Schedule D From Section 7

National Highways Authority of India Request for Proposal – Bid Documents
SECTION 7 - INNER LINING CONCRETE

7.1 GENERAL
This section contains specifications for the construction of the final tunnel lining, the foundation
beams and the invert arch. These structures are predominantly un-reinforced, but they may also
be reinforced locally or fully as required, as agreed with the Authority Engineer.
7.1.1 Description
a. The final tunnel lining, a cast-in-situ concrete lining increases the safety factor of the tunnel
lining system, provides a uniform interior surface, and improves the water tightness of the tunnel
lining. A smooth interior surface is required for air flow, aesthetic, lighting, and maintenance
reasons.
b. The foundation beams form the abutment for the final tunnel lining. They also form the
connecting link in the case an invert arch is required. Cable ducts and sidewalks are mostly
founded on these longitudinal concrete beams.
c. The invert arch forms the ring closure of the tunnel lining (tunnel tube) where poor geological
conditions prevail. The concreted invert arch has to resist ground pressures and to provide
stability for the whole tunnel structure.
d. The formwork or shutters for the foundation beams invert and arch and roof arch provide the
necessary tools for the construction of the final tunnel lining. They shall be designed and
constructed of steel in such a manner that the shape, dimensions and surface finish of the
concrete are obtained, as specified.
e. Contact grouting is the injection of grout material under pressure to fill voids between in-situ
concrete lining and the rock or shotcrete or the membrane lining (waterproofing). A systematic
contact grouting shall be carried out in the roof section of the tunnel after hardening of the
concrete lining, and satisfactory results from the 28 day cube test. Provision shall be made in the
roof arch shutter for the casting of the necessary holes for contact grouting. Positioning of these
grout holes shall be reviewed by the Authority Engineer.
7.1.2 Submissions
a. Working drawings shall be submitted showing the camber of formwork as required for
compensation of deflection by concrete placing operation.
b. The CONTRACTOR shall submit detailed shop drawings of the formwork for review by the
Authority Engineer.
c. Separate shop drawings for the formwork for the tunnel cross section, cross passages and
niches shall be submitted by the CONTRACTOR for review by the Authority Engineer.
d. Test reports shall be submitted for the concrete to be used in accordance with General
Specification.
e. Method statement, plant and material description for contact grouting shall be submitted to the
AE for review before commencement of inner lining concreting works.
7.1.3 Job Conditions
Construction of Balance work and Value Addition Works of Four Laning of part of Ramban to Banihal Page D-1
Section of NH-1A (Now NH-44), From Km 151.000 to Km 187.000 on Engineering Procurement &
Construction (EPC) Mode in the Union Territory of Jammu & Kashmir under NHDP Phase-II
a. The inner concrete lining in the tunnel shall not be placed until the rate of displacement at any
position on the tunnel periphery and normal to the periphery is less than 2 mm per month, unless
otherwise agreed with the Authority Engineer.
b. The inner concrete lining shall not be placed before the re-profiling operations have been
reviewed by the Authority Engineer.
c. The inner concrete lining in the tunnel shall not be placed before the waterproofing system
installed is reviewed by the Authority Engineer.
7.1.4 Quality Assurance
a. General Specification.
7.2 MATERIAL
7.2.1 Formwork
a. Section 1500 of the General Specification.
b. Formwork shall be held to comprise all temporary staging and formwork required and used for
the construction of the final lining.
c. Formwork shall be sufficiently rigid to maintain the forms in their correct position, shape and
profile so that the final concrete structure is within the limits of tolerances (± 10 mm).
d. The formwork shall be made of steel and suitable for repetitive use, and to give a class F5
finish.
The formwork shall be provided with openings along each side wall and in the crown. The
opening shall be so designed as to permit the use of vibrators for compacting the concrete, and to
permit inspection of the concrete during placing and of the hardened concrete surface prior to the
striking or the removal of the formwork. They shall be a minimum of 600 mm square. Openings for
pouring of concrete shall be located at such heights as to prevent segregation of the concrete.
Joints in the forms shall be sufficiently tight to prevent leakage of grout and absorption of water
from concrete.
e. The forms shall be maintained at all times in good condition as accuracy of shape, strength,
rigidity, water tightness and smoothness of surface is warranted. All forms shall be kept clean,
free of corrosion and in good repair.
f. The design of the formwork shall be reviewed by the Authority Engineer.
g. The upper sector of the formwork shall have facilities for mounting external vibrators at regular
intervals to ensure thorough compaction of the arched soffit.
h. The steel form shall be furnished with suitable devices for the erection of stop ends and to
enable chamfers along the periphery at the start/end of each concreting section in order to
produce a regular surface between pours where the tunnel is on curve.
7.2.2 Concrete
b. The concrete grade for inner concrete lining, abutment and invert arch shall be 30 N/mm2
according to Section 1700 General Specification.
c. Maximum aggregate size is to comply with the Section 1700 General Specification.
d. The consistency of the mix shall be chosen to allow placing of concrete by pumping.
e. Plasticizers may be used in the concrete mix to improve flow and compaction. Details of such
additives shall be submitted to the AE for review prior to their use.
7.2.3 Grout for Contact Grouting
a. Grout shall be based on a mixture of Cementous materials and water, but may contain
additives to improve the performance, subject to the Authority Engineer's review. All sources of
water to be used with cement shall be approved by the Authority Engineer. If at any time during
construction, water from an approved source becomes unsatisfactory, the CONTRACTOR shall
provide satisfactory water from other main sources.
b. Cementous materials shall conform to current Standards. The grout shall be a uniform mixture
of which the consistency shall be sufficiently fluid but not more to ensure that the grout flows
freely under pressure into all parts of the void.
c. The grout mix shall have low or no bleed ability and low shrinkage characteristics. When set the
grout should have the lowest permeability possible.
7.3 EXECUTION
7.3.1 Preparation of Formwork before Concreting
a. Section 1500 General Specification.
b. The inside surface of forms, except permanent formwork or unless otherwise agreed by the
Authority Engineer, shall be coated with an approved non-staining mould oil to prevent adhesion
of the concrete.
c. Release agents shall be applied strictly in accordance with the manufacturer's instructions and
shall not come into contact with reinforcement and anchorages. The composition of the release
agent shall be such that it will not interfere with future surface treatments.
d. Before concreting, all forms shall be thoroughly cleaned. Faces of formwork in contact with
concrete shall be free from adhering foreign matter, projecting nails and the like, splits or other
defects.
e. The formwork shall be erected and anchored in such a way that it rigