a concave weld be deposited, unless
specifically permitted. Where permitted, the leg length shall be increased
above that specified length, so that the resultant throat thickness is as great as
would have been obtained by the deposition of a flat-faced weld of the
specified leg length.

1.8.25 Dislodging
After making each run of welding, all slag shall be thoroughly removed and
the surface cleaned.
1.8.26 Quality of Welds

The weld metal, as deposited (including tack welds), shall be free from-
cracks, slag inclusions, porosity, cavities and other deposition faults. The
weld metal shall be properly fused with the parent metal without under
cutting or overlapping at the toes of the weld. The surface of the weld shall
have a uniform consistent contour and regular appearance.
1.8.27 Weather Conditions

Welding shall not be done under weather conditions, which might adversely
affect the efficiency of welding.
1.8.28 Qualification and Testing of Welders

The Contractor shall satisfy the department that the welders are suitable for
the work for which they will be employed, and shall produce evidence to the
effect that welders, have satisfactorily completed appropriate tests, as
described in IS:817 Part I (1992). The Engineer may, at his own discretion,
order periodic tests of the welders and/or of the welds produced by them.
Such tests shall be at the expense of the Contractor.
1.8.29 Supervision
The Contractor shall employ competent welding supervisors to ensure that
the standard of workmanship and the quality of the materials comply with the
requirements laid down in this Specification.
1.8.30 Machining of Butts and Bases

Splices and butt joints of compression members, depending on contact for
stress transmission, shall be accurately machined over the whole section. In
column bases, the ends of shafts together with the attached gussets, angles.
channels etc., after bolting and/or welding together as the case may be, shall
be accurately machined so that the parts connected butt over the entire
surface of contact. Care shall be taken that connecting angles or channels are
fixed with such accuracy that they are not reduced in thickness by machining
by more than 0.8mm.
1.8.31 Requirement of Welded Joints

Apart from the requirements of welding specified under the above sub
clauses, sections above, the Contractor shall ensure the following
requirements in the welded joints.
i) Strength-quality with parent metal.
ii) Absence of defects
iii) Corrosion resistance of the weld shall not be less than that of parent
material in an aggressive environment.
1.8.32 Welding of Stud Shear Connectors

The headed stud shear connectors shall be welded using Drawn Arc Stud

Welding technique. This is achieved using Stud welding Automatic gun.

Other methods are not allowed. The height of the stud is reduced by
approximately 10mm during welding process and this should be considered
while selecting the appropriate height of the stud connector.
Shear connectors meet requirements of the following codes:

- AWS D1.1 Structural Welding Code – Steel, Type B
- AASHTO/AWS D1.5 Bridge Welding Code, Type B
- AASHTO Standard Specification for Highway Bridges
- AISC Manual of Steel Construction – Allowable Stress Design
- AISC Manual of Steel Construction – Load & Resistance Factor Design
1.8.33 Shop Assembly
1. The steelwork shall be temporarily shop assembled, as necessary, so

that the accuracy of fit may be checked before dispatch. The parts shall
be shop assembled with a sufficient number of parallel drifts to bring
and keep the parts in place.
2. Since parts drilled or punched, with templates having steel bushes shall
be similar and, as such, interchangeable, such steelwork may be shop
erected in part only, as agreed by the Engineer.
1.8.34 Erection Marking

1. Each fabricated member, whether assembled prior to dispatch or not so
assembled, shall bear an erection mark, which will help to identify the
member and its position in respect of the whole structure, to facilitate
re-erection at site.
2. These erection marks shall be suitably incorporated in the shop detail

and erection drawings.
1.8.35 Welders
Welders employed on the work shall be tested to BS 4871 and BS
4872 : Part1.Welding shall be carried out under the supervision of a
competent welding technologist and the test pieces shall be tested to BS
4870.
1.8.36 Testing
(1) The Contractor shall make radiographic examination of butt welds in
accordance with Section 8 of American Petroleum Industry (API)
Standard 1104 and shall carry out dye-penetrant tests in accordance
with BS 6443.
(2) Not less than 10% of the length of each butt weld shall be
radiographically inspected and 10% shall be tested using the dye-
penetrant method.
(3) Not less than 10% of the length of each fillet weld shall be tested
using dye- penetrant testing.
1.8.37 Site Welding

(1) The Contractor may, subject to prior notice, use site welding as an

alternative to bolted connections.

(2) Site-welded joints shall be inspected by radiography in accordance with
Section 8 of API Standard 1104. Initially 100% of each butt weld shall
be inspected. At the notice of the Engineer, the number of inspections
may subsequently be reduced.
(3) Finished welds shall comply with Section 6 of API Standard 1104.
Defective welds shall be cut out, remade and retested as noticed.
1.8.38 Erection of Steelwork

(1) Erection of steelwork shall comply with the requirements of BS-EN
1993 , Stanchions shall be plumbed using steel packs and wedges
and restrained while the spaces beneath the base-plates are filled with
an noticed non-shrink cementations grout. Packs and wedges shall
be protected by grout to a minimum thickness of 50mm.
(2) The Contractor shall be responsible for checking the alignment and
level of foundation and correctness of foundation bolt centres, well
in advance of starting erection work, and shall be responsible for any
consequences for non- compliance thereof. Discrepancies if any shall
immediately be brought to the notice of the Engineer.
(3) The structure should be divided into erectable modules as per the total
scheme.
This should be pre-assembled in a suitable yard/platform and its matching
with members of the adjacent module checked by trial assembly before
erection.
(4) Immediately prior to erection any rust in the paint area shall be
removed by power wire brushing to a standard equivalent to SA3.
(5) During erection the rough handling of fabricated materials such as
bending, straining or pounding with sledges shall be avoided.
Any damage to the structure during transportation or erection shall be
immediately rectified by the Contractor at his own cost. The
straightening of bend edges of plates, angles and other sections shall
be done by methods which will not cause fracture.
(6) Following the completion of the straightening, the surface of the
member shall carefully be inspected for damage before further use.
(7) The Contractor shall be responsible for accurately positioning, levelling
and plumbing of all steelwork and placing of every part of the
structure in accordance with the noticed drawings and to the
satisfaction of the Engineer. All stanchion base, beam and girder
bearings etc. shall be securely supported on suitable steel packs. All
reference and datum points shall be fixed near the work site for
facilitating the erection work.
(8) All equipment used by the Contractor shall be sufficient for the
purpose and for the erection of the steel work, in the time specified in
the contract. Any lifting or erecting machinery shall be noticed to be
removed from the site if the Engineer considers such appliances
dangerous or unsuitable for their functions. The Notice of No Objection
from the Engineer shall not relieve the Contractor of the responsibilities
for the loads to which the erection equipment shall be called upon
to carry. Adequate arrangement shall be made to resist wind loads
and lateral forces arising at the time of erection.

(9) The Contractor is entirely responsible for the stability of the structure
during erection and shall arrange that sufficient tack bolts, braces or
guy ropes are used to ensure that work will remain rigid until final
bolting, rivetting or welding is completed. The Contractor shall supply
and fix, without extra charge, any temporary bracing which may be
necessary.
(10) All steelwork shall be erected in the exact position as shown on the
Drawings. All vertical members shall be truly vertical throughout
and all horizontal members truly horizontal, fabrication being such
that all parts can be accurately assembled and erected. No permanent
bolting, welding or grouting shall be done until proper alignment has
been obtained and checked.
(11) At stanchion splices and at other positions where concrete cover to the
steel is liable to be restricted, bolts will be placed with their heads on
the outside of the members.
(12) All field assembly bolting and welding shall be executed in accordance
with the requirements for shop fabrication excepting such as
manifestly apply to shop conditions only. Where steel has been
delivered painted the paint shall be removed before field welding for a
distance of at least 50mm on either side of the joints. The number of
washers on permanent bolts shall not be more than two for the nut and
one for the bolt head.
1.8.39 Tolerances
The tolerances for erected steelwork shall be as shown on the Drawings. In-
lieu of other information the tolerances from BS-EN 1993 shall be adopted.
1.8.40 Bolted Connections

General
Scope of Specifications
This specifications cover the supply, fabrication and delivery to site of bolted
structural steelwork, including the supply of all consumables and other
materials required for fabrication and field connections of all structural
steelwork covered under the scope of the Specification.
Products
Ref. Specification for Structural Steelwork –General
1.8.41 Workmanship
General
All workmanship shall be in accordance with the best practice in modern

structural shops. Greatest accuracy shall be maintained in the manufacture of
every part of the work and all similar parts shall be strictly interchangeable.
Templates
Templates used throughout the work shall be of steel. In cases where actual
materials have been used as templates for drilling similar pieces, the Engineer
shall decide whether such materials are fit to be used as parts of the finished
structure.

Straightening
All materials shall be straight and free from twists, and if necessary, before
being worked, shall be straightened and/or flattened by pressure, unless
required to be of curvilinear form.
Clearance
The clearance between fraying surface of bolted connections shall not be
greater than 1 mm at each end. If the separation is between 1 to 3 mm the
surface should be tapered to eliminate the separation. Over 3mm separation
shall be filled with filler plates.
Shearing, Cutting and planning
1. Cutting shall be done automatically. Cutting by sheathing machine may
be used for plates not exceeding 10mm in thickness provided that the
plate edges be fully enclosed in a weld. Oxygen cutting may be used
provided a smooth and regular surface free from cracks and notches is
secured.
2. Chipping of angle flanges and edges of plates, wherever necessary, shall

be done without damaging the parent metal. Chipped edges shall be
ground to a neat finish and sharp and sharp corners and hammered
rough faces shall be rounded off.
3. The edges and ends of all cut/sheared flange plates, web plates of plate
girders, and all cover plates, and the ends of all angles, tees, channels
and other sections forming the flanges of plate girders, shall be
planed/ground.
4. The butting surfaces at all joints of girders shall be planed so as to but

in close contact throughout the finished joint.
5. The ends of all build up girders and of all columns shall be faced in an
end-milling machineafter the members have been completely
assembled. Bearing edges for girder bearing stiffeners and column bases
shall be machined.
6. Unless clean, square and true to sharp, all flame-cut edges shall be
planed. Cold sawn ends, if reasonably clean and flame-cut ends of
sections not inferior to sawn ends in appearance need not be planned,
except for butting ends.
Drilling
1. Holes for bolts shall be drilled to conform to Clause 10 of IS:7215-
1974. Punching of holes shall not be permitted. All holes, except as
stated hereunder, shall be drilled to the required size, 3mm less in
diameter and reamed thereafter to the required size. All matching holes
for bolts shall register with each other so that a gauge of 0.8mm less in
diameter than the hole cab pass freely through the members assembled
for bolting, in the direction at tight angle to such members.
2. All drilling shall be free burrs.

3. No holes shall be made by gas cutting process.
Assembly
1. All parts assembled for bolting shall be in close contact over the whole
surface
2 The component parts shall be so assembled that they are neither twisted
nor otherwise damaged. Specified cambers, if any, shall be provided.
3 All parts of bolted and welded members shall be held firmly in position
by means of jigs or clamps while bolting or welding. No drifting of
holes shall be permitted, except to draw the parts together and no drift
used shall be larger than the nominal diameter of the bolt. Drifting done
during assembling shall not distort the metal or enlarge the holes.
4 Trial assemblies shall be carried out at the fabrication stage to ensure
accuracy of workmanship, and these checks shall be witnessed by the
Engineer. Such trial assemblies shall be at the cost of the contractor.
Field Bolts
1. Requirements stipulated under bolting shall apply for field bolts. Field
bolts nuts and washers shall be furnished by the Contractor in excess of
the nominal numbers required. He shall supply the full number of bolts,
nuts and washers and other necessary fittings required completing the
work, together with the additional bolts, nuts and washers totaling to
10% of the requirement subject to minimum of 10 Nos. Only HSFG
bolts of class 8.8 shall be used.
2 At the time of assembly, the surfaces in contact shall be free of paint or
any other applied finish, oil, dirt, loose rust, loose scale, burrs and other
defects which would prevent solid seating of the parts or would
interfere with the development of friction between them.
3 If any other surface condition, including a machined surface, is
specified, it shall be the responsibility of the Contractor to work within
the slip factor specified for the particular case.
4 Each bolt and nut shall be assembled with washers of appropriate shape,
quality and number in cases where plane parallel surfaces are involved.
Such washers shall be placed under the bolt head or the nut, whichever
is to be rotated during the tightening operation. The rotated nut or bolt
head shall be tightened against a surface normal to the bolt axis, and the
appropriate tapered washer shall be, used when the surfaces are not
parallel. The angle between the bolt axis and the surface under the non-
rotating component (i.e. the bolt head or the nut) shall be 90 + 3 degree.
For angles outside these limits, a tapered washer shall be placed under
the non-rotating component. Tapered washers shall be correctly
positioned.
5 No gasket or other flexible material shall be placed between the holes.
The holes in parts to be joined shall be sufficiently well aligned to
permit bolts to be freely placed in position. Driving of bolts is not
permitted. The nuts shall be placed so that the identification marks are
clearly visible after tightening. Nut and bolts shall always be tightened
in a staggered pattern and where there are more than four bolts in any
one joint, they shall be tightened from the centre of the joint outwards.
6 If, after final tightening, a nut or bolt is slackened off for any reason, the

bolt, nut and washer or washers shall be discarded and not used again.
Shop Assembly
The steelwork shall be temporarily shop assembled, as necessary, so

that the accuracy of fit may be checked before dispatch. The parts shall
be shop assembled with a sufficient number of parallel drifts to bring
and keep the parts in place.
Erection Marking
1. Each fabricated member, whether assembled prior to dispatch or not so
assembled, shall bear an erection mark, which will help to identify the
member and its position in respect of the whole structure, to facilitate
re-erection at site.
2. This erection mark shall be suitably incorporated in the shop detail and
erection drawings.
1.8.42 Transportation and Storage

Steelwork and protective coatings shall be protected from damage during
packing, handling, transportation and storage. The Contractor shall ensure
that members are not subjected to greater stresses than those allowed in BS
5950, Part 2 during fabrication, transportation, storage and erection.
Stored items shall not be in contact with each other and shall be clear of the
ground.
1.8.43 Damaged Material

Steelwork deemed to be damaged during the Contract period shall be
replaced. The Contractor shall provide notice to the Engineer for
remedial work to damaged material if repairable. The method of repair and
final repaired condition shall have a Notice of No Objection from the
Engineer.
1.8.44 Galvanising
(1) Galvanising of steelwork, if required, shall be carried out after
fabrication is complete. Steelwork required to be galvanised shall be
pickled in dilute hydrochloric acid, washed, fluxed and stoved, and
then coated with zinc by dipping in a bath of molten zinc.
Components shall be immersed in the bath only for the period sufficient
to attain the temperature of the bath and shall be withdrawn at a speed
which ensures that a coating of 610 grams per square meter of
surface is achieved – ie, 85 microns minimum Dry Film Thickness
(DFT). Components shall be covered evenly on all surfaces.
Items shall not be galvanised in more than one dip event due to potential
warping or additional stresses that may be induced in the metal.
(2) Items described as heavily galvanised shall be grit or sand blasted
prior to galvanising and shall receive a minimum coating of 1000
grams per square metre of surface – ie,140 microns minimum DFT.
(3) Lightweight gauge metalwork shall be galvanised by the hot-dip
process as specified in BS 3083 or BS 2989.
(4) Contact between galvanised steel members and aluminum surfaces or

between galvanised and ungalvanised steel members shall be prevented

by means of noticed insulating washers and grommets.
(5) Galvanised steelwork shall be cleaned, degreased and etch primed
before application of the specified paint treatment.
1.8.45 Preparation of Steelwork for Protective Treatment

(1) Surfaces shall be cleaned to BS 7079 before any protective
treatment is commenced.
(2) Steelwork shall be degreased and shot or grit blasted to Sa 2.5 quality
standard with surface amplitude of 50 to 75 microns to remove rust
and mill scale. Dust and debris shall be removed by vacuum cleaner,
compressed air or brush. Site welds and adjacent steelwork shall be
blast cleaned and similarly prepared. Surface defects shall be removed
in accordance with BS 5950.
(3) Regular mill scale detection tests shall be made using the Copper
Sulphate method.
(4) Blasting operations and painting processes shall be segregated.
1.8.46 STRUCTURAL STEEL SPECIFICATIONS -PAINTING WORKS

General
1. Unless otherwise specified, all metal work shall be given approved shop
coats as well as field coats of painting. The work shall include
preparation of metal surfaces, application of protective covering and
drying of the paint coatings and supply of all tools, scaffolding, labour
and materials necessary. Coatings shall be applied only to dry surfaces
and the coated surfaces shall not be exposed to rain or frost before they
are dry. The coatings shall be applied to all surfaces excluding shear
connectors and inner surfaces of fully sealed hollow sections. Care shall
be taken during coating of adjacent surfaces to build up primer on the
shear connectors.
2. Surfaces which are inaccessible for cleaning and painting after
fabrication shall be painted as specified before being assembled for
riveting. All rivets, bolts, nuts, washers etc., are to be thoroughly
cleaned and dipped into boiling linseed oil conforming to IS: 77. All
machined surfaces are to be well coated with a mixture of white lead
conforming to IS: 34 and Mutton Tallow conforming to IS: 887 Scope
of Specification.
3. All paint used in the work shall be ready mixed, in original sealed
containers, as packed by the manufacturers, and no thinner shall be
permitted.
This Specification covers the scope of painting, methods for the surface
preparation, application of paints and precautions to be taken for the painting
of structural steel work. It covers the supply and delivery of all necessary
materials, labour, scaffolding tools, equipment and everything that is
necessary for the job completion on schedule.
Applicable Codes
The following Specifications, Standards and Codes are included as part of
this Specification. All standards and codes of practice referred to herein shall

be the current editions during the currency of project including all applicable
official amendments and revisions.
In case of discrepancy between this Specification and those referred to herein,
this specification shall govern. In case of discrepancy between Contract
drawings and this specification, the Contract drawings shall govern.
a) IS: 102 (1962) : Ready Mixed Paint, Brushing, Red lead, Non Setting,
Priming.
b) IS: 159 (1981) : Ready Mixed Paint, Brushing, Acid Resisting for
.Protection against Acid Fumes, Colour as Required.
c) IS: 341 (1973) : Black Japan, Types A, B & C.
d) IS: 384 ( 1979) : Brushes, Paints and Varnishes, Flat.
e) IS: 487 ( 1985) : Brush, Paint and Varnish i) Oval Ferrule Bound ii)
Round Ferrule Bound.
f) IS: 958 (1975) : Temporary Corrosion Preventive Grease, Soft Film,
Cold Application.
g) IS: 1153(1975) : Temporary Corrosion Preventive, Fluid, Hard Film,
Solvent Deposited.
h) IS: 1477(1971) : Code of Practice for Painting of Ferrous Metals in
Building.
Part I -Pretreatment
Part II -Painting
i) IS: 1674(1960) : Temporary Corrosion Preventive Fluid, Soft Film,
Solvent Deposited.
j) IS: 2074( 1992) : Ready Mixed Paints, Red Oxide -Zinc Chrome,
Priming.
Products
1.8.47 Materials
Paint
1. All paint delivered to the fabrication shop/Site shall be ready mixed, in

original sealed containers, as packed by the paint manufacturers, and no
thinners shall be permitted.
2. Paint shall be stirred frequently to keep the pigment in suspension
Storage of Paints
1. All paints shall be stored strictly in accordance with the requirements
laid down by the paint manufacturers. The storage area shall be well
ventilated and protected from sparks, flame, direct exposure to sun or
excessive heat, preferably located in an isolated room or in a separate
building.
2. All paint containers shall be clearly labelled to show paint

identification, date of manufacture, batch number, order number and
special instructions in legible form. The containers shall be opened only
at the time of use. Paints which have liveried, gelled or otherwise
deteriorated during storage, shall not be used. Paints for which the shelf
life specified by the supplier has expired shall not be used without
inspection and approval by the Engineer.

Paint System
1 Sand blasting where specified shall be carried out in accordance with

IS:1477.
2 Painting work shall be carried out as follows:
DESCRIPTION GENERAL SURFACE

FABRICATION EXTERNAL SURFACES INTERNAL SURFACES
SHOP
Abrasive blast cleaning to Abrasive blast cleaning to
minimum minimum
Surface Treatment
SA-2.5 SIS-055900 near – SA-2.5 SIS-055900 near-
white blast cleaning white blast cleaning
INTERNAL SURFACE = Internal surface are those which will become

inaccessible after fabrication.
EXTERNAL SURFACE = All other surfaces which are prone to humidity

and moisture from the atmosphere.
The following precautions must be taken:
a. After abrasive blast cleaning, the first undercoat (primer coat) should be
applied well before surface deterioration.

b. At least EPOXY MIO coating application should be completed before
giving any long overcoating interval for external surface.
c. At least up to one coat of coaltar epoxy shall be completed before
giving any long overcoating interval for internal surface.
d. Overcoating intervals, application parameters shall conform to
manufacturer’s instruction manual.
e. The DFT (Dry film thickness) shall be measured after completion of
each coat.
1.8.48 Surface Preparation
General
All surfaces shall be cleaned of loose substances and foreign materials. e. g.
dirt. rust, scale, oil, grease, welding flux etc so that the prime coat adheres to
the original metal surface. The work shall be carried out in accordance with
IS: 1477 (1971) (Part I). Any oil. grease, dust or foreign matter deposited on
the surface after preparation shall be removed and care shall be taken to
ensure that the surface is not contaminated with acids, alkalis or other
corrosive chemicals. The primer coat shall he applied immediately after the
surface preparation is completed.
Before the application of any paint the surfaces to be treated shall be

thoroughly cleaned freed from all scale, loose paint, rust and other deleterious
matters. Oil and grease shall be removed from the surface by washing with
solvents or with a detergent solution before blast cleaning operation of metal
polish with metal pellets. If any traces of oil or grease remain after blasting
they shall be removed by solvent cleaning and the area will be re-blasted
thereafter.
All welding areas shall be given special attention for removal of weld flux
slag, weld metal splatter weld head oxides, weld flux fumes silvers and other
foreign objects before blasting. If deemed necessary by the Engineer, acid
washing and subsequent washing with clean water shall be used.
Any rough seams will have to be ground and must be inspected and approved
by the Engineer-in-Charge before application of the coatings.
All structural steel to be painted shall be cleaned blast cleaning in accordance

with SA 2 1/2 Near- White Blast cleaning (equivalent Swedish Standard SIS
055900). For SA 2 1/2 the profile should be in the range of 40-70 microns
and shall be measured with comparator. Mill scale, rust and foreign matter
shall be removed to the extent that the only traces remaining are light stains
in the form of spots or stripes. Finally the surface shall be cleaned with a
vacuum cleaner or clean dry compressed air.
The blast cleaning shall produce a surface roughness complying with the one
specified by the paint manufacturer for the primer concerned. If, cleaned
surfaces are rusted or are contaminated with foreign material before painting
is accomplished they shall be re-cleaned by the Contractor at his expenses.

The surface shall be cleaned by impingement of abrasive materials, such as

grit of cast iron, malleable iron, steel or synthetic material, at high velocity
created by clean and dry compressed air blast. Prior to application of the
blast, heavy deposits of oil and grease shall be removed by solvent cleaning
and excessive surface scale removed by hand tool or power tool cleaning.
The last finish paint shall be applied after structural steel erection and slab
construction.
Mixing and Thinning
1. All ingredients in a paint container shall be thoroughly mixed to break-

up lumps and disperse pigments, before use and during application, to
maintain homogeneity. All pigmented paints shall be strained after
mixing to remove skins and other undesirable matters.
2. Dry pigments, pastes, tinting pastes and colours shall be mixed and/or
made into paint so that all dry powders get wetted by vehicles and
lumps and particles are uniformly dispersed.
3. Additives that are received separate such as curing agents, catalysts,

hardeners etc. shall be added to the paint as per the manufacturers
instructions. These shall be promptly used within the pot life specified
by the manufacturers and unused paint thereafter shall be discarded.
4. Thinners shall not be used unless essential for proper application of the
paint. Where thinners are used, they shall be added during the mixing
process and the type and quantity of thinner shall be in accordance with
the instructions of paint manufacturer.
1.8.49 Paint Application

General
1. Paint shall be applied in accordance with the manufacturer
recommendations, as supplemented by these Specifications. The work
shall generally follow IS:1477 (1971) (Part II). Prior approval of the
Engineer shall be taken in respect of all primers and/or paints, before
their use in the works.
2. Paint shall generally be applied by brushing except that spraying may
be use for finish coats only when brushing may damage the prime coats.
Roller coat or other method of paint application shall not be used unless
specifically authorized.
3. Spraying paint shall not be adopted on red lead or zinc rich paints.
Daubers may be used only when no other method is practicable for
proper application in difficult accessible areas.
4. Paint shall not be applied when the ambient temperature is 10°C and
below. For paints which dry by chemical reaction the temperature
requirements specified by the manufacturer shall be met with. Also,

paint shall not be applied in rain, wind, fog or at relative humidity of

80% and above or when the surface temperature is below dew point,
resulting in condensation of moisture. Any wet paint exposed to
damaging weather conditions shall be inspected after drying and the
damaged area repainted after removal of the paint.
5. Each coat of paint shall be continuous, free of pores and of even film
thickness without thin spots. The film thickness shall not be so great as
to detrimentally affect either the appearance or the service life of the
paint.
6. Each coat of paint shall be allowed to dry sufficiently before

applicaliol1 of the next coat, to avoid damages such as lifting or loss of
adhesion. Undercoats having glossy surface shall be roughened by mild
sand papering to improve adhesion of subsequent coats. Successive
coats of same colour shall be tinted. Whenever practical, to produce
contrasts and help in identifying the progress of the work.
7. The dry thickness of paint (DFT) shall be determined using fixed probe
magnetic gage. The DFT gage shall be calibrated over a blasted
approved surface. An average DFT value shall be recorded and
calculated for every 100m2 prepared, using minimum 5 spots
measurements. Areas failing to meet the specified thickness shall be top
coated with the same paint to produce the total dry film thickness
required.
1.8.50 Brush Application

1. Proper brushes shall be selected for a specific work piece. Round or
oval brushes which conform to IS:487( 1985) are better suited for
irregular surfaces, whereas flat brushes which conform to IS:384( 1979)
are convenient for large flat areas. The width of flat brushes shall not
generally exceed 1.25mm.
2. Paint shall be applied in short strokes depositing a uniform amount of

paint in each stroke followed by brushing the paint into all surface
irregularities, crevices and corners and finally smoothening or leveling
the paint film with long and light strokes at about right angles to the
first short strokes. All runs and sags shall be brushed out. The brush
marks left in the applied paint shall be as few as practicable.
1.8.51 Spray Application

1. The spraying equipments shall be compatible with the paint material and
provided with necessary gauges and controls. The equipment shall be cleaned
of dirt, dried paint, foreign matter and solvent before use.
2. The paint shall be applied by holding the gun perpendicular to the surface at a
suitable distance and moved in a pattern so as to ensure deposition of a
uniform wet layer of paint. All runs and sags shall be brushed out
immediately. Areas not accessible to spray shall be painted by brush or
dauber.

3. Watertrap acceptable to Engineer shall he furnished and installed on all

equipment used in spray painting.
1.8.52 Shop Painting

1. The painting system specified in Table shall be followed.
2. Surfaces in contact during shop assembly shall not be painted. Surfaces

which can not be painted but require protection shall be given a rust inhibitive
grease conforming to IS:958-1975 or solvent deposited compound
conforming to IS: 1153 (1975) or IS: 1674 (1960) or treated as specified in
the drawing.
3. Surface to be in contact with concrete shall not be painted.
4. The shop coats shall be continuous over all edges, including ends meant for
jointing at site by bolting, except where the paint could be detrimental to
bolting. In such cases, no paint shall be applied within 50mm, and the
unprotected surface shall be given a coat of corrosion inhibitive compound.
5. The unpainted area shall be cleaned prior to welding. The welded joint shall
be cleaned and deslagged, and immediately after covered by the same paint as
has been used for the remaining surface.
1.8.53 Protection of Paintwork
1. The Contractor shall provide measures as necessary to prevent damage to the
work and to other property or persons from all cleaning and painting
operations. Paint or paint stains which result in other unsightly appearance on
surfaces not designated to be painted shall be removed or obliterated by the
contractor at his cost.
2. All painted surfaces that in the opinion of the Engineer are damaged in
anyway, shall be repaired by the contractor at his cost with materials and to a
condition equal to that of the requirements specified in these specifications.
3. Upon painted surfaces that in the opinion of any other work that would cause
dust, grease or foreign materials to be deposited upon the painted surfaces,
the painted surfaces shall be thoroughly cleaned. At the time of opening the
flyovers to public traffic, the painting shall be completed and the surfaces
shall be undamaged and clean.
4. The areas for high-strength bolts shall be protected by masking tape against
undercoat application at the fabrication shop. Immediately prior to erection
any rust in the paint area shall be removed by power wire brushing to a
standard equivalent to SA3.
5. Paint shall be applied by brushing or spraying in accordance with the
manufacturer’s instructions. When permitted, thinners shall be added to paint
in strict accordance with the manufacturer’s permitted percentages.
6. Brushes stored in thinners shall be worked to remove thinners before re-use.
7. Painting shall not be carried out when the steelwork temperature is below
4 oC, above 50oC, less than 3oC above the dew point, or when the relative
humidity is above 80%.
8. Stripe coats shall be applied to welds and steel edges before painting.
9. Strong paint films shall be achieved on all cleats, arises, bolt holes, bolt
heads and the like.
10. Protective treatment, other than the site-applied coatings, shall be applied
under factory conditions in an enclosed shop. Completed coats shall be
checked for continuity by a low-voltage wet sponge holiday detector and for
thickness by an Elcometer. The colour of each coat shall be sufficiently
different to permit detection of incomplete application.
11. If a required film thickness is specified, it shall be the minimum dry film
thickness (DFT) as measured by a noticed gauge. The gauge shall be
calibrated for each coating by the use of a shim placed on the shot
blasted blank or on the underlying coat. The shim shall correspond to the
theoretical film thickness of the coating to be measured. Otherwise, a full
coating shall be applied in accordance with the rate of coverage
recommended by the manufacturer, having regard to the surface profile of
the steel and the conditions of application.
12. Sample plates shall be prepared for approval and shall thereafter be adopted
as the standard to be achieved in the finished work.
13. The Contractor shall prevent dust and dirt coming into contact with freshly
painted surfaces.
14. Before the site painting coats are applied, the surfaces shall be lightly
abraded, if required by the manufacturer's instructions, and washed with clean
water to remove salt and other impurities.
15. Paint shall not be applied to the embedded portions of metal items except
those within 75 millimeters of the finished concrete surface.
1.8.54 Application of Protective Layers

Blast-cleaned surfaces shall be kept dry and shall receive the first coat within
4 hours of the start of cleaning – i.e., 2 hours for outdoor blast-cleaning.
They shall be treated in accordance with the protective treatment schedule,
except the faying surfaces for high strength friction grip bolt connections.
1.8.55 Protection of Bolts etc.

Bolts, including high strength friction grip bolts, nuts and washers shall be
hot-dip spun-galvanised or as noticed by the Engineer. The threads of nuts
may be re-tapped as provided for in BS 729.
1.8.56 High Strength Friction Grip Connections

(1) Faying surfaces for high strength friction grip connectivity shall be
blast-cleaned to Sa 2.5 quality standard, masked within two hours to
exclude air and exposed just before bolting-up. Paint and other
contaminants shall not be allowed on faying surfaces.
(2) Each consecutive coat of paint shall be stepped back from the edge of
the faying surface by 15 millimeters.
1.8.57 Protective Treatment
(1) Damaged paintwork shall be blast-cleaned if bare metal is exposed or
corrosion is present. If the first coat is intact the surface shall be
prepared by power wire brushing. The prepared surface shall be
protected with a nominated full paint protection system.
(2) Submerged steelwork shall, in addition, be coated with a compatible
chlorinated rubber-based anti-fouling paint to a DFT of 75 microns.

1.8.58 Paintwork Executed on Site

(1) Following erection, the exposed parts of galvanised nuts, washers
and bolts (except chain fixing bolts) shall be degreased, etch-primed
and painted to the specification for adjacent steelwork. Freshly
galvanised surfaces shall be abraded and washed before application of
the etch-primer.
(2) After the preceding operations, and prior to the erection of cladding, if
any, the Contractor shall apply to the superstructure steelwork the finish
coat(s) as specified. Any damage to shop-coats will be made good on
site prior to application of the Site coats. If steel has been exposed
then the area shall be blast-cleaned primed and receive all shop-coats
or Site-coats to the required standard.
(3) Before the Site-coats are applied, the surfaces shall be lightly abraded, if
required by the manufacturer's instructions, and washed with clean
water to remove salt and other impurities. Paint shall not be applied to
the embedded portions of metal items except those within 75
millimeters of the finished concrete surface.
1.8.59 Earthing and Bonding System

Earthing and bonding system shall comply with EN-50122-1 Railway
applications fixed Installations-Part I: provisions relating to electrical safety
and earthing and BS 7430 Code of Practice for Earthing.
1.8.60 Structural Steel Work – Quality Control & Testing Requirements

General
The scope of work of these specifications is to establish the norms for
ensuring the required Quality Control through established testing norms of
the welded structural steelwork.
Codes / Standards
Relevant IS codes for tolerance and tests of welding procedures as specified
in the specification for Structural Steelwork -General.
Submittals
The Contractor shall submit the following:
• Proposed overall schedule for documentation of calculations,
shop drawings, plan/procedures and records, submission of
procedure of fabrication.
• The contractor shall himself inspect all materials, shop work
and field work to satisfy the specified tolerance limits and
Quality norms before the same are inspected by Engineer or his
authorized representative.
Products
Not Applicable
1.8.61 Tolerances
The contractor shall through appropriate planning and continuous
measurements in the workshop and the erection at site, ensure that the

tolerance specified below are strictly adhered to.
1.8.62 Dimensional & Weight Tolerance

The dimensional and weight tolerance for rolled shapes shall be in
accordance with IS: 1852.
The acceptable limits of straightness for rolled or fabricated members as per
IS: 7215 are:
Struts and columns: 1/1000 or 10 mm whichever is smaller
where L is the length of finished member
A limit for distortion in transverse direction δ from the true axis of plate and
box girder shall not be more than L/1000 where L is the length of diagonal of
profile.
Tolerance in specified camber of members shall be 3mm in 12m length
Tolerance in specified lengths shall be as follows:

- Column finished for contact bearing ± 1 mm
- Other members (cols.) upto and over 10 m ± 5 mm
- Including 10 m L/2000 sub to max of ± 8 mm
- Other members (beams) upto 12 m ± 3 mm
- Over 12m L/4000 sub max. of ± 5 mm
1.8.63 End of Members

Beam to beam and beam to column connection -Where the abutting parts are
to be jointed by butt welds, permissible deviation from the squareness of the
end is :
Beam upto 600 mm in depth : 1.5 mm

Beam over 600 mm in depth : 1.5 mm for increase in depth of every 600 mm
subjected to max of 3 mm.
Where abutting parts are to be jointed by bolting through cleats or end plates,
the connections require closer tolerance, permissible deviation from the
squareness of the end is:
Beams upto 600 mm in depth 1mm per 600mm of depth subject to a max of
1.5 mm.
For full bearing, two abutting ends of columns shall first be aligned to within
1 in 1000 of there combined length and then the following conditions shall be
met :
a) Over atleast 80% of the bearing surface the clearance between the
surfaces does not exceed 0.1mm.
b) Over the remainder of the surfaces the clearance between the surfaces
does not exceed 0.3 mm.
Where web stiffeners are designed for full bearing on either the top flange or
the bottom flange or both, atleast half the stiffener shall be in positive contact

with the flange. The remainder of the contact face could have a max. gap of
0.25 mm.
1.8.64 Depth of Members

Acceptable deviation from the specified overall depth as per 1S:7215 (1974)
is:
Upto and including 1000mm : 1.0 mm
Over 1000 mm : 2.0mm
1.8.65 Web Plates

An acceptable deviation from flatness in girder webs in the length between
the stiffeners or in a length equal to the girder depth shall be:
Upto 500 mm depth : 0.5 mm

Over 500 mm & including 1000 mm : 1.0 mm
Over 1000 mm : 2.0 mm
1.8.66 Flange Plates
A reasonable limit for combined warpage and tilt on the flanges of a built-up
member is 1/200 of the total width of flange or 2 mm whichever is smaller
measured with respect to centerline of flange.
Lateral deviation between centreline of web plate and centreline of flange

plate at contact surfaces measured as the difference δ between diagonals of
nominal length L shall not be greater than L/1000.
1.8.67 End Milling
Column ends bearing on each other or resting on base plates and compression
joints designed for bearing shall be milled true and square to ensure proper
bearing and alignment. Base plates shall also have their surfaces milled true
and square.
1.8.68 Steel Girder & bridges
Tolerances for fabrication of steel structures shall be indicated in the

fabrication drawings and shall be in accordance with IRS - Specification for
fabrication and erection of steel girder & bridges & loco turn tables (B1-
2001).
Below are, for reference, extracted from Appendix – II of this Specification:-




1.8.69 Quality Control
In order to exercise proper control of the quality of the welding, Contractor shall
enforce methods of control as tabulated below:
Purpose Control subjects Methods of control

1 2 3
1. Control of Quality control of Weldability test to determine the
welding electrodes, welding wire, Technological properties if materials.
Materials and flux and protective gases
basic metal Mechanical test of weld metal
quality Checking of quality and
Weldability of the basic Metalographical investigations of
metal and welded members welds macro-structure and
microstructure
Checking of weld metal resistance for

intercrystalline corrosion. Study if
weld metal
solidity by physical control methods.
Mechanical tests, metalographical

investigation & checking of welded
joints by physical control methods
2. Checking of Welding of specimens for Checking of assembly quality
welders quality determination &centering of welded members
qualifications

3. Control of Control of assembly Checking of welding equipment

welded accuracy conditions.
joint quality and technological welding
process Checking correctness of welding
procedure.
Visual examination of welds
1.8.70 Tests & Testing Procedures

Agency for testing of weld shall be approved by the Engineer prior to testing.
1.8.71 Visual Examination

The contractor shall conduct visual examination and measurement of the
external dimensions of the weld for all joints. Before examining the welded
joints, areas close to it on both sides of the weld for a width not less than 20
mm shall be cleaned of slag and other impurities. Examination shall be done
by a magnifying glass which has a magnification power of ten (10) and
measuring instrument which has an accuracy of + 0.1 mm or by weld gauges.
Welded joints shall be examined from both sides. The contractor shall
examine the following during the visual checks.
i) Correctness and shape of the welded joints

ii) Incomplete penetration of weld metal.
iii) Influx
iv) Burns
v) Unwelded craters
vi) Undercuts
vii) Cracks in welded spots and heat affected zones
viii) Porosity in welds and spot welds
ix) Compression in welded joints as a result of electrode impact while
carrying out contact welding
x) Displacement of welded element
The contractor shall, document all data as per sound practices.
1.8.72 Mechanica1 Test

The Contractor shall carry out various mechanical tests to determine
weldability, metal alloyability, nature of break, correct size and type of
electrodes, degree of pre-heat and post-heat treatment. The type, scope and
sample of various mechanical tests shall be determined in agreement with the
purchaser. The number of tests conducted shall depend on the result obtained
to satisfy the Engineer that the correct type and size of electrode, degree of
pre-heating and post-heating and weldability of metal are being followed.
1.8.73 Dye Penetration Test

All welds shall be tested by “Dye Penetration test” as per current practices.
1.8.74 Radiography Test

Radiography test shall be conducted by the contractor to determine gas

inclusion (blow holes, hollows) slag inclusion, shallow welds and cracks for
25% lengths all butt joints.
Before conducting the examination the welded joints shall be cleaned of slag
and scales and visually examined. The welds shall be marked into separate
portions depending on the length of photograph. The length of photograph
shall be such as to ensure that there are no distortions and shall reveal the
defect correctly. The length shall not be more than 0.75 of the focal distance
and the width of the photograph would depend on the width of the welded
joint plus 20 mm on either side of the weld. The cassette with film shall be
protected by sheet of lead or equivalent of proper thickness against incidental,
diffused and secondary radiation.
The direction of the ray with relation to the film shall be as specified
hereunder.
Welds of butt joints without edge slopes with edge processing shall be
examined by central ray directed at right angles to the weld.
In special cases examination of welds with inclined rays directed along edge
slopes may be permitted by the Engineer.
Lap joints shall be examined by directing rays at 45 degree to the bottom

plate. Welds in T-joints without any edge preparation shall be examined by
rays directed at 45 degree to the weld. Angle welds in lap and tee-joints shall
be examiner by the rays in opposite direction i.e. the film will be on the side
of the weld. Weld in angle joints shall be checked by directing ray along the
bisector of the angle between the welded elements. Opposite direction of the
ray and location of the film may also be permitted by the Employer.
1.8.75 Ultrasonic Test

Ultrasonic test shall be conducted by the contractor to detect gas inclusion
(pores), slag inclusion, shallow welds, cracks, lamination and friability etc.
Prior to starting of ultrasonic test the welded joint shall be thoroughly cleaned
of slag and other material. Surface of the basic metal adjacent to welded joint
on both sides shall be mechanically cleaned by the grinder or a metal brush to
provide the contact of the whole ultrasonic probe surface with surface of
basic metal. The width of the clean surface shall be as directed by the
Engineer. The welded joint then shall be covered with a thin coat of
transformer oil, turbine or machine oil to ensure acoustic contact. The joints
so treated shall be marked and the marks shall be entered into the
documentation, subsequent to this, ultrasonic test shall be carried out as
directed by the Engineer. At least 50% of weld shall be tested by ultrasonic
testing.
1.8.76 Load test of Steel Truss span

The steel open web girder spans shall be load tested to prove the proper
camber provided while fabrication, as under:
(1) In Un-pre-stressed open web girders spans, the camber of the main
girders and the corresponding variations in length of members shall be

such that when the girders are loaded with full dead load plus 75% of
the live load without impact producing maximum bending moment,
they shall take up the true geometrical shape assumed in their design.
(2) Where girders are pre-stressed the stress camber change should be
based on full dead load and live load including impact.
1.8.77 STRUCTURAL STEEL SPECIFICATIONS - ERECTION

General
1. The Contractor shall submit for approval of the Engineer a full
description of his proposed erection method including sequence of
erection, use of temporary supports, connection details and erection
camber diagram and design calculations covering various stages of
erection process.
2. No detailed erection or shop drawings for temporary structures will be

accepted for examination by the Engineer unless the same, have first
been completely checked by the Contractor's qualified structural
engineer and are accompanied by an erection plan showing the location
of all pieces detailed. The Contractor shall check and ensure that
detailing of connections is carefully planned to obtain ease in erection of
structures, including field-welded connections and/or bolting.
3. No erection work shall be started by the Contractor without prior

approval of Engineer on the relevant drawings. Approval by the
Engineer of any of the drawings shall not relieve the contractor of his
responsibility to provide correct design of connections, workmanship, fit
of parts, details, materials and errors or omissions of all work shown
thereon.
4. Drawings, for approval, shall be submitted by the Contractor in an

orderly manner commensurate with erection sequence and approved
construction programme.
This Specification covers the delivery to site, storage and erection of
structural steelwork at site.
This includes plant and equipment requirements, installation of fabricated
steel work in position and grouting all complete as per drawings,
specifications and other provisions of the Contract.
Submittals
5. Ref. Specification for Structural Steelwork –General
6. The contractor shall submit for approval a full description of his

proposed erection method including sequence of erection, use of
temporary supports, connection details and erection camber diagram and
design calculations covering various stages of erection process.
Delivery, Storage & Handling

1. Before the shop assembling is dismantled, all members and sections

shall be appropriately marked with paint or grooved with their
identification numbers as detailed in shop drawings.
2. The Contractor shall deliver the fabricated structural steel materials to

site, with all necessary field connection materials, in such sequence as
will permit the most efficient and economical performance of the
erection work. As per scheduled programme, the Engineer may, at his
discretion prescribe or control the sequence of delivery of materials.
3. Fabricated parts shall be handled and stacked in such a way-that no

damage is caused to the components. Measures shall be taken to
minimize damage to the protective treatment on the steelwork. All work
shall be protected from damage in transit. Particular care shall be taken
to stiffen free ends, prevent permanent distortion and adequately protect
all machined surfaces. All bolts, nuts, washers, screws, small plates and
articles generally shall be suitably packed and identified.
Plant and Equipment

All erection tools and plant & equipment proposed to be used shall be
efficient, dependable and in good working condition, and the suitability and
adequacy of such shall be determined by the Engineer. The Contractor shall,
in his technical proposal submittal, specify the plant and equipment proposed
by him for erection of structural steelwork at Site.
Storage
Materials to be stored shall be placed on skids above the ground and shall be
kept clean and properly drained.
Method and Sequence of Erection

The method and sequence of erection shall have the prior approval of the
Engineer. The contractor shall arrange for the most economic method and
sequence consistent with the drawings and Specifications and such
information as may be furnished to him prior to the execution of the Contract.
The erection of steelwork shall be planned so as to ensure safe-working
conditions at all times. The Contractor shall be solely responsible for
enhancing the safety of his construction activities at Site.
Assembly & Erection

1. During erection, the members and sections shall be accurately
assembled as shown on the approved shop drawings and any
matchmarks shall be followed. The material shall be carefully handled
so that no sections will be bent, broken or otherwise damaged.
Hammering which will damage or distort the members shall not be
done. Bearing surfaces and surfaces to be in permanent contact shall be
cleaned before the members are assembled. Splices and field
connections shall have one half of the holes filled with bolts and
cylindrical erection pins (half bolts and half pins) before bolting with
high-strength bolts. Fitting-up bolts shall be of the same nominal
diameter as the high-strength bolts, and cylindrical erection pins shall

be 1 mm or larger.
2. The correction of minor misfits involving harmless amounts of reaming,

cutting and chipping will be considered a legitimate part of the erection.
However, any error in the shop fabrication or deformation resulting
from handling and transportation which prevents the proper assembling
and fitting up of parts by the moderate use of drift pins or by a moderate
amount of reaming and slight chipping or cutting, shall be reported
immediately to the Engineer and his approval of the method of
correction obtained. The contractor shall be responsible for all misfits,
errors and injuries and shall make the necessary corrections and
replacements.
3. The straightening of plates, angles, other shapes and built-up members,

when permitted by the Engineer, shall be done by methods that will not
produce fracture or other damages. Distorted members shall be
straightened by mechanical means or, if approved by the Engineer, by
the careful planned and supervised application of a limited amount of
localized heat, each application subject to the approval of the Engineer.
4. The responsibility in respect of temporary bracing and guys shall rest

with the Contractor until the structural steel is located, plumbed,
leveled, aligned and grouted within the tolerances permitted under the
Specification, and the permanent bracing/framing system has been
installed.
5. The temporary guys, braces, false work and cribbing shall not be the
property of the department and may be removed by the Contractor, with
the approval of the Engineer, without any charge, once the permanent
framing system has been installed to the satisfaction of the Engineer and
when the temporary bracing, guys etc. can be removed without any
potential danger/damage to the erected structure.
Setting Out
1. Positioning and leveling of all steelwork, plumbing and placing of every
part of the structure, with accuracy, shall be in accordance with the
approved drawings and to the satisfaction of the Engineer. The
Contractor shall check the positions and levels of the anchor bolts etc.
before concreting and ensure that they are properly secured against
disturbance during pouring operations. The Contractor shall remain
responsible for correct positioning and shall set proper screed bars to
maintain proper level. No extra payment shall be made on this account.
2. No permanent field connections by bolting shall be carried out until

proper alignment and plumbing guides have been attached.
Field Bolting
1. Bolts shall be inserted in such a way that they remain in position under
gravity, even before fixing the nut. Bolted parts shall fit solidly together
when assembled and shall not be separated by gaskets or any other
interposed compressible materials. When assembled all joint surfaces

including those adjacent to the washers shall be free of scales. They

shall be free of dirt, loose scales, burns and other defects that would
prevent solid seating of the parts.
2. Holes for turned bolts to be inserted in the field shall be reamed in the
field. All drilling and reaming for turned bolts shall be done only after
the parts to be connected are assembled. Tolerances applicable in the fit
of the bolts shall be in accordance with relevant Indian Standard
Specifications.
3. All high tensile bolts shall be tightened to provide when all fasteners in
the joint are tight, the required minimum bolt tension as per relevant
Indian Standard/Specification.
4. The manufacturer and use of high strength friction grip bolts shall
comply with the requirements of IS:3757 (1985).
5. Load indicating bolts or washers may be used, subject to the approval of

the Engineer.
Holes, Cutting and Fitting
1. No cutting of sections, flanges, webs, and cleats, rivets, bolts, welds etc.
shall be done unless specifically approved and / or instructed by the
Engineer.
2. The erector shall not cut, drill or otherwise alter the work of other
trades, or his own work to accommodate other trades, unless such work
is clearly specified in the Contract, or directed by the Engineer.
Wherever such work is specified, the Contractor shall obtain complete
information as to size, location and number of alterations, prior to
carrying out any work.
Drifting
1. Correction of minor misfits will be considered as permissible. For this,
light drifting may be used to draw holes together and drills shall be used
to enlarge holes, as necessary, to make connections. Reaming, that
weakens the member or makes it impossible to fill the holes properly or
to adjust accurately after reaming, shall not be allowed.
2. Any error in shop work which prevents the proper assembling and
fitting of parts by moderate use of drift pins and reamers shall
immediately be called to the attention of the Engineer, and approval of
the method of correction obtained. The use of gas cutting torches at the
erection site is prohibited.
Grouting
1. The positions to be grouted shall be cleaned thoroughly with
compressed air jet and wetted with water, and any accumulated water
shall be removed. Grouting shall be carried out under expert

supervision, takings care to avoid air locks. Edges shall be finished

properly.
2. Whatever method of grouting is employed, the operation shall not be

carried out until the steelwork has been finally leveled. Immediately
before grouting, the space under steel is thoroughly cleaned. Where
packing are to be left in place, they shall be placed such that they are
completely covered with grout.
3. The grout to be used shall be Non-shrink grout conbextra GP-2 of M/S

Fosroc or equivalent.
4. All steel in foundations shall be solidly encased in Portland Cement

Concrete of minimum characteristic strength at 28 days as specified in
the drawings, subject to a minimum of 35 N/mm2. A minimum cover of
100mm shall be provided to all steelwork where surrounding concrete is
in contact with soil.
Inserts And Embedments

Various steel inserts and embedments are required under the contract to be
fabricated, positioned and secured firmly into place inside the formwork prior
to concrete being poured. There are also requirements of jointing, threading,
bolting and welding inserts and embedments of different concrete and
structural steel elements in order to establish structural continuity and
connection. Great care shall be exercised by the contractor in executing all
aspects of the work related to inserts and embedments, including tolerances,
so that the final assembly of the concrete elements can meet satisfactorily the
continuity and contiguity requirements intended in the structure. After
fabrication of all inserts to be left in any concrete member such as precast
parapet & its in-situ connection with girder shall be hot dipped galvanized to
BS EN ISO 1461:2009 and BS 729:1971 requirements except that the
average coating weight for any individual test area is not less than 500
gm/m2.
Painting after Erection

1. Steelwork coated with rust inhibitor shall not be left exposed for a
period exceeding 15 days otherwise, such steelwork shall be re-cleaned
and re-coated with such finish until encased in concrete.
2. No steelwork with shop paint shall be left exposed at site for a period
exceeding that approved by the Engineer.
3. The surfaces required to remain unpainted at shop, shall be given a

protective coating after the structure is erected, leveled, plumbed,
aligned in its final position, and accepted by the Engineer. However,
touch up painting, making good any damaged shop painting and
completion of any unfinished portion of the shop coat shall be
progressively carried out by the Contractor.
4. Painting shall not be done in frost or foggy weather, or when humidity
is such as to cause condensation on the surfaces to be painted. Before,

commencing painting of steel, which is delivered unpainted, all surfaces

to be painted shall be dried and thoroughly cleaned from all loose scale
and rust.
5. All field bolts, welds and abrasions to the shop coat, and surfaces
delivered unpainted from fabrication shop, shall receive the full
protective treatment as specified in Table defined in painting
specifications before delivery to Site.
6. Surfaces, which will be inaccessible after field assembly, shall receive

the full-specified protective treatment before assembly. Bolts and
fabricated steel members, which are galvanised or otherwise treated,
shall not be painted.
7. The contractor shall be responsible for any damage caused to other

components of the structure including the substructure. In particular, he
shall take all necessary precautions to minimise concrete splash onto
completed steelwork or rust staining of concrete due to erected steel
work and clean and/or repair all stains and other damages to completed
work prior to tests on completion.
Final Cleaning up
Upon completion of erection, and before final acceptance of the work by the
Engineer, the Contractor shall remove, free of cost, all falsework, rubbish and
all temporary works, resulting from or in connection with the performance of
his work.

1.9 Cut and Cover Construction
1.9.1 General
(1) Cut and cover construction shall comply with the relevant
requirements of the Contract for temporary ground support including
elements to be incorporated into Permanent Works.
(2) Temporary ground support including elements to be incorporated
into the Permanent Works are described in Volume 4, Division H1
subsections 1.2, 1.4 & 1.5 of this Specification.
(3) Support by bracing, ties or anchors: are described in Volume 4,
Division H1, subsections 1.4 & 1.8 of this Specification.
(4) Excavation and backfilling: are described in Volume 4, Division H1,
subsection 1.2 of this Specification.
(5) Reinforced concrete construction is described in Volume 4, Division
H1, subsections 1.5 of this Specification.
(6) Vibration recording devices shall be provided to monitor for vibrations
which may cause damage to the proposed constructions and EBS. These
devices shall be installed at intervals and locations to provide
comprehensive coverage of the Works. Unless otherwise directed by the
Fire/Life Safety Authorities/Agencies, these devices shall record ground
accelerations generated by the Works to ensure that these accelerations
do not exceed the values set by the Relevant Authorities or those
determined by the Contractor for the stability and safety of the
Temporary and Permanent Works and adjacent EBS and as accepted by
the Engineer.
1.9.2 Waterproofing
1.9.2.1 General
Waterproofing System
1. The contractor shall include details of his intended waterproofing methods in his
design submissions for acceptance by the Engineer.
2. Manufacturer’s literature and detailed drawings shall be provided where necessary

to confirm the suitability of the proposed details.
3. Specification covers the material, workmanship, testing, design life and warrantee
(minimum 15 years) requirements for whole of the waterproofing system,
including membrane, water-stops, injection hose and other elements as necessary
to keep water out of the structure and to protect the structure against ground water.
4. In order to have uniformity of whole of the waterproofing system, manufacturer for

the supply of all necessary materials for the associated works, including any
durability enhancing admixtures and experience subcontractor who is approved by
manufacturer for the application of entire waterproofing system shall be deployed
with approval of Engineer. All the accessories and other auxiliary products to be
used as per system specification of the manufacturer must be also supplied by the

same manufacturer with a declaration of manufacturing mentioning the factory of

origin (local / overseas). The chosen manufacturer must also have an established
set up with registered office and plant in India as “Make in India” preference.
5. The Tenderer shall submit the full details about the details of manufacturer of the
waterproofing system including name, experience in the field of waterproofing
system particularly in underground metro station and cut & cover tunnels with
complete international in general and also in specific to projects in Asia and India.
This information shall include: project name, type / grade of material used,
quantity of material used, name of client, name of consultant, name of contractor &
subcontractor. The manufacturer shall have expertise record of at least 15 years in
substructure waterproofing for metro rail project and necessary work completion
certificates are required to validate his expertise for acceptance by Engineer.
6. The Tenderer shall submit comprehensive technical proposal of the entire

waterproofing system including product data for each type of waterproofing
specified, manufacturer’s written instructions, technical data, test requirements,
working / workshop drawings showing location and extent of waterproofing,
details of joints, penetrations; and other terminal conditions for base slabs, walls,
roof slabs, diaphragm-walls, piles heads, construction joints, dewatering pumps
location/pipes etc or similar as required by an Engineer.
7. The Tender shall provide a tentative quality control, testing and inspection plan.
8. All components of water proofing system shall be provided by one manufacturer
1.9.2.2 Waterproofing Application

Waterproofing material shall be supplied and installed only by the manufacturer of
the products or his approved applicator with approval by Engineer. The contractor
shall submit a method statement, prepared in conjunction with the applicator and
endorsed by the manufacturer of the material, describing the details of the
waterproofing works including protective measures at all stages. Details shall
include manufacturer’s printed approved specifications and Installations
instruction, including procedures and materials for water protection, compatibility,
jointing, bonding, repair and testing.
Contractor shall arrange to depute one competent engineer from the manufacturer
during the whole waterproofing application period to supervise and certify the
quality of work.
The finalization of manufacture is subject to final approval by Engineer
1.9.2.3 Water proofing – stations, cut cover structures

Waterproofing treatment for the base slabs to be done by protective fully bonded
membrane and its concrete having crystalline growth admixture, vertical concrete
walls (In-situ or D-wall or any other type) should have crystalline growth
admixture including liquid cold sprayed polymer applied in two layer and roof
slabs are done by providing liquid cold sprayed polymer applied in two layers.
A high standard of water-resistance to the station structure & C/C tunnels will be

required. No round water leakage shall be acceptable. Water resistance shall be

achieved by in-situ concrete designed and constructed to water-resisting principles
in addition to the external waterproofing.
An external waterproofing material shall be provided over all external surfaces of
the structure to ensure no leakage occurs. Pre Engineered provision for the
rectification measures to plug the leakage, at later date, are also to be made, which
should be part of the approved system and available in submission through
method statement of the manufacturer and shop drawing.
Detailing of structures shall include provision of splays, chamfers and fillet as

appropriate to facilitate the laying and performance of waterproofing material to
all junctions of slabs and walls. All waterproofing membrane to be protected with
minimum 75mm thick PCC (M20) as per membrane manufacture’s approved
method.
The grade of concrete, treatment of construction joints, areas of slab pours and
external elements shall be chosen such that the required standard of water-
resistance can be achieved.
1.9.2.4 Concrete joints
Notwithstanding the provision of waterproofing material, where specified, the

contractor shall construct his concrete works so as to minimize the likelihood of
water penetration. Before placing new concrete against concrete that has already
hardened, the face of the old concrete shall be treated in accordance with
specification.
All construction joints at Roof slab, Cast In-Situ walls should be treated with
crystalline growth admixture/materials before application of spray applied liquid
polymer membrane. Also all construction concrete joints should have approved
water stopper before its casting to prevent any kind of water leakage through
such joints.
Construction joints shall be cast with continuity reinforcement capable of

controlling early-age thermal movement to 0.2mm or below. Should the joint be
found to leak or exhibit moist patches, the affected concrete shall be rectified by
injection of resin material (either through the installed ground tube, or if
necessary from the concrete surface), breaking out and recasting, or other
methods of sealing within the concrete. Inside rendering will not be accepted as a
method of making watertight.
1.9.2.5 Construction joint with Re-Injection Hose system
The injection material shall be used must be very low viscosity (<40 cpc at 20
ºC), capable of being flushed out by vacuum for future re-injection and of poly
acrylic resin or similar approved material.
Injection hoses or channels shall be capable of re-injection to seal joints if

leakage persists or reappears at a later date. The chosen re-injectable system shall
be demonstrated to have the reinjection capability for minimum two times with
vacuum/water cleaning through an actual mock up as per the separate method
statement for a mock up by the manufacturer.
The injectable material must also be manufactured and applied by approved
applicator of the same manufacturer of the hose system for total compatibility as
a system.
The Contractor shall provide full details of his proposed injection hose or channel
system for the Engineer’s review and acceptance.
1.9.2.6 WATERPROOFING AT CONSTRUCTION JOINTS
Construction joints are to be constructed as follows:
a) All construction joints in external slabs and walls will be provided with PVC
water stop located at the center of the element.
b) In the top & bottom surface of Roof, Base, Concourses and any intermediate
level slabs at junctions with diaphragm walls, a 25x25mm recess will be cast in the
slab and subsequently filled with a high performance water stop grout of the
crystalline growth type.
c) All construction joints in external slabs and wails will be cast with a 25x25
recess on the outer face (except the base slab where it will be provided on the
upper face). The recess will be filled with a high performance water stop grout of
the crystalline growth type.
d) All construction details and materials are to be submitted to the Engineer for
approval.
1.9.2.7 Base Slab, Walls and Roof Slab waterproofing with bonded membrane
Performance Requirement
The performance of the waterproofing shall be from a single manufacturer long-

term engaged in manufacturing waterproofing having an expertise record of at
least 15 years in substructure of Metro Projects having proven waterproofing
system. All components and elements, which are needed to make the structure
watertight, shall be proven to work together. There shall be a single source of
responsibility and performance of the products. Specifically, material and water
stops shall be manufactured out of virgin raw materials only from the same
formulation of raw material. The manufacturer shall confirm full and proven
compatibility of the entire waterproofing system in writing. The waterproofing
system provided shall be installed without damage and protected against
construction operations. The waterproofing system shall be designed to be fully
effective over the design life of the structure and shall demonstrate to be designed
to fulfil all requirements according to the specification. All materials shall be
compatible with other materials. Particular attention shall be paid to the
compatibility of interfaces and junctions with adjacent structure.
Shop drawings of integrated waterproofing system shall be prepared by
Contractor, manufacturer, applicator and endorsed by DDC of Contractor and

submit to Engineer for its approval before start of work.
Waterproofing to Base Slab of underground structures
a. General
Waterproofing treatment for the base slabs to be done by as per below mentioned
membrane and its concrete having crystalline growth admixture type for entire
element. The admixture shall have a proven track record of successful application
in similar conditions. Membrane shall be applied to the full thickness of the base
slab and full extend to the sidewalls of sumps and similar depression within the
base slab so as to form a continuous watertight surface.
Waterproofing of Base slab shall have Synthetic fully-bonded FPO (Flexible
PolyOlefins) waterproofing sheet membrane, laminated with non-woven fabric
and Pressure sensitive adhesive for waterproofing underground structure,
Membrane shall be executed upto grade slab PCC level. The membrane shall be
CE Certified EN 13967, UV resistant having total thickness 1.7 mm FPO (1.2mm
thickness of FPO Sheet) thickness, Water tightness (no lateral migration)
according to following test Parameters:
Property Testing Code Parameter

Sr. no
01 Water tightness ASTM D5385 ≥ 7BARS
02 Water Vapour Permeability EN 1391 (Method B) Value declared by
Manufacturer
03 Tensile Strength EN 12311 >Longitudinal 8 /
Transverse 9
04 Elongation at Break EN 12311 Longitudinal > 500 /
Transverse .>
700
04 Durability Water tightness EN 12961 Impermeability after 24
after artificial hours
ageing
05 Impact resistance EN12961 Method A / Method B as
declared by
manufacturer
The membrane shall be resistant to root penetration according to CEN/TS 14416.

The membrane should be resistant to moisture and impermeable to methane gas as
per ISO. Membrane overlap joints and other detailing connections are sealed and
bonded using integral self-adhesive strips tapes on membrane. The width of
membrane should not be more than 1 mtr so as to be easy for applications.
FPO membranes must be installed with the PP fiber side upwards and positioned
so that it will be in direct contact with the structural concrete when it is poured
Overlapping of Membrane:
Overlap the sheets lengthways so that the self-adhesive edges hold them in place.
Use Self Adhesive (SA) Tape as per manufacturer to join the ends between each
sheet. Before placing the steel, reinforcement and pouring the concrete, make sure
all the joints are well bonded. If any of the joints are poorly bonded, apply more
Fully Bonded Tape to form a better bond. For end to end lap min 500 mm
overlapping is required.
b. Trials
Prior to construction, trial mixes are to be conducted under the supervision of the
Engineer or his Representative and with the manufacturer present to confirm that
the proposed mix conforms to strength, w/c ratio, slump and other requirements.
The trial mix concrete shall further have an average water permeability coefficient
when tested at 28 days of not greater than 5x10-13 m/s under 5kgf/cm2 and an
average penetration depth not greater than 15mm as measured by DIN 1048 Part
5:1991.
Waterproofing to Roof slabs

Roof slab concrete shall have crystalline growth admixture. The spray applied
polymer membrane of Polymeric based (Pure Polyurea system) over constructed
roof slab shall be suitable for use in an ambient temperature range not greater than
30-degree C. It shall allow diffusion of water vapor to prevent any build up
pressure between the membrane and substrate.
The polymer membrane shall meet or surpass the following requirements: -
Total Membrane Thickness 2.5mm dry film thickness (in two

equal layers)
Tensile Strength 20.0 MPa minimum in any of the
three orthogonal planes of
the membrane
Membrane Elongation Strength at Break >300%
Peel adhesion to concrete 2.0 MPa minimum
Static crack bridging (tested to recognized 2.5mm minimum
international standard acceptable to
the Engineer)
Density at 25 C 1.01g/ml
Tear Resistance >80 N
Temperature -40º C to 180º C
The cured membrane shall be chemically resistant to the effects of hydraulic

fluids, diesel fuel and diluted mineral acids etc.
The substrate shall be prepared and primed in strict accordance with the
manufactures recommendations and requirements. The membrane shall be of a
thixotropic nature and cold applied to ensure consistent thickness is achieved over

all substrate irregularities.
The materials used must be based upon resin systems that do not react with
moisture although the substrate should be dry during application, the polymer
membrane shall be continued down the vertical side of the walls.
All components of water proofing system shall be provided by one manufacturer.

All materials must be supplied to site in unopened packaging, with batch numbers
marked and corresponding manufactured certificates of conformity, and must be
used within the products shelf life. All components of the system exposed to rain
within the curing period shall be replaced unless agreed otherwise by the
Engineer.
The membrane wet film thickness should be checked every 100 square meter
during application of each layer, using a pin or comb gauge. Destructive testing to
measure dry film thickness shall be carried out on the cured membrane every 400
square meter or at every working shift or near construction joint of cast roof slab
panel, whichever occurs Sonner, and shall be made good to the satisfaction of the
Engineer.
Tests to the acceptance of the Engineer shall be carried out on the cured
membrane to identify any discontinuities in the membrane and to prove the
integrity of the membrane.
Protection of membrane before Backfilling over Roof slab:

i) Placing 7-8 mm thick dimple drain board onto membrane.
ii) After that, Laying the HDPE sheets of 500 micron over the board and overlap
of Joints around 80-100 mm and sealing with masking tape ,before laying of the
M-20 screed.
Waterproofing to Concrete Walls

All concrete walls should have crystalline growth admixture (refer to Clause
1.5.1.6 B) including liquid cold sprayed polymer applied in two layers, other
parameter to be followed as per roof slab waterproofing.
Sealing of Pipe /sleeves Penetration in Retaining Walls:

The surface of the cut-out hole & pipe shall thoroughly be prepared to ensure the
removal loose particles & dust etc. including abrading the pipe pouter surface to
ensure proper bond to fill the material. it should be ensured that the annular space
around the pipe should be of min 50mm to allow free flow and proper filling with
non-shrink grout, Providing & supplying swellable sealant shall be squeezed out
and applied and fixing the slurry tight shuttering and laying high strength non-
shrinkable non-shrink.
Sealing of Tie Rod Holes

Sealing of tie rod holes in retaining walls by filling dual compensated
cementitious mortar Non-Shrink Mortar.
Diaphragm Walls and Slab junctions:

Diaphragm wall concrete shall have crystalline growth admixture. All leaks in the
diaphragm wall shall be sealed. At junctions with the slabs as a minimum 25x25
recesses filled with water stop grout will be formed at top and bottom surface of
slabs. Additional protection in the form of reinject able grout tubes, etc. shall be
considered by the contractor.
Waterproofing of NATM tunnel and Cross-passage

NATM tunnel
In NATM tunnel, FPO membrane or spray applied waterproofing membrane (as per
parameter mentioned above) as per decision of engineer shall be placed between the
initial support and the final concrete lining. No concreting of final support shall take
place before inspection of the initial support surface and the waterproofing membrane
by the Engineer.
NATM tunnel permanent concrete lining shall have crystalline growth admixture
and all construction joints shall be treated with crystalline growth material. At the
junction of NATM tunnel with the other part of station/Tunnel, waterproofing
arrangement shall be finalized and approval shall be taken from Engineer before
its execution
Cross passage
FPO membrane or spray applied waterproofing membrane (as per parameter
mentioned above) as per decision of Engineer shall be placed between the initial
support and the final concrete lining.
Permanent concrete lining shall have crystalline growth admixture and all
construction joints shall be treated with crystalline growth material.
If cross-passage is constructed by Box-pushing technique, concrete shall have

crystalline growth admixture. Water proofing arrangements for its interconnection
with the main tunnel shall be taken up as per the decision of Engineer.
Water proofing for Box-pushing section

The precast member of Box-pushing segment shall have crystalline growth
admixture in concrete and its joints between two Box shall have epoxy or resin
based spray applied or latest available water proofing system as per decision and
approval of Engineer.
Shop drawings of integrated waterproofing system for NATM, Cross passage and
Box-pushing etc. shall be prepared by Contractor, manufacturer, applicator and
endorsed by DDC of Contractor and submit to Engineer for its approval before
start of work.

1.9.2.8 Water stops

All water-stops used in the Works shall be of PVC material and of a type
appropriate to the location. All joints shall be made with molded or prefabricated
intersection pieces properly jointed in accordance with the manufacturer's
instructions. The water-stops having width of 250mm shall be installed at center
of element so that they are securely held in their correct positions whilst the
concrete is being placed. No holes shall be made through any water-stop except
where provided for by the manufacturer.
It shall have following properties:
Property UOM Requirement

Tensile strength Mpa ≥15.0 N/mm²
Elongation at break % ≥300%
(%)
Shore A hardness - 80±5
Density gm/cc 1.4g/cc (±0.1 g/cc)
Tear strength N/mm2 ≥15 N/mm²
*or equivalent
1.9.2.9 Surface preparation
Surface cleaning
Before application the material, the surface shall be thoroughly cleaned using
compressed air (without oil contamination). All other surface contamination, such
as dust, oil, loose particles, etc., shall be removed. Any external curing agent
applied to the surface shall be thoroughly removed, using a method approved by
the Engineer, before application of the membrane.
No laying shall be commenced until all rough edges and excrescencies have been
removed from the surfaces to receive the material. Surface depressions shall be
filled in accordance with consented –to procedures and the filling allowed to set.
The surface to be waterproofed shall be thoroughly cleaned, dried and swept, and
kept clean and dry at all stages until the work is complete.
The surface of structures which are to be waterproofed are to be primed with the
appropriate primer to ensure good adhesion between the structure and the
waterproofing medium.
1.9.2.10 Application Method
For Horizontal & Vertical application

The cement concrete (PCC/RCC) shall be finished in a smooth finish, free from any
projections.
1.9.2.11 Testing and quality assurance
The contractor shall examine substrate surfaces to receive works of this section and
ensure that works done as part of the works of other sections is complete and that
there are no conditions which will adversely affect the performance of the
waterproofing works. Waterproofing works must not be commenced until
unsatisfactory conditions have been corrected. Commencement of works of this
section implies acceptance of surfaces and conditions.
The contractor has to follow in any respect the approved quality control and
management process in order to fully comply with the site installation, testing and
inspection procedure given by the Manufacturer and approved by the Engineer
prior to the commencement of the works.
The contractor in coordination with and delegation to the applicator or

manufacturer shall maintain full and complete documentation of the progress of the
work, testing protocols and inspection certificates. Special attention shall be given
to the detailed and complete documentation of the progress of the work.
All testing shall be carried out by the contractor in compliance with the written
instructions by the Manufacturer and the Engineer.
1.9.2.12 Inspection and acceptance
The waterproofing shall be mutually inspected by the contractor and the Engineer
and signed off for acceptance.
Any finished and tested section of the waterproofing system shall be finally
inspected by the Contractor and the Engineer prior to covering. Prior to any
concreting work the visible parts of the waterproofing system like water stops,
injection flanges etc. shall be thoroughly cleaned and inspected for any damages by
the applicator. Any damage or unclean area shall immediately be reported by the
contractor to the Engineer. Any remedial work shall be carried out and finally
inspected prior to any other work.
All the cost related to testing for inside/outside the project, the inspection by
Engineer/Employer shall be borne by the Contractor.
1.9.2.13 Warranty
All waterproofing system shall be warranted from the date of completion of the
works against all defects for minimum period of 15 years from the work
completion date. The warranties shall cover the whole of the waterproofing
systems and shall be given jointly and severally by the contractor,
supplier/manufacturer and applicator.
1.9.2.14 Safety and Environment

• It is the duty of the contractor/sub-contractor engaged with the application
of waterproofing to produce and implement a risk assessment prior to
commencing the work.
• Suitable protective clothing, gloves and eye/face protection should be worn
all times by the application as per guidance set by manufacture.
• Adequate ventilation to be provided during epoxy application .
• The zone (radius of m) of spray waterproofing is to be isolated for
workmen and public executing activities other than waterproofing and these
without safety gears.
1.9.2.15 Environment factor
Storage
Storage of epoxy material chemicals need to be in a dry and air conditioned store
as per guideline provided by manufacture.
Cleaning
All equipment must be thoroughly cleaned after each working shift otherwise the
material performance will be reduced and excessive dust may occur during
spraying.
Cleaning after each shift should be done with compressed air, removing all
powder remains, hence leaving the machine dry as much as possible. Course dry
sand (0-4 mm) pumped through the entire equipment can remove spray material
build-up. However, inspection must be carried out to ensure all parts are clean.
If air and sand is not sufficient to clean the machine completely, the machine
should be dismantled completely and cleaned with a high pressure
cleaner(water). It is essential that machine is left dismantled, allowing the parts to
dry before reassembling the machine.
The nozzle system should always be completely dismantled and cleaned with
after each shift, and attention paid to the injector section of the nozzle. At the end
of the job we recommend a thorough cleaning with high pressure cleaner
followed by a complete drying of the machine before re-assembly.
Chemical hazard
Adequate checks need to be made to ensure the chemicals used in waterproofing

material shall not have any adverse effect on local flora & fauna.
Disposal of water from waterproofing application
The contractor shall not dispose any waterproofing materials, including liquid
waste from cleaning of equipment’s to any water body and public drainage
system. All these shall be contained and disposed in accordance with a plan
produced by the contractor approved by the engineer.
1.9.2.16 Fillers and sealant to expansion joints
All material used to fill expansion joints shall be such that they will accept the
calculated movements of the joints without extrusion and shall not shrink away
from either surface of the joints. Consented to backing strips and fillers shall be
used in accordance with the manufacture’s recommendation.
Where joints are required to be filled with consented to single component, the
material shall comply with BS 5254 or BS 5212.
The appropriate sealant grades shall be used for horizontal and vertical joints, and
joint shall be thoroughly cleaned and primed with the appropriate primer before
applying the sealant. The sealant shall be of a colour to match as nearly as
possible the colour of the adjoining surfaces where it is to be permanently
exposed. Application of primer and sealant materials as per the recommendations
of the manufacturer and/or the technical data sheet of the product is a must and
the primer must be manufactured by the same manufacture of sealant.
The sealing material shall be used and applied strictly in accordance with the
manufacture’s instructions. The contractor’s attention is drawn to the
undesirability of the sealant being smeared over the adjacent surfaces, and
appropriate precautionary measures, including the use of masking tape, shall be
taken to avoid this. The caulking gun and other tools for installation should be as
per the manufacturer’s recommended list of equipment’s and tools.
Mode measurement:
Measurement for payment shall be made on area basis on square metre and the
area shall be calculated by simple geometrical concepts and formula of the
surface area of the structural member on which the waterproofing treatment has
been applied as per engineer’s approved drawing.

1.10 Shaft Excavation in Rock
1.10.1 General
This section is applicable to construction of shaft and cut and cover station in
rock, but not for excavation of bored and NATM tunnels in rock,
1.10.2 Excavation Method

(1) The Contractor shall provide to the Engineer full details of the proposed
rock excavation methods for ‘Notice of No Objection’, at least 28 days
before the commencement of excavation. Similarly, the Contractor
shall submit his plans for methods for monitoring, particularly vibration
adjacent to the EBS .
(2) Blasting and other methods (where blasting is not permitted)
such as mechanical, pneumatic or hydraulic plants or expansive
chemical agents etc. are expected to be used in rock excavation.
1.10.3 Rock Stabilization

(1) The rock stabilization measures should be based on rock joint
mapping result carried out by the Contractor and agreed by the
Engineer. The rock joint mapping results shall be kept on the Site
and submitted to the Engineer within 48 hours after the excavation.
The name of the personnel who will carry out mapping shall be
submitted to the Engineer for Notice of No Objection.
(2) The Contractor shall carry out rock stabilization measures with
minimum delay after the excavation of each round.
(3) All rock stabilization proposals shall be submitted to the Engineer for
Notice of No Objection.

1.11 Blasting
1.11.1 General
1.11.1.1 Definitions
(1) “Controlled blasting” means that a designed drill and charging
pattern has been noticed and will incorporate one of the following
techniques.
(2) "Pre-splitting" means drilling a line of closely spaced parallel holes of
appropriate diameter along the excavation surface, charging the holes
with an appropriate amount of explosive and detonating these holes
simultaneously, prior to the main production blast, to shear the rock
along the line of drill holes.
(3) "Smooth blasting" means the drilling of a line of closely spaced
parallel holes along the excavation surface, with a suitable
burden/spacing ratio, loading all the holes lightly with an appropriate
amount of explosive and detonating all these charges simultaneously,
after the detonation of the main production blast.
1.11.1.2 General Requirements

(1) All blasting operations shall be conducted under the direction of a
certified blaster. Evidence of blaster certification shall be carried by
blasters or shall be on file at the Engineer office during blasting
operations. The blaster shall be present at the firing of a blast at all
times.
(2) A blast design shall be submitted to the Engineer for ‘Notice of No
Objection’ prior to any blasting operations. The blast design will
include sketches of drill patterns, delay times and blasting mats and
shall indicate the type and amount of explosives to be used, critical
dimensions, and the location and general description of structures to be
protected, as well as an outline of design factors to be used, which
protect the public and meet the applicable airblast and ground vibration
standards. The Work shall be programmed so as to minimize blasting
adjacent to previously constructed sections of the Works.
(3) Every precaution including the use of blast mats, timber boarding
or other means shall be exercised to protect the Works and
persons, animals and property in the vicinity of the Site. The
Contractor shall accept responsibility for all injury or damage
occasioned by any blasting operations and shall make good such
damage without any additional payment.
(4) The Contractor shall, in particular, note the requirement that he must
limit to the maximum extent practicable the spillage of material from
surface excavations, whether by blasting or other means. To this end
the Contractor shall take all necessary precautions including, if
necessary, covering the rock prior to blasting with sufficient loose
material to prevent the blasted material being thrown into the
adjacent areas. If the Engineers is of the opinion that insufficient
precautions are being taken to minimize the spillage of material, he may
instruct the Contractor to adopt further measures to reduce the
spillage. No additional payment will be made to the Contractor for any
such measures required and extension of time will not be granted.

1.11.2 Use of Explosives

(1) Explosives shall not be used without notice of No objection from the
Engineer and Only after the appropriate permits have been obtained.
Notice of No objection for blasting does not remove the contractors
liabilities or responsibilities to ensure that his method of blasting is safe
and complies with all statutory and imposed limitations.
(2) A Relevant authority will issue all blasting permits and related
permissions pertaining to storage, transportation, control and use etc.
the permits will include local /national requirements and other
requirements of the international fire code and other international
standards for explosive and blasting procedures, explosives training,
blasters handbook and safety practice manual etc. All explosives and
related material shall be in conformity with the requirements of the
Relevant authority having jurisdiction and the specifications contained
herewith. Blasting will not be permitted close to any building structure
without appropriate monitoring systems and no objection from the
Engineer.
(3) Both cartridge and bulk explosives may be used where appropriate.
(4) Only sufficient explosives and detonators may be brought on to the Site
for immediate blasting requirements. Explosives and detonators
remaining unused after each blasting operation shall be disposed of, or
removed from the site.
(5) The contractor shall appoint a responsible person or persons to order
and receive explosives on the site. The name (s) shall be notified to the
Engineer.
(6) No persons other than those authorised by the Engineer shall approach
within 50m of the area being prepared for blasting, i.e. during
charging and firing of the blast holes. The Contractor shall inform the
Engineer of the names of his authorised personnel and his method for
excluding others.
(7) The Contractor shall provide an agreed system of warning and
preparing the general public and all Site personnel of an impending
blast by both audible and visual means and shall ensure that the blasting
area is cleared of all personnel immediately prior to blasting. This
system shall comply with all statutory requirements.
(8) The limits for air-overpressure and vibration monitoring together with
actions associated with the alert, alarm and action levels shall be
addressed in the Blast Assessment Report / Method Statement for the
(9) The Contractor shall use a lightning detector on site to assess the
potential risk of lightning risk during delivery, loading and charging
blast holes with explosives. The lightning detector shall be
capable of detecting thunderstorms.
(10) The Contractor shall check for stray electric current at the blasting site
prior to commencing charging.
(11) All blast air, exhaust gases and dust shall be filtered in an agreed
manner before being ventilated into the air exhaust system. A detailed
method statement will be required for seeking a Notice of No Objection
from the Engineer.

(12) Blast partition doors separating the Contractor's Working Areas from the
public and other operational areas shall be of adequate fire protection,
water tightness, weight, thickness and density to effectively reduce the
noise, water and dust transmitted from the Works and confine the
effects of the blast to acceptable levels. The effective damping mass
of the partitioning materials shall not be less than 30 kg/m2
1.11.3 Delivery of Explosives

(1) The handling of explosives including storage, transportation and
charging will be carried out in accordance with BS 5607 , ‘Code of
Practice for Safe use of Explosives in the Construction Industry’ and
IS 10386 Part 4 ‘Handling Storage & Transportation of Explosives’.
(2) The Contractor shall submit his proposal for explosives collection and
delivery for Notice of No Objection from the Engineer. The risk
assessment for the proposed arrangement shall be addressed in the
Blasting Assessment Report.
(3) The Vehicle shall not carry more than 200kg of explosives at any one
time or the figures agreed by the Engineer. Upon each delivery of
explosives, the Vehicle shall be escorted by the Contractor's appointed
Responsible Person(s) and armed guards and as agreed by the Relevant
Authority & the Engineer.
(4) The explosive container shall be secured to the body of the Vehicle.
(5) At least two serviceable fire extinguishers shall be installed on the
Vehicle.
(6) The Vehicle which has been fitted out to the above requirement is
required to be presented for inspection and agreed with the Engineer.
1.11.4 Blasting Trials

(1) The Contractor shall submit to the Engineer for Notice of No
Objection full details of the blasting trials at least 14 days before the
trials are carried out. Blasting trials shall be carried out for each
proposed blasting procedure to demonstrate that:
(a) the procedure is safe;
(b) the dust and noise created are within acceptable limits;
(c) the resulting maximum peak particle velocity and maximum
allowable vibration amplitude at locations stated in the Contract,
or instructed by the Engineer, can be satisfactorily predicted,
recorded and demonstrated to be within the prescribed limits, and
shall not adversely affect the safety and stability of adjoining
structures, installations and land, facilities and equipment;
and
(d) the specified tolerances for the final blasted surfaces and
formations can be achieved.
(2) Blasting trials shall be carried out in accordance with the blasting
procedure submitted to the Engineer. The location and size of blasting
trials shall have a Notice of No Objection from the Engineer. These
trials should not normally be part of the permanent works.
(3) Blasting trials shall be completed at least 7 days before the
related main blasting starts.
(4) Blasting trials for pre-splitting and other methods of controlled blasting
shall be carried out to form a face similar to the permanent works

design. The blasting trials shall be carried out on rock which has
similar properties to production blast areas and which is at least 6m
away from any permanent excavated surface, or at a distance agreed by
the Engineer.
(5) The blasting trials shall be sufficient to demonstrate the
effectiveness of the Contractor's proposed methods of blasting in all of
the different areas of the blasting works.
(6) The blasting trials shall be conducted by qualified personnel with a
(7) If in the opinion of the Engineer any aspect of the proposed blasting
procedure as demonstrated by the blasting trials is unsatisfactory,
particulars or proposed changes to the procedure shall be submitted to
the Engineer for Notice of No Objection; further blasting trials shall be
carried out until the procedure is demonstrated to the satisfaction of the
Engineer.
(8) The results of all trial blasts shall be interpreted using regression
analysis method. Regression lines together with all blasting data
showing the relationship of peak particle velocity against scaled
distance shall be plotted on logarithmic scale to define the site
vibration constants for the 50%, 84% and 95% confidence levels.
All subsequent main production blasting results shall be produced on
the same plot, and the plot modified and updated, as appropriate
to allow for the additional information. Separate trials are required for
different blasting types and areas.
(9) Blasting shall not proceed until the Engineer has issued a Notice
of No objection to the proposed blasting procedure.
(10) If changes to the agreed blasting procedure are proposed further
blasting trials shall be carried out to demonstrate proposed changes are
acceptable.
1.11.5 Blasting Schedule

(1) The Contractor shall submit a weekly schedule to the Engineer advising
the proposed dates, times and locations of blasting, in advance of each
week.
(2) The Contractor shall confirm his intention to proceed with each
scheduled blast to the Engineer not less than 18 hours, nor more than
24 hours in advance of the predetermined time. The confirmation shall
show the location of and the intended time of each blast and the name
of the licensed blaster and shift foreman responsible.
(3) The Contractor shall distribute written notification to all organizations
on Site 24 hours prior to undertaking surface blasting. Any delay or
postponement of any blasts shall be notified to all organizations
immediately
1.11.6 Vibration Due to Blasting

(1) Arrangements for installing instruments and taking measurements
both inside and outside the Site shall be made by the Contractor.
(2) Measurement of vibrations generated by blasting shall be taken at
locations proposed by the Contractor in his Blasting Assessment

Report, Building Damage Assessment Report and Monitoring Proposal

or as instructed by the Engineer at all times when blasting are carried
out. Records of the vibrations shall be kept by the Contractor on the
Site and a copy provided to the Engineer within 24 hours of
measurement.
(3) Vibrations due to blasting shall be measured in terms of Peak
Particle Velocity (PPV) and Vibrational Amplitude. The peak values
shall be taken as the maximum resultant calculated by vector
summation of the three orthogonal components of velocity and
amplitude respectively measured as instantaneously as the resolution of
the recording instrument permits.
(4) Measurements shall be made with seismographs of a type with Notice
of No Objection from the Engineer. The accuracy of
seismographs shall be checked before blasting are carried out and
shall be calibrated at least once a year.
(5) No blasting works shall be permitted without vibration
measurements being recorded with approved vibration monitoring
equipment mounted on a geophone pad which is rigidly bonded to form
an integral part of the structure.
(6) If a production blast results in vibration amplitudes or peak particle
velocity in excess of the specified limits, the Engineer shall be notified
immediately. The Contractor shall immediately check the fixing of
monitoring equipment to confirm the reading accuracy and inspect the
integrity of affected structures to ensure no immediate danger to the
public and to implement remedial measures if necessary. No further
blasting shall take place until measures to reduce the PPV and/or
amplitude are adopted with a Notice of No Objection from the
Engineer.
1.11.7 Blasting Near Structures

(1) Blasting will not be permitted within 3m of the outside face of any
existing underground structure. The Contractor shall propose
alternative appropriate means of mechanical, pneumatic or hydraulic
splitting for excavations at connections to existing structures for the
Relevant Authorities’ and Engineer’s Notice of No Objection.
(2) The Contractor s h a l l b e r e s p o n s i b l e for avoiding personal injuries
and damage to adjacent structures from fly rock by erecting barricades
and/or the use of blast mats or other means acceptable to the
Engineer. Should any damage be caused by his operations this shall be
made good without any additional payment.
(3) The unrestricted use of explosives will generally not be permitted in
any part of the Works. The amount of explosives that may be
detonated shall not result in a ground vibration sufficient to damage
the nearest point of any part of the Permanent Works to the blasting
Site.
(4) In each and every case where the Contractor wishes to blast within 15
m of a structure, he shall prepare a proposal for this blasting and submit
it to the Engineer for a ‘Notice of No Objection, No blasting work of
this nature may be carried out without the Notice of No Objection from
the Engineer .

(5) The Contractor shall prepare a photographic record of each structure

within 100 m of any Works, whether on the surface or underground,
prior to any blasting taking place.
1.11.8 Limits of Peak Particle Velocity and Vibration Amplitude

(1) The vibrations at structures and installations due to blasting
measured in terms of peak particle velocity and vibrational amplitude
shall not exceed the values stated in Table 1.11-1.
Table 1.11-1 Restriction on PPV and Vibration Amplitude
Max Allowable
Description Max Allowable Vibration
PPV (mm/sec) Amplitude (mm)
Structures in “good” condition and Roads 25 0.2
/Pavements/open areas
Structures in “fair” condition 12 0.15
Structures in “poor” condition and Heritage 5 0.1
Structures/bridges and water supply
structures
Fresh concrete:
Less than 2 days old 5 0.1
2 to 8 days old 25 0.2
3 more than 8 days old 50 0.2
(2) The Contractor shall submit calculations which demonstrate that the
charge weights per delay period proposed at 84% Confidence Level
do not exceed the vibration limitations stated in Table 1.11-1 to the
Engineer for Notice of No Objection. No blasting operations shall be
carried out without Notice of No Objection from the Engineer.
1.11.9 Blasting Risk Assessment

(1) The Blasting Risk Assessment and Blasting Risk Assessment Report
shall be undertaken by a qualified engineer with the Notice of No
(2) The Blasting Risk Assessment and Blasting Risk Assessment Report
shall be carried out in accordance with the procedures submitted to and
agreed by the Engineer. The location and size of the blasting trials
associated with the Blasting Risk Assessment shall have a Notice of No
(3) The Blasting Risk Assessment shall evaluate the impact caused by
blasting using gradual increase in vibration levels generated by trial
blasts, which shall not be exceeding the specified values in the
Contract. Planned vibration target levels generated by the trial blasts
shall be obtained by adjusting explosive charge weights at the same
time taking in to consideration changes in distance, drilling pattern,
confinement of the blast and rock condition. The design of explosive
charge weights shall be made from linear regression based on
previous blasting works. The predicted PPV (not exceeding the
specified values in the Contract) for each trial blast shall be made in
accordance to a confidence level of 84%.
(4) After each trial blast a structural inspection of structures and tunnels
shall be carried out to assess the effect of blasting induced vibration.
The scope and extent of the structural inspection shall be agreed with
the Engineer. When no structural defects are reported the
subsequent trial blasting may be increased to the next higher
vibration target level, which shall not be exceeding the values
specified in the Contract. Following completion of the Blasting Risk
Assessment field works a Blasting Risk Assessment Report shall be
required to be submitted to the Engineer for Notice of No Objection.
The Report shall include the followings as minimum contents.
(a) drilling and explosive loading details for each trial blast;
(b) delay plan for each trial blast;
(c) charge weight per blast hole and charge weight per delay for
each trial blast;
(d) details of vibration monitoring instruments and geophone
locations and orientation for each trial blast;
(e) details of instrumentation and settlement monitoring for each trial
blast;
(f) graphical record of Elapse Time against Particle Velocity and
Acceleration for each of the three orthogonal geophone directions
for each trial blast for each filtering frequency used. All records
are to identify the following: date, time, monitor, location,
filtering frequency, channel number, channel maximum,
project and trial blast identification;
(g) full wave form of the vibration measured on structures and
installations showing; PPV, predominate frequency, displacement
and acceleration;
(h) maximum resultant peak values calculated by vector
summation of the three orthogonal components of velocity and
amplitude for the monitoring point closest to each trial blast at
each filtering frequency used. Results to include distance from
blast and range of the dominant vibration frequency;
(i) results of structural condition survey conducted following each
trial blast, and results of vibration monitoring and all other
structures and buildings;
(j) results of all trial blasts plotted as a linear regression defining
constants for that site condition and the 50%, 84% and 95%
confidence levels. Results to include dominant vibration
frequency recorded.
1.11.10 Blasting: Tunnels and Shafts

1.11.10.1 General
(1) One probe hole shall be drilled ahead of every rock face for
probing the ground conditions ahead prior to the blast hole drilling.
Probing ahead shall be by impact or rotary drilling techniques, and
is intended to detect any ground water or potential unstable soils,
which may be treated by grouting techniques (ground treatment
techniques)

(2) All blasting work for bulk excavation of tunnels and shafts shall be
carried out using perimeter drilling and blasting techniques to control
the geometry of and to minimize any damage to the theoretical
excavation profile and minimize geological overbreak.
(3) All charges shall be accurately made up and inserted into the holes
at the correct spacing, and all holes shall be correctly stemmed and
connected in the correct sequence with detonators being correctly
delayed.
(4) Where tunnel excavation by explosives is within 6m of the ground
surface or an adjacent opening the Contractor shall modify his
blasting pattern to reduce the over break and to produce the minimum
amount of disturbance to the surrounding rock mass. Such Controlled
Blasting shall incorporate, but may not be limited to, pre-splitting or
smooth blasting techniques, decoupled charges and shall make use of
explosives specifically manufactured for these purposes.
1.11.10.2 Controlled Blasting Tolerance

(1) The Contractor shall carry out Controlled Blasting so as to achieve
a final blast surface that exhibits a regular fracture plane between
barrels without Under break or over break greater than those which
have been considered in deriving the theoretical excavation line and
the required finished tunnel profile.
(2) If at any time the methods of drilling and blasting do not produce a
uniform profile within the tolerances to achieve the required finished
tunnel profile , no further blasting works shall be permitted until the
Contractor establishes a technique that results in an excavation profile to
the acceptable tolerances.
1.11.11 Blasting: Stations

(1) Screens and other protective covers as specified in the Method
Statement shall be erected to prevent the projection of flying fragments
of material resulting from blasting.
(2) Presplitting and other methods of controlled blasting shall be
carried out in such a manner that the rock mass is cleanly split on the
required plane such that the remaining rock mass is not shattered or
loosened.
(3) Faces formed by presplitting or other methods of controlled blasting
shall not exceed 1.5m in height in any one blasting operation or as
agreed by the Engineer.
(4) If at any time, any method of drilling and blasting does not produce a
uniform final surface profile without over break, all within the required
tolerances, the Contractor shall undertake further trials until a
technique is established that results in an excavation profile to the
acceptable tolerances.
1.11.12 Submission
(1) The following are a minimum contents of blasting procedures that shall
be submitted to the Engineer for Notice of No Objection:
(a) Any conditions or restrictions imposed by the Relevant
Authorities, including copies of applications, licences, permits and

correspondence;
(b) Names, qualifications and experience of the persons responsible
for the design and supervision of blasting operations;
(c) The roles and responsibilities of key personnel for blasting
supervision shall be clearly defined on the Blasting Assessment
Report.
(d) Location with survey control, diameter, inclination and depth of
holes to be charged with explosive;
(e) Type and total mass of explosive to be used and its mass and
distribution in each hole;
(f) Initiation sequence, delay periods and mass of explosive per delay;
(g) Burden and bench height;
(h) Ratio of diameter of explosive to diameter of hole;
(i) Ratio of explosive charge weights to both volume and weight of
rock to be removed by the proposed blast;
(j) Arrangements for vibration monitoring system (e.g. relevant
vibration and air overpressure monitory points) and methods of
instrumentation and monitoring the effects of blasting;
(k) Details of vibration monitoring system, including manufacturers
literature and calibration certificates;
(l) Methods of controlled blasting; and
(m) Protective measures that have been agreed by the Engineer to
ensure there is no damage to surrounding property or equipment
or EBS and to fully comply with the provisions of the Contract in
this respect.
(2) Items (a) & (b) shall be submitted at least 30 days before blasting
in a particular works area starts. Items (c) to (m) shall be submitted to
the Engineer at least 48 hours before the relevant blasting starts.
(3) The blasting procedures shall be reviewed as blasting continues and
shall be updated to suit particular local conditions. When the
procedures are required to be revised the Items (c) to (m) shall be
submitted to the Engineer for Notice of No Objection at least 48
hours before blasting starts.

1.12 ROOF SHEETING
General :
The roofing material shall consist of single skin crimp curved profiled sheeting made
up of either of the below mentioned materials:
• High tensile PVDF galvalume steel
• Modified polyester coated GI sheet
• Powder Coated MS sheet
• Aluminium/Aluminium Alloy sheets
The profile and length of sheets shall be commensurate with the design and site
requirements and pre-coated with approved colour.
The contractor shall prepare shop drawings based on the drawings supplied by the
Engineer. These shall be submitted in five sets sufficiently in advance to the
Engineer for approval. All manufacturers shall be ISO 9001:2000 accredited.
Steel Material
• High tensile PVDF galvalume steel as per following specifications 0.50mm
(TCT excluding paint thickness) High tensile with 330 to 550 MPa yield
strength, metallic hot-dipped coated with Al-Zn alloy (55% Aluminium, 43.5%
Zinc, 1.5% Si ) as per AS1397 / IS15961 - (min. 150 g/m2 total on both sides)
with PVDF or equivalent superior quality paint system of approved color,
suitable for exterior application conforming to AS/NZS 2728 type-4 / IS15965
Steel make. The sheet shall have a total coating thickness of 35 microns, PVDF
paint system of 20 microns on exposed surface and 5 micron reverse polyester
coat on back surface over 5 micron primer coat on both surfaces. The paint
system should have stable resin & inorganic pigments for paint durability and
Lead free for water harvesting. The steel sheet shall have brand marking of
coated steel manufacturer (product details, date, mfg name, etc) on back side at
regular interval confirming genuineness of the material. The steel sheet shall be
fastened with nominal 40 µm zinc coated or nominal 25 µm Zinc-Tin alloy
coated, Hex head, self-drilling screw as per AS 3566-2002 Class 3 fasteners
with EPDM washer and also as per the requirement considering the profile
shape and design load.
The profile sheet, fastener size etc. shall be approved by the concern authority.
All the accessories like gutter/ flashing / capping shall be made from same
material.

The material shall be 0.50 mm TCT (Total Coated Thickness) modified
polyester coated Galvanised steel. The sheets shall have a hot-dip metallic
coating of Zinc (180 gms/Sq.M. zinc. Coating mass total on both sides) and
have a yield strength not less than 240 Mpa as per relevant IS codes.
• Powder Coated MS sheet

The material shall be 0.60 mm TCT (Total Coated Thickness) powder coated
mild steel. The sheets shall have a yield strength not less than 240 Mpa as per
relevant IS codes.
• Aluminium/Aluminium Alloy sheets

The External sheet shall be 65/400 profile straight sheets or tapered sheets
Aluminium Alloy: EN AW-3004-AIMn1Mg1 (as per DIN 1725)with minimum

ultimate tensile strength of 225 N/mm² and 0.2% Proof stress - min 200 N/mm²
modulus of elasticity - 70,000 N/mm². Profile reference shall be 65/400 with
min 65mm standing seam; 400mm cover width and nominal thickness/gauge:
0.9mm.
The roofing system shall comply to the British Board of Agreement and be
certified as CLASS 1 roofing by Factory Mutual Research Corporation.
Profile
Trapezoidal profile with minimum depth of 30/40 mm with 2 to 3 small ribs at
the centre to stiffen the profile. The profile shall have the seam and rib height
as per the material used, thickness, purlin spacing and profile of the sheeting.
Coating/ Finishing
• High tensile PVDF galvalume steel
The sheet shall have a total coating thickness of 35 microns, PVDF paint
system of 20 microns on exposed surface and 5 micron reverse polyester coat
on back surface over 5 micron primer coat on both surfaces. The paint system
should have stable resin & inorganic pigments for paint durability and Lead
free for water harvesting. The steel sheet shall have brand marking of coated
steel manufacturer (product details, date, mfg name, etc) on back side at regular
interval confirming genuineness of the material.
The sheet shall have modified polyester coating of approved colour of total
thickness of 35 microns comprising of 20 microns exterior coat of modified
polyester coating over top surface and 5 micron polyester backer coat over 5
micron primer coats on both surfaces.
• Powder Coated Mild Steel Sheet
The sheet shall have powder coating of approved colour of total thickness of 35
microns on both surfaces.
• Aluminium /Aluminium Alloy sheeting
The outer sheet shall have PVF 2 coat system (non-clad 3004 type) or stucco
embossed and colour as per requirements and specifications. The fluorocarbon
(PVF2) coating system shall have 2 coats. The first coat shall be of inhibitive
primer, with a dry film thickness averaging 5-7m. Second coat shall have
Fluorocarbon colour coat, with a minimum dry film thickness of 20 m.
The exterior finish coat shall be PVF2 paint system containing at least 70% of
PVF2 resin in dry paint film, as required by approved licensed coating
formulate. The finish coat shall have a dry film thickness of 0.020mm. The
paint finish system shall have mica particles to achieve its unique appearance,
which result in a visual effect known as geometric metamerism.
In order to minimise appearance differences; all requirements shall be
processed in one production run using the same batch of paint.
Standard colours will have a nominal gloss level of 20 to 35% (60o) - subject to
choices of colours. A Backing Coat of nominal thickness of 0.005mm with
standard colour coating. The coated finish for flashing and roofing sheet shall
have the following properties:
• Humidity Resistance Blistering tested accordance to ASTM D 2247 (3000
Hours) with no blistering.
• Acid Salt Spray tested accordance to ASTM B117 (3000 Hours) with no
creepage sighted.
• Formability of 0T to 2T, tested accordance to ASTM D4145.

• Pencil hardness conforming to ASTM D3363 with HB to 2T hardness grading.
• Reverse Impact tested accordance to ASTM D2794, with no loss of adhesion.
• Flame test tested to ASTM E84. Class A coating
Specular gloss of 20 - 35%, measured at 60o and tested in accordance to ASTM
D523.
1.12.1 Gutter
Material description:
Outer skin: 2.0 mm aluminium, plain mill finish or galvalume, GI or MS powder
coated sheet as per the cladding system adopted as per the specifications mentioned
above.
Special requirements
• Gutter shall be supported by colour matched 2mm thick GI support brackets at
every meter and butt jointed at (maximum) every 3 meters.
• Gutter fixings: stainless steel bolts, nuts, stainless steel & EPDM washers.
Gutter sealing: All joints to be sealed with suitable sealant and water flow area
shall be lined with waterproofed using suitable material.
1.12.2 Warranty Period

The manufacturer / Supplier / fabricator/ contractor of the roofing system shall give a
guarantee for 25 years with regarding to its composition, surface and tensile strength.
General
All complete stainless steel railing elements, terminal sections, posts, and other
fittings shall be of shape, size and designation of approved material and make as
given in the item of work or as directed by Engineer.
The Contractor shall take every precaution against damage of the components during
fixing in position.
Fixing
The railing shall be carefully adjusted prior to fixing in place to ensure proper
matching at abutting joints, correct alignment and camber throughout their length.
Fixing shall be strictly as per fixing details shown in the drawings or as directed by
Engineer.
If sections are not galvanised, railing shall be given one shop coat of paint, and three
coats of paint after erection.
All necessary holes, chases, etc., required in fixing shall be made by the contractor
and made good after installation, without any extra charge.
Epoxy
Epoxy bonding agents for match cast joints shall be thermosetting 100 percent
compositions that do not contain solvent or any non-reactive organic ingredient or
pigments required for coloring. Epoxy bonding agents shall be of two components
i.e., a resin and a hardener. The two components shall be distinctly pigmented. So
mixing produces a third color similar to the concrete in the segments to be joined,
shall be packaged in proportioned, labeled, ready-to-use containers.
Epoxy bonding agents shall be formulated to provide application temperature range

that will permit erection of match cast segments at substrate temperature from 5 C
to 40 C. Depending upon the ambient temperature range, the following types of
epoxy are recommended for use:
• 5 to 20 C : Fast reacting
• 15 to 30 C : Medium fast reacting
• 25 to 40 C : Slow reacting
If two surfaces to be bonded have different substrate temperatures, the adhesive

applicable at the lower temperature shall be used.
Epoxy bonding agents shall be insensitive to damp conditions during application

.After curing, shall exhibit high bonding strength to cured concrete, good water
resistivity, low creep characteristics and tensile strength greater than concrete. In
addition, the epoxy bonding agents shall function as a lubricant during the joining of
match cast segments, as a filler to accurately match the surface of the segments and
act as a durable water tight bond at the joint.
Epoxy bonding agents shall be tested to determine their workability get time, open
time, bond and compressive strength and working temperature range. The frequency
of the tests shall be as stated in the Special Specifications of the Contract.
The contractor shall furnish the Engineer with samples of the material for quality
assurance testing and a certification from a reputed independent laboratory having
NABL. Certification indicating that the material has passes the required tests.
Specific properties of epoxy and the test procedures to be used to measure these
properties shall conform to FIP requirement.
Mixing and Installation of Epoxy

Instructions furnished by the supplier for the safe storage, mixing and handling of the
epoxy bonding agent shall be followed. The epoxy shall be thoroughly mixed until it
is of uniform color. Use of a proper sized mechanical mixer operating at no more
than 600 RPM will be required. Contents of damaged or previously opened
containers shall not be used. Surfaces to which the epoxy material is to be applied
shall be at least at 40F and shall be free from oil, laitance form, release agent or any
other material that would prevent epoxy from bonding to the concrete surface. All
laitance and other contaminants shall be preferably removed by water rinsing, or,
alternatively, by light sand-blasting. Wet surfaces shall be dried before applying
epoxy bonding agents. The surface shall be at least the equivalent of saturated
surface dry (no visible water).
Mixing shall not start until the segment is prepared for installation. Application of
the epoxy bonding agent shall be according to the manufacturer’s instructions using
trowel rubber glove or brush on one or both surfaces to be joined. The coating shall
be smooth and uniform and shall cover the entire surface with a minimum thickness
of 1.5 mm applied on both surfaces and 3 mm if applied on one surface. Epoxy
should not be placed within 10 mm of prestressing ducts to minimize flow into ducts.
A discernible bead line must be observed in all exposed contact areas after temporary
post-tensioning. Erection operations shall be coordinated and conducted so as to

complete the operations of applying the epoxy bonding agent to the segments,
erection, assembling and temporary post-tensioning of the newly joined segment
within 70% of the open time period of the bonding agent.
The epoxy material shall be applied to all surfaces to be joined within first half of the
get time as shown on the containers. The segments shall be joined within 45 minutes
after the application of the first epoxy material placed and a minimum required
temporary prestress over the cross section should be applied within 70 percent of the
open time of epoxy material. The joint shall be checked immediately after the
erection to verify uniform joint width and proper fit. Excess epoxy from the joint
shall be removed where accessible. All tendon ducts shall be swabbed immediately
after stressing while the epoxy is still in the non-gelled condition to remove or
smooth out any epoxy in the conduit and to seal any pockets or air bubble holes that
have formed that joint.
If jointing is not completed with 70 percent of the open time, the operation shall be
terminated and the epoxy bonding agent shall be completely removed to the
maximum possible extent from the surfaces. The surface must be prepared again and
fresh epoxy shall be applied to the surface before resuming joining operations. As
general instructions cannot cover all situations, specific recommendations and
instructions shall be obtained in each case from the Engineer

1.13 ROAD WORKS
CONTROL OF TRAFFIC
The Contractor shall take all necessary precautions in co-ordination with and to the
requirements of all the competent authorities concerned to protect the work from
damage until such time as the seal coat or surface treatment has developed
sufficient strength to carry normal traffic without any damage to it.
The new work shall be opened to traffic only after it is authorised by the Engineer.
The Contractor shall submit a detailed traffic diversion/or control and regulation plan
taking all safety measures during the course of work permitted by the concerned
authorities to the Engineer for his consent before start of work.
The Contractor shall take all precautions to avoid or minimize delays and
inconvenience to road users during the course of the work. Where adequate detours or
side tracks are available, traffic shall be temporarily diverted while the work is in
progress depending on volume of traffic and subject to approval by Surat Traffic
Police .Adequate signs, signals, barriers and lamps for the warning and guidance of
traffic shall be provided at all times during the course of the work till it is opened to
traffic.
The Contractor shall take all reasonable precautions to protect traffic against
accident, damage or disfigurement by construction equipment, tools, and materials,
splashes and smirches of bitumen/bituminous material or any other construction
materials and shall be responsible for any claims arising from such damage or
disfigurement.
Traffic signs erected shall be in accordance with the IRC Standards and/or as
prescribed and approved by the Surat Traffic Police Department.
GRANULAR SUB-BASE (NON-BITUMINOUS)

This work shall consist of laying and compacting well-graded material on prepared
sub-grade in accordance with the requirements of these specifications or as per IRC
standards, as acceptable to Highway authorities. The material shall be laid in one or
more layers according to lines, grades and cross-sections shown on the drawings.
i) Material
The Material to be used for the work shall be natural sand, moorum, gravel,
crushed stone, or combination thereof depending upon the grading specified in
MORTH specifications for Roads and Bridges. The material shall be free
from organic or other deleterious constituents.
ii) Physical requirements

The material shall have a 10 percent fines value of 50 KN or more (for sample
in soaked condition) when tested in compliance with BS: 812 (Part III). The
water absorption value of the coarse aggregate shall be determined by IS:2386
(Part 3); if this value is greater than 2 percent, the soundness test shall be carried
out on the material delivered to site as per IS:383. CBR Value shall be
determined at the density and moisture content likely to be developed in

equilibrium conditions which shall be taken as being the density relating to a

uniform air voids content of 5 percent.
iii) Strength of sub-base
It shall be ensured prior to actual execution that the material to be used in the
sub-base satisfies the requirements of CBR and other physical requirements
when compacted and finished.
Construction Operations
a) Preparation of sub-grade
Immediately prior to the laying of sub-base, the sub-grade already finished as
per MORTH Clause 301 or 305 as applicable or existing surface shall be
prepared by removing all vegetation and other extraneous matter, lightly
sprinkled with water if necessary and rolled with two passes of 80 – 100 KN
smooth wheeled roller. Damage to the subgrade shall be made good before sub
base is laid.
b) Spreading and compacting

The sub-base material of grading specified in the Contract shall be spread on
the prepared subgrade with the help of a motor grader of adequate capacity, its
blade having hydraulic controls suitable for initial adjustment and for
maintaining the required slope and grade during the operation or other means
as approved by the Engineer.
When the sub-base material consists of combination of materials mentioned

in Clause 401.2.1, mixing shall be done mechanically by the mix-in-place
method.
Manual mixing shall be permitted only where the width of laying is not
adequate for mechanical operations, as in small-sized jobs. The equipment used
for mix-in-place construction shall be a rotavator or similar approved
equipment capable of mixing the material to the desired degree. If so desired by
the Engineer, trial runs with the equipment shall be carried out to establish its
suitability for the work.
Moisture content of the loose material shall be checked in accordance with IS:
2720 (Part 2) and suitably adjusted by sprinkling additional water from a truck
mounted or trailer mounted water tank and suitable for applying water
uniformly and at controlled quantities to variable widths of surface or other
means approved by the Engineer so that, at the time of compaction, it is from 1
per cent above to 2 per cent below the optimum moisture content
corresponding to IS: 2720 (Part 8). While adding water, due allowance shall be
made for evaporation losses. After water has been added, the material shall be
processed by mechanical or other approved means like disc harrows, rotavators
until the layer is uniformly wet.
Immediately thereafter, rolling shall start. If the thickness of the compacted

layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN
weight may be used. For a compacted single layer upto 225 mm the

compaction shall be done with the help of a vibratory roller of minimum 80 to

100 kN static weight with plain drum or pad foot-drum or heavy pneumatic
tyred roller of minimum 200 to 300 kN weight having a minimum tyre
pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the
required compaction. Rolling shall commence at the lower edge and proceed
towards the upper edge longitudinally for portions having unidirectional cross
fall and super-elevation and shall commence the center at the edges and
progress towards for portions having crossfall on both sides.
Each pass of the roller shall uniformly overlap not less than one-third of the
track made in the preceding pass. During rolling, the grade and crossfall
(camber) shall be checked and any high spots or depressions, which become
apparent, corrected by removing or adding fresh material. The speed of the
roller shall not exceed 5 km per hour. Rolling shall be continued till the density
achieved is at least 98 per cent of the maximum dry density for the material
determined as per IS: 2720 (Part 8). The surface of any layer of material on
completion of compaction shall be well closed, free from movement under
compaction equipment and from compaction planes, ridges, cracks or loose
material. All loose, segregated or otherwise defective areas shall be made good
to the full thickness of layer and re-compacted.
iv) Control of Traffic

Control of traffic shall be as described under Subsection
WET MIX MACADAM SUB-BASE/BASE (NON-BITUMINOUS)
i) Description
This work shall consist of laying and compacting clean, crushed, graded
aggregate and granular material, premixed with water, to a dense mass on a
prepared subgrade/sub- base/base or existing pavement as the case may be in
accordance with the requirements of these Specifications. The material shall be
laid in one or more layers as necessary to lines, grades and cross-sections
shown on the approved drawings or as directed by the Engineer.
The thickness of a single compacted Wet Mix Macadam layer shall not be less
than 75 mm. When vibrating or other approved types of compacting equipment
are used, the compacted depth of a single layer of the sub-base course may be
increased to 200 mm upon approval of the Engineer.
a) Materials
Physical requirements: Coarse aggregates shall be crushed stone. If crushed
gravel/shingle is used, not less than 90 per cent by weight of the
gravel/shingle pieces retained on 4.75 mm sieve shall have at least two
fractured faces. The aggregates shall conform to the physical requirements
set forth in Table below.
Table. 1.13.1 PHYSICAL REQUIREMENTS OF COARSE AGGREGATES

FOR WET MIX MACADAM FOR SUB-BASE/BASE COURSES

Sl.No Test Test Method Requirements

1. * .Lost Angeles Abrasion Value IS : 2386 (Part-4) 40 Per cent (Max)
or
* Aggregate
Impact value
IS : 2386 (Part-4) 30 Per cent (Max.)
or IS : 5640
2. Combined Flankiness and IS : 2386 (Part-1) 30 Per cent (Max.)**
Elogation indices (Total)
* Aggregate may satisfy requirements of either of the two tests.

** To determine this combined proportion, the flaky stone from a
representative sample should first be separated out. Flakiness index is weight
of flaky stone metal divided by weight of stone sample. Only the elongated
particles be separated out from the remaining (non-flaky) stone metal.
Elongation index is weight of elongated particles divided by total non-flaky
particles. The value of flakiness index and elongation index so found are added
up.
If the water absorption value of the coarse aggregate is greater than 2 per
cent, the soundness test shall be carried out on the material delivered to site as
per IS: 2386 (Part-5).
Grading requirements : The aggregates shall conform to the grading given in

Table
Table 1.13.2 - GRADING REQUIREMENTS OF AGGREGATES FOR

WET MIX MACADAM
IS Sieve Designation Per cent by weight
passing the IS
sieve
53.00 Mm 100
45.00 Mm 95-100
26.50 mm --
22.40 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 micro 8-22
75.55 micron 0-8
n
Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
The final gradation approved within these limits shall be well graded from
coarse to fine and shall not vary from the low limit on one sieve to the high limit
on the adjacent sieve or vice versa.
b) Construction Operations
Preparation of base: MORTH Clause 404.3.1. shall apply.

Provision of lateral confinement of aggregates: While constructing wet mix

macadam, arrangement shall be made for the lateral confinement of wet mix.
This shall be done by laying materials in adjoining shoulders along with that of
wet mix macadam layer and following the sequence of operations described in
Clause 407.4.1.
Preparation of mix: Wet Mix Macadam shall be prepared in an approved

mixing plant of suitable capacity having provision for controlled addition of
water and forced/positive mixing arrangement like pugmill or pan type mixer of
concrete batching plant. For small quantity of wet mix work, the Engineer may
permit the mixing to be done in concrete mixers.
Optimum moisture for mixing shall be determined in accordance with IS: 2720
(Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with
material of 4.75 mm to 22.4 mm size. While adding water, due allowance
should be made for evaporation losses. However, at the time of compaction,
water in the wet mix should not vary from the optimum value by more than
agreed limits. The mixed material should be uniformly wet and no segregation
should be permitted.
Spreading of mix : Immediately after mixing, the aggregates shall be spread

uniformly and evenly upon the prepared subgrade/sub- base/base in required
quantities. In no case should these be dumped in heaps directly on the area
where these are to be laid nor shall their hauling over a partly completed stretch
be permitted.
The mix may be spread either by a paver finisher or motor grader. For
portions where mechanical means cannot be used, manual means as approved
by the Engineer shall be used. The motor grader shall be capable of spreading
the material uniformly all over the surface. Its blade shall have hydraulic
control suitable for initial adjustments and maintaining the same so as to
achieve the specified slope and grade.
The paver finisher shall be self-propelled, having the following

features :
Loading hoppers and suitable distribution mechanism
The screed shall have tamping and vibrating arrangement for initial compaction
to the layer as it is spread without rotting or otherwise marring the surface
profile.
The paver shall be equipped with necessary control mechanism so as to
ensure that the finished surface is free from surface blemishes.
The surface of the aggregate shall be carefully checked with templates and
all high or low spots remedied by removing or adding aggregate as may be
required. The layer may be tested by depth blocks during construction. No
segregation of larger and fine particles should be allowed. The aggregates as
spread should be of uniform gradation with no pockets of fine materials.
Compaction: After the mix has been laid to the required thickness, grade and
cross fall/camber the same shall be uniformly compacted, to the full depth with

suitable roller. If the thickness of single compacted layer does not exceed 100
mm, a smooth wheel roller of80 to 100 kN weight may be used. For a
compacted single layer upto 200 mm, the compaction shall be done with the
help of vibratory roller of minimum static weight of 80 to 100 kN or equivalent
capacity roller. The speed of the roller shall not exceed 5 km/h.
In portions having unidirectional cross fall/super elevation, rolling shall

commence from the lower edge and progress gradually towards the upper edge.
Thereafter, roller should progress parallel to the centre line of the road,
uniformly over-lapping each preceding track by at least one third width until
the entire surface has been rolled. Alternate trips of the roller shall be
terminated in stops at least 1 m away from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running
forward and backward until the edges have been firmly compacted. The roller
shall then progress gradually towards the centre parallel to the centre line of the
road uniformly overlapping each of the preceding track by at least one-third
width until the entire surface has been rolled.
Any displacement occurring as a result of reversing of the direction of a roller

or from any other cause shall be corrected at once as specified and/or removed
and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the
mixture shall be thoroughly compacted with mechanical tampers or a plate
compactor. Skin patching of an area without scarifying the surface to permit
proper bonding of the added material shall not be permitted.
Rolling should not be done when the subgrade is soft or yielding or when it
causes a wave- like motion in the sub-base/base course or subgrade. If
irregularities develop during rolling which exceed 12 mm when tested with a
3 metre straight edge, the surface should be loosened and premixed material
added or removed as required before rolling again so as to achieve a uniform
surface conforming to the desired grade and crossfall. In no case should the use
of unmixed material be permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material as determined by the method outlined in
IS: 2720 (Part-8)
After completion, the surface of any finished layer shall be well-closed, free
from movement under compaction equipment or any compaction planes, ridges,
cracks and loose material. All loose, segregated or otherwise defective areas
shall be made good to the full thickness of the layer and recompacted.
Setting and drying: After final compaction of wet mix macadam course, the
road shall be allowed to dry for 24 hours.
Opening to Traffic: Preferably no vehicular traffic of any kind should be

allowed on the finished wet mix macadam surface till it has dried and the
wearing course laid.

BITUMINOUS MATERIALS
i) Materials
Materials shall meet the requirements of the relevant IS Codes. These shall
be of the following types.
a) Cut back Bitumen

Cut back bitumen shall be Rapid Curing (RC), Medium Curing (MC)
or Slow Curing (SC) conforming to IS:217.
b) Cationic Emulsion
Bitumen emulsions of the cationic type for roads shall conform to IS:8887.
Emulsified bitumen shall be Rapid Setting (RS), Medium Setting (MS), or
Slow Setting (SS).
The physical and chemical requirements of the three types emulsions

shall comply with the requirements specified in Table 1 of IS:8887.
c) Paving Bitumen
Paving bitumen shall be conforming to IS:73 and of the following two
types:
1) Type 1: Paving bitumen from non-waxy crude shall

satisfy the requirements given in Table 1 of IS:73.
2) Type 2: Paving bitumen from waxy crude shall satisfy the

requirements given in Table 2 of IS:73.
The temperature at application of bituminous materials shall be

maintained as per manufacturer’s instructions and/or as directed by the
Engineer’s Representative.
ii) Methods of Storage and Handling
a) Asphaltic material shall be handled and stored with due regard for safety
and in such a way that at the time of use in the work the material
conforms to the Specifications. Following precautions shall be taken
while using these materials:
b) Work with these materials shall be carried out in good weather

conditions and it shall be carried out in warm and dry weather, and not
in wet or extremely cold weather.
c) Emulsified asphalt shall be handled with care and not subjected to

mechanical shocks or extremes of temperature likely to cause separation
of the asphalt. Emulsified asphalt showing sign of separation shall not be
used.

d) During heating, no water or moisture shall be allowed to enter the boiler.
e) Heating of bitumen shall be done to the correct temperature

range, as prescribed by the manufacturer for the grade used. The
temperature shall be controlled with the use of a suitable thermometer,
and the material shall be drawn and used while still at such temperature
as is prescribed by manufacturer or in accordance with MORTH
specifications.
f) It shall be ensured that mixing of ingredients is through and all
particles of aggregates are coated uniformly and fully.
PRIME COAT
i) Description
This work shall consist of the cleaning and preparing of the surface to be
primed to specified lines, grade, and cross-section, booming and clearing
thoroughly and applying bituminous material in accordance with these
Specifications.
ii) Materials
The choice of the primer shall depend upon the porosity characteristics of the
surface to be primed. The primer shall be Medium Curing Cutback (MC) and
the particular grade to be used for the work shall have the consent of the
Engineer. Slow setting Cationic emulsion conforming to IS:8887 may also be
used. Sampling and testing of bituminous primer shall be as per IS:217,
IS:454 and IS:8887.
iii) Construction Methods
a) Weather Limitations
Prime coat shall not be applied at a time when the surface is wet or
when the weather is foggy, rainy or windy.
b) Equipment
The equipment used for the work shall include a power broom and
primer material distributor spraying it uniformly at specified rates and
temperatures. It shall be equipped with self-heating arrangement,
suitable pump, adequate capacity compressor and spraying bar with
nozzles having constant volume or pressure system. Spraying by
manual methods may be allowed for inaccessible or small areas with
the consent of the Engineer.
c) Cleaning Surface
Immediately prior to applying the prime coat the surface to be primed
shall be swept clean from all loose dirt and other objectionable material
and shall be shaped to the required lines, grades, cross section.
d) Application of bituminous primer

The primer material shall be applied by means of a distributor at rates
usually from 0.8 to 1.4 litres per square metre and at a temperature

within the allowable range corresponding to the material used and

porosity condition of surface over which it is laid .The temperature of
primer at time of application may vary from 40 0 C to 600 C for
cutback bitumen and 400C to 600C for bitumen emulsion
Prime coat shall be allowed to penetrate for at least 48 hours to allow

penetration into the base course and aeration of volatile from the primer
material, then covered with clean dry sand or stone screening.
Areas containing an excess or deficiency of priming material shall be

corrected by the addition of sand or primer.
TACK COAT
i) Description
This work shall consist of furnishing and applying bituminous material to an
existing road surface or to an existing bituminous prime coat surface which
has dried out or preparatory to laying another bituminous layer over it.
ii) Materials
The material for tack coat shall be a bituminous or cut back emulsion of
suitable type and grade.
iii) Construction Methods

a) Cleaning Surface
The whole surface on which the tack coat is to be applied shall be cleaned
of dust and any extraneous material before the start of application of tack
coat by using a power broom or any other equipment/ method.
b) Application of tack coat material

The tack coat material shall be applied uniformly by means of a
distributor at controlled rates as per MORTH specifications and at the
temperature within the allowable range corresponding to the material
used It shall be done with self propelled or towelled bitumen. Surfaces
of structures and trees adjacent to the areas being treated shall be
protected in such a way as to prevent their being spattered or marred.
DENSE GRADED BITUMINOUS MACADAM
a) Scope
This clause specifies the construction of Dense Graded Bituminous Macadam,
(DBM), for use mainly, but not exclusively, in base/binder and profile
corrective courses. DBM is also intended for use as road base material. This
work shall consist of construction in a single or multiple layers of DBM on a
previously prepared base or sub-base. The thickness of a single layer shall be
50mm to 100mm.
b) Materials
Bitumen: The bitumen shall be paving bitumen of Penetration Grade
complying with Indian Standard Specifications for “Paving Bitumen” IS: 73,

and of the penetration indicated in Table 12.7.3 for dense bitumen macadam,
or this bitumen as modified by one of the methods specified in Clause 521,
or as otherwise specified in the Contract. Guidance on the selection of an
appropriate grade of bitumen is given in The Manual for Construction and
Supervision of Bituminous Works.
Coarse aggregates: The coarse aggregates shall consist of crushed rock,

crushed gravel or other hard material retained on the 2.36 mm sieve. They
shall be clean, hard, durable, of cubical shape, free from dust and soft or
friable matter, organic or other deleterious substances. Where the
Contractor’s selected source of aggregates have poor affinity for bitumen,
as a condition for the approval of that source, the bitumen shall be treated with
an approved anti-stripping agent, as per the manufacturer’s
recommendations, without additional payment. Before approval of the
source, the aggregates shall be tested for stripping. The aggregates shall
satisfy the physical requirements specified in Table 12.7.1, for dense
bituminous macadam. Where crushed gravel is proposed for use as aggregate,
not less than 90% by weight of the crushed material retained on the 4.75 mm
sieve shall have at least two fractured faces.
Fine aggregates: Fine aggregates shall consist of crushed or naturally

occurring mineral material, or a combination of the two, passing the 2.36mm
sieve and retained on the 75 micron sieve. They shall be clean, hard, durable,
dry and free from dust, and soft or friable matter, organic or other deleterious
matter.
The fine aggregate shall have a sand equivalent value of not less than 50
when tested in accordance with the requirement of IS: 2720 (Part 37).
The plasticity index of the fraction passing the 0.425 nun sieve shall not
exceed 4. When tested in accordance with IS: 2720 (Part 5)
TABLE 1.13.3 PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE

FOR DENSE GRADED BITUMINOUS MACADAM
Property Test Specification
Cleanliness (dust) 1 Grain size analysis Max 5% passing 0.075mm

sieve
Particle shape Flakiness and Elongation Index Max 30%
(Combined) 2
Strength* Los Angeles Abrasion Value3 Max 35% Max 27%
Aggregate Impact Value4
Durability Soundness:5 Sodium Sulphate
Magnesium Sulphate Max 12% Max 18%
Water Absorption Water absorption6 Max 2%
Stripping Coating and Strippingof Minimum retained coating
Bitumen Aggregate Mixtures7 95%

Water Sensitivity** Retained Tensile Strength8 Min 80%
Notes: 1. IS: 2386 Part 1 5. IS: 2386 Part 5

2. IS: 2386 Part 1 6. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3.IS:2386 Part 4* 7. IS: 6241
4. IS: 2386 Part 4* 8. AASHTO T283**
* Aggregate may satisfy requirements of either of these

two tests.
** The water sensitivity test is only required if the minimum retained coating in
the tripping test is less than 95%.
Filler: Filler shall consist of finely divided mineral matter such as rock dust,
hydrated lime or cement approved by the Engineer. The filler shall be graded within
the limits indicated in Table
TABLE 1.13.4 GRADING REQUIREMENTS FOR MINERAL FILLER
IS Sieve (mm) Cumulative per cent passing by weight of total

aggregate
0.6 100
0.3 95-100
0.075 85-100
The filler shall be free from organic impurities and have a Plasticity Index not
greater than 4. The Plasticity Index requirement shall not apply if filler is cement or
lime. When the coarse aggregate is gravel, 2 per cent by weight of total aggregate,
shall be Portland cement or hydrated lime and the percentage of fine aggregate
reduced accordingly. Cement or hydrated lime is not required when the limestone
aggregate is used. Where the aggregates fail to meet the requirements of the water
sensitivity test in Table 12.7.1, then 2 per cent by total weight of aggregate, of
hydrated lime shall be added without additional cost.
Aggregate grading and binder content: When tested in accordance with IS: 2386 Part
1 (wet sieving method), the combined grading of the coarse and fine aggregates and
added filler for the particular mixture shall fall within the limits shown in Table
12.7.3, for dense bituminous macadam grading 1 or 2 as specified in the Contract.

The type and quantity of bitumen, and appropriate thickness, are also indicated for
each mixture type.
TABLE 1.13.5. COMPOSITION OF DENSE GRADED BITUMINOUS

MACADAM PAVEMENT LAYERS
Grading 1 2
Nominal aggregate size 40mm 25 mm
Layer Thickness 80-100 mm 50-75 mm
IS Sieve1 (mm) Cumulative % by weight of total aggregate passing

45 100
37.5 95 - 100 100
26.5 63 - 93 90 - 100
19 - 71 - 95
13.2 55 - 75 56 - 80
9.5 - -
4.75 38 - 54 38 - 54
2.36 28 - 42 28 - 42
1.18 - -
0.6 - -
0.3 7 - 21 7 - 21
0.15 - -
0.075 2-8 2-8
Bitumen content % by
mass of total mix2 Min 4.0 Min 4.5
Bitumen grade (pen) 65 or 90 65 or 90
The combined aggregate grading shall not vary
Notes: 1. from the low limit on one
sieve to the high limit on the adjacent sieve.
2. Determined by the Marshall method.
Mixture Design
Requirement for the mixture: Apart from conformity with the grading and quality
requirements for individual ingredients, the mixture shall meet the requirements
TABLE 1.13.6. REQUIREMENTS FOR DENSE GRADED BITUMINOUS

MACADAM
Minimum stability (kN at 60 oC 9.0

Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 blows on each of the two faces of the specimen

Per cent air voids 3-6

Per cent voids in mineral aggregate (VMA) See Table 12.7.5 below
Per cent voids filled with bitumen 65-75
The requirements for minimum per cent voids in mineral aggregate (VMA) are set
out in
Table
TABLE 1.13.7 MINIMUM PER CENT VOIDS IN MINERAL AGGREGATE

(VMA)
Nominal Minimum VMA, Per cent Related to Design Air Voids, Per cent2
Maximum
3.0 4.0 5.0
Particle Size1
9.5 14.0 15.0 16.0
(mm)
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0
Notes:
1. The nominal maximum particle size is one size larger than the first sieve
to retain more than 10 per cent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design .air
voids values between those listed.
Binder content: The binder content shall be optimised to achieve the requirements of
the mixture set out in Table 12.7.4 and the traffic volume specified in the Contract.
The Marshall method for determining the optimum binder content shall be adopted
as described in The Asphalt Institute Manual MS-2, replacing the aggregates retained
on the 26.5 mm sieve by the aggregates passing the 26.5 mm sieve and retained on
the 22.4 mm sieve, where approved by the Engineer.
Where 40 mm dense bituminous macadam mixture is specified, the modified

Marshall method described in MS-2 shall be used. This method requires modified
equipment and procedures; particularly the minimum stability values in Table be
multiplied by 2.25, and the minimum flow shall be 3 mm.
Job mix formula: The Contractor shall inform the Engineer in writing, at least 20 days
before the start of the work, of the job mix formula proposed for use in the works,
and shall give the following details:
1. Source and location of all materials;
2. Proportions of all materials expressed as follows where each is applicable:
3. Binder type, and percentage by weight of total mixture;

a. Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of total

aggregate including mineral filler;
4. A single definite percentage passing each sieve for the mixed aggregate;
5. The individual grading of the individual aggregate fractions, and the proportion
of each in the combined grading.
6. The results of tests enumerated in Table as obtained by the Contractor;
7. Where the mixer is a batch mixer, the individual weights of each type of
aggregate, and binder per batch,
8. Test results of physical characteristics of aggregates to be used;
9. Mixing temperature and compacting temperature.
While establishing the job mix formula, the Contractor shall ensure that it is based
on a correct and truly representative sample of the materials that will actually be
used in the work and that the mixture and its different ingredients satisfy the
physical and strength requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the
Engineer for which samples of all ingredients of the mix shall be furnished by the
Contractor as required by the Engineer.
The approved job mix formula shall remain effective unless and until a revised
Job Mix Formula is approved. Should a change in the source of materials be
proposed, a new job mix formula shall be forwarded to the Engineer for approval
before the placing of the material.
Plant trials - permissible variation in job mix formula: Once the laboratory job mix
formula is approved, the Contractor shall carry out plant trials at the mixer to
establish that the plant can be set up to produce a uniform mix conforming to the
approved job mix formula. The permissible variations of the individual percentages
of the various ingredients in the actual mix from the job mix formula to be used
shall be within the limits as specified in Table
These variations are intended to apply to individual specimens taken for quality
control tests in accordance with Section 900.
TABLE 1.13.8 PERMISSIBLE VARIATIONS FROM THE JOB MIX

FORMULA
Description Permissible Variations
Permissible Variations
Description Base/binder course Wearing course
Aggregate passing 19mm sieve or larger ± 8% ± 7%
Aggregate passing 13.2mm, 9.5mm .± 7% ± 6%

Aggregate passing 4.75mm ± 6% ± 5%
Aggregate passing 2.36mm, 1.18mm, ± 5% ± 4%

0.6mm
Aggregate passing 0.3mm, 0.15mm ± 4% ± 3%
Aggregate passing 0.075mm ± 2% ± 1.5%

Binder content ± 0.3% ± 0.3%
Mixing temperature ± 10°C ± 10°C
Once the plant trials have demonstrated the capability of the plant, and the trials are
approved, the laying operation may commence. Over the period of the first month of
production for laying on the works, the Engineer shall require additional testing of
the product to establish the reliability and consistency of the plant.
Laying Trials: Once the plant trials have been successfully completed and approved,
the Contractor shall carry out laying trials, to demonstrate that the proposed mix can
be successfully laid, and compacted all in accordance with Clause 501. The laying
trial shall be carried out on a suitable area which is not to form part of the works,
unless specifically approved in writing, by the Engineer. The area of the laying trials
shall be a minimum of 100 sq.m. of construction similar to that of the project road,
and it shall be in all respects, particularly compaction, the same as the project
construction, on which the bituminous material is to be laid.
The Contractor shall previously inform the Engineer of the proposed method for
laying and compacting the material. The plant trials shall then establish if the
proposed laying plant, compaction plant, and methodology is capable of producing
satisfactory results. The density of the finished paving layer shall be determined by
taking cores, no sooner than 24 hours after laying, or by other approved method.
Once the laying trials have been approved, the same plant and methodology shall be
applied to the laying of the material on the project, and no variation of either shall be
acceptable, unless approved in writing by the Engineer, who may at his discretion
require further laying trials.
vii) Construction Operations
Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.
Preparation of base: The base on which Dense Graded Bituminous Material is to be

laid shall be prepared in accordance with Clauses 501 and 902 as appropriate, or as
directed by the Engineer. The surface shall be thoroughly swept clean by a
mechanical broom, and the dust removed by compressed air. In locations where-
mechanical broom cannot access, other approved methods shall be used as directed
by the Engineer.
Geosynthetics: Where Geosynthetics are specified in the Contract this shall be in

accordance with the requirements stated in Clause 703

Stress absorbing layer: Where a stress absorbing layer is specified in the Contract,
this shall be applied in accordance with the requirements of Clause 522.
Prime coat: Where the material on which the dense bituminous macadam is to be
laid is other than a bitumen bound layer, a prime coat shall be applied, as specified,
in accordance with the provisions of Clause 502, or as directed by the Engineer.
Tack coat: Where the material on which the dense bituminous macadam is to be
placed is a bitumen bound surface, a tack coat shall be applied as specified, in
accordance with the provisions of Clause 503, or as directed by the Engineer.
Mixing and transportation of the mixture: The provisions as specified in Clauses

501.3 and 501.4 shall apply.
Spreading: The provisions of Clauses 501.5.3 and 501.5.4. shall

apply.
Rolling: The general provisions of Clauses 501.6 and 501.7 shall apply, as modified
by the approved laying trials. The compaction process shall be carried out by the
same plant, and using the same method, as approved in the laying trials, which may
be varied only with the express approval of the Engineer in writing.
Opening to Traffic
The newly laid surface shall not be open to traffic for at least 24 hrs after laying and
completion of compaction, without the express approval of the Engineer in writing.
BITUMINOUS CONCRETE
i) Description
This work shall consist of a surfacing of single-layer bituminous concrete of
specified thickness on previously prepared bituminous surface to the lines,
grades, dimensions and cross section as shown on Drawings. It shall be
25mm/40mm thick as required by Engineer.
ii) Materials
a) Bitumen
The bitumen shall be paving bitumen of suitable penetration grade
within the range S 35 to S 90 or A 90 to IS:73. The actual grade of
bitumen to be used shall be appropriate to the requirements of the work
and environmental conditions.
b) Coarse aggregates
The aggregates shall satisfy the physical requirements given in Table
12.7.1. Flankiness index shall not exceed 30% and water absorbed not
more than 1%
c) Fine aggregates
Fine aggregates shall be the fraction passing 2.36 mm sieve and
retained on 75 micron sieve, consisting of crushed run screenings,

natural sand or a mixture of both. These shall be clean, hard, durable,

uncoated, dry and free from any injurious, soft or flaky pieces and
organic or other deleterious substances.
d) Filler
Filter shall consist of finely divided mineral matter such as rock dust,
hydrated lime or cement. The filter shall be graded within following
limits: IS Sieve Per cent passing by weight
00 micron 100
300 micron 95 – 100
75 micron 85 –
100
The filter shall be free from organic impurities and have a Plasticity
Index not greater than 4. The Plasticity Index requirement shall not
apply if filler is cement or lime. When coarse aggregate is gravel, 2
per cent of mass of total aggregate of Portland cement or hydrated lime
shall be added and percentage of fine aggregate reduced accordingly.
Cement or lime is not required when the gravel is lime stone.
e) Aggregate gradation
Mineral aggregates, including filler shall be so graded or combined as
to conform to grading set-forth in in Table below.
Table 1.13.9 Sieve analysis designation:-

Sieve Per cent by weight passing through sieve for
Designation 25 mm thick 25-40 mm thick Grade 2 >40 mm thick
Grade 1 Grade 1
26.5 mm -- -- 100
22.4 mm -- 100 75-100
13.2 mm 100 80-100 --
11.2 mm 90-100 75-95 50-85
5.6 mm 60-80 55-75 20-40
2.8 mm 40-55 40-55 5-20
710 micron 20-30 20-30 --
300 micron 15-25 15-25 --
180 micron 10-20 10-20 --
90 micron 5-11 5-11 0-5
iii) Mix Design
a) Requirement of Mix

Apart from conformity with grading and quality requirements of

individual ingredients, the mix shall also meet the requirements set forth
in Table.
Table 1.13.10 - Requirements of bituminous concrete:
S.No. Description Requirements

1 Marshall stability (ASTM Designation: D-1559) 820 Kg (1800
.
determined on Marshall specimens compacted by 75 pounds)
compaction blows on each end
2 Marshall flow (mm) Minimum 2-4
3 . cent air voids in mix
Per 3-5
4 . cent voids in mineral aggregate (VMA)
Per Minimum 11-
5 .
Percent voids in mineral aggregates filled by 13
65-75
.
bitumen (VFB)
6 Binder content, per cent by weight of mix Minimum 4.5
7 .
Water sensitivity (ASTM : D-1075) loss of Minimum 75%
Stability
. on immersion in water at 60 deg. C Retained
8 Swell Test (Asphalt Instt. MS-2, No. 2) strength
Maximum
. 1.5%
b) Binder content
Binder content shall be so determined as to achieve the requirements of
the mix set forth in Table. Marshall method for arriving at binder
content shall be adopted.
c) Job Mix Formula

Before starting work the Contractor shall submit to the Engineer for his
consent. The job mix formula for the mixture shall fix a single
percentage of aggregate passing each required sieve size, a single
percentage of asphalt to be added to the aggregate, and a single
temperature at which the mixture is to be delivered on the road, all of
which shall fall within the ranges of the composition and the
temperature limits. The formula shall give the following details:
1) Source and location of all materials

2) Proportions of all materials as described under :
Binder as percentage by weight of total mix

Coarse aggregate as percentage by weight of total
Fine aggregate aggregate including mineral filler
Mineral Filler
3) A single definite percentage passing each sieve for the mixed

aggregate.
4) The results of test as obtained by the Contractor
5) Test results of physical characteristics of aggregates to be used
6) Mixing temperature and compacting temperature
d) Application of job-mix formula and Allowable Tolerances

The approved job mix formula shall remain effective unless and until
modified. Each day as many samples of the materials and mixtures
shall be taken and tested considers necessary for checking the required
uniformity of the mixture.
All mixture furnished shall conform to the job-mix formula within the
range of tolerances set in forth in Table.
When unsatisfactory results or changed conditions make it necessary, a

new job mix shall be submitted to the Engineer.
Should a change in a material be encountered or should a change in

a source of material be made, a new job mix formula shall be
submitted before the mixture containing the new material is delivered.
Table 1.13.12 Permissible variation from the job-mix formula

Permissible
S.No. Description of Ingredients Variation
by Weight of
Total mix in
Percentage
1. Aggregate passing 13.2mm sieve and +8
2. larger
Aggregate passing 9.5mm sieve and +7
4.75mm
3. Aggregate
sieve passing 2.36mm sieve & +6
1.18mm
4. Aggregate
sieve passing 600 sieve & 300 +5
5. sieve
Aggregate passing 150 micron sieve +4
6. Aggregate passing 75 micron sieve +3
7. Binder + 0.3
8. Mixing Temperature (Centigrade) + 10
iv) Construction Methods
a) Weather Limitation
The control over the weather conditions shall be as described as per
MORTH Clause
501.5.1 shall apply.
b) Progress of Work
No work shall be performed when there is insufficient hauling,
spreading or finishing equipment, or labour to ensure progress at a rate
not less than 75% of the capacity of the mixing plant.
c) Preparation of Existing Surface

The surface on which the mix is to be laid shall be swept thoroughly
and cleaned of all loose dirt and other objectionable material using
mechanical broom immediately before start of work, in portions where
mechanical means cannot reach.

The surface shall be prepared, shaped and conditioned to specified

levels, grade and cross-fall (camber).
d) Preparation of Mix
A Hot-mix plant of adequate capacity and capable of producing a proper
and uniform quality mix shall be used for preparing the mix. The
plant may be either a weigh batch type or volumetric proportioning
continuous or drum mix type. The plant shall have co-ordinated set of
essential units capable of producing uniform mix as per the job-mix
formula.
The temperature of the binder at the time of mixing shall be in the

range of 150 to 163 degree C and of aggregates in the range of 155 to
163 degree C. Provided also that at no time shall the difference in
temperature between the aggregates and binder exceed 14 degree.C.
The Contractor shall submit the exact temperatures and total mixing
time for the consent of the Engineer.
Mixing shall be thorough to ensure that a homogeneous mixture is

obtained in which all particle of mineral aggregates are coated
uniformly.
e) Transportation and Delivery of Mix.

The mix shall be transported from the mixing plant to the point of use
in suitable tipper vehicles. The vehicles employed for the transport shall
be clean and be covered in transit.
f) Spreading and Finishing

The mix transported from the hot mix plant to the site and shall be
spread by means of a self-propelled mechanical paver with suitable
screeds capable of spreading, tamping and finishing the mix to specified
grade, elevation, and cross-section. However, in restricted locations and
narrow widths, available equipment can not be operated, other suitable
means shall be employed subject to the consent of the Engineer. The
mixture shall be laid upon an approved surface and only when weather
conditions are considered suitable. The temperature of the mix, at the
time of laying, shall be in the range of 120 degree C to 160 degree C.
The prime coat and tack coat to be applied shall be as per Subsections
12.5 and 12.6 respectively.
Spreading, finishing and compacting of the mix shall be carried out

during daylight hours only, unless satisfactory illumination is provided
by the Contractor.
g) Compaction of Mixture
Immediately after spreading of mix by paver, it shall be thoroughly

and uniformly compacted by rolling with a set of self-propelled rollers
moving at a speed not more than 5 km per hour, immediately following

close to the paver. Generally with each paver, two steel wheeled tandem
rollers and one pneumatic tired roller will be required. The initial or
breakdown rolling shall be with 8 to 10 ton static weight smooth three
wheeled steel roller and finish rolling with 6 to 8 ton tandem roller. The
breakdown rolling shall preferably be followed by an intermediate
rolling with a smooth wheel pneumatic roller of 10 to 25 ton having a
tire pressure of 7kg/sqcm moving with a speed not more than 7 km per
hour and shall be at all times slow enough to avoid displacement of the
hot mixture. Means shall be provided for checking and adjusting the tire
pressure on the job at all times. All compaction operations, i.e.,
breakdown rolling can be accomplished by using vibratory roller of 8 to
10 ton static weight. During initial or breakdown rolling and finished
rolling, the vibratory shall be switched off. The joints and edges shall be
rolled with an 8 to 10 ton three wheeled static roller.
No delays in rolling the paved surface shall be permitted. The

breakdown roller must be right up to the paver at all times and the
intermediate pneumatic roller right up to the breakdown roller. The
compaction of the asphaltic concrete shall be controlled by temperature
as follows:
Roller Temperature
Breakdown 120º C – 135º C
Pneumatic 95º C – 115º C
Finishing < 65º C
Rolling procedure shall be as specified under Subsection.
Rolling shall be continued till the density achieved is at least 98%

of that of laboratory Marshall specimen. Rolling operations shall be
completed in all respects before the temperature of the mix falls below
100 degree C.
h) Joints
Both longitudinal and lateral joints in successive courses shall be
staggered so as not to be one above the other. Longitudinal joints and
edges shall be constructed true to delineating lines parallel to the centre
line of the road. Longitudinal joints shall be offset by at least 150mm
from those in the lower course.
Longitudinal and transverse joints shall be made in a careful manner

so that well bonded and sealed joints are provided for the full depth of
the course.
i) Surface regularity
Surface shall be tested for undulations in longitudinal and cross
profiles with 3 m straight edge and crown template respectively. Crown
template shall conform to the typical cross section.

Maximum permissible undulation in longitudinal profile with 3m

straight edge shall be as 8mm.
Maximum permissible variation from specified cross profile under

camber template shall be as 4mm.
Surface evenness requirements in respect of both longitudinal and

cross profiles should be simultaneously satisfied
.j) Protection of the pavement from traffic

Subsection 12.7.5 shall apply except as stated below.
Section of the newly finished works shall be protected from traffic of any
kind until the mixture has cooled to approximately ambient air temperature
and well set.
SEAL COAT
i) Description
This work shall consist of application of a seal coat for sealing the
voids in a bituminous surface laid to the specified levels, grade, and
cross fall. Seal coat used shall be of premix type unless otherwise
approved by the Engineer.
a) Binder
The binder shall be bitumen of a suitable grade appropriate to the
requirements of the work and other environmental conditions as
directed by the Engineer and satisfying the requirements of IS:73, 217,
454 or other cut back as applicable.
b) Aggregates
The aggregates shall be sand or grit and shall consist of clean, hard,
durable, dry particles and shall be free from dust, soft or flaky/
elongated material, organic matter or other deleterious substances. The
aggregates shall pass 2.36mm sieve and be retained on 180 micron
sieve. The quantity used for premixing shall be 0.06 cum per 10 sq m
area.
ii) Construction Methods
a) Preparation of base
The seal coat shall be applied immediately after laying of bituminous
course which is required to be sealed. Before application of seal coat
materials, the surface shall be cleaned free of any dust or other
objectionable matter.
b) Preparation and Application of Mix

Mixtures of approved type shall be employed for mixing aggregates
with suitable bituminous binder.

The binder shall be heated in boilers of suitable design, to a temperature

appropriate to the grade of bitumen. The aggregates shall be clean, dry
and suitably heated to a temperature before the same are placed in the
mixture. Mixing of binder with aggregates to specified proportions shall
be continued till the latter are thoroughly coated with the former.
The mix shall be immediately transported from the mixing plant to the
point of use and spread uniformly on the bituminous surface to be
sealed.
c) Rolling
As soon as sufficient length has been covered with pre-mixed material,
the surface shall be rolled with 8-10 ton smooth wheeled steel, suitable
vibratory, or other equipment.
d) Control of Traffic
Subsection 12.1 shall apply

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DESIGN, CONSTRUCTION AND COMPLETION OF UNDERGROUND STATIONS AND TUNNEL

INCLUDING FINISHES FROM KAPODRA RAMP TO SURAT RAILWAY STATION FROM

TENDER NO.: GMRC/CONS/UG-1/PKG-CS2/PH-1/2020

DIVISION H - OUTLINE CONSTRUCTION

PACKAGE – UG-1/PKG CS2

Gujarat Metro Rail Corporation (GMRC) Limited

Corporate Identification No (CIN): U60200GJ2010SGC059407

1.1.1.2 Reference to the Standard Codes of Practice

IRS Indian Railway Standards

JIS Japanese Industrial Standard

The detailed list of Standards referred to is mentioned in Section 1.1.3

2 All labour, materials, plant, equipment and temporary works, overhead

4 Continuous & Rigid temporary fences, barricades/hoardings on both sides

All fences, barricade/hoardings shall be as per approved drawings and

5 All equipment, instruments, labour and materials required by the Engineer

6 Design mixes and testing them as per relevant clauses of specifications

GMRC JULY 2020 Page 2 of 218

Cost of safety measures and requirements of site safety plan as per

A testing laboratory as specified by the Engineer equipped with the

A testing laboratory as specified by the Engineer equipped with the

GMRC JULY 2020 Page 3 of 218

Quality Assurance & Quality Control

All testing shall be performed in the presence of Engineer or his authorised

GMRC JULY 2020 Page 4 of 218

Setting out of Works

The triangulation points given by Employer/Engineer before start of work

GMRC JULY 2020 Page 5 of 218

Sampling and Testing

Samples provided to the Engineer for their retention are to be labeled in

Samples required for approval and testing must be supplied sufficiently in

Materials shall be tested before leaving the manufacturer’s premises, quarry

GMRC JULY 2020 Page 6 of 218

materials have been tested in accordance with the requirement of these

1.1.1.3 Storing of Materials at site

Cost of arranging, storing and testing of water shall be deemed to be included

GMRC JULY 2020 Page 7 of 218

Supply/procurement of cement shall be through bulk carrier and stored in

Cement (OPC of 53 grade/PPC/PSCas specified shall be arranged by the

GMRC JULY 2020 Page 8 of 218

specific approval of Engineer-in-charge. The silt content by volume in fine

1.1.1.6 Load testing on Completed Structures

GMRC JULY 2020 Page 9 of 218

load shall be recorded by sufficient number of agreed deflectometers capable

D = 0.001 L2/25 T, where,

D = max deflection due to imposed load only

a) Establishing GPS stations, if require, at an interval not more than 2-2.5

c) Detailed Topographical survey, if require, shall be carried out with

GMRC JULY 2020 Page 11 of 218

Providing adequate road safety devices. A tentative list given hereunder

Supply of Progress Photographs and Album

The photographs shall be of acceptable quality and they shall be taken by a

GMRC JULY 2020 Page 12 of 218

approved by the Engineer. Each photograph in the album shall be suitably

Supply of DVD of Works

1.1.2 Structural Work

1.1.2.4 Procedure of mixing the admixtures shall be strictly as per the

1.1.2.7 Formwork for beams of Reinforced Cement Concrete works shall be

1.1.2.8 Wherever there are tension/suspended concrete members which are

1.1.2.9 The Contractor shall incorporate seismic considerations of anchoring and

1.1.2.10Formwork shall be provided for full height at all locations. Special

1.1.2.12 Casting yard shall have following minimum facilities:

GMRC JULY 2020 Page 14 of 218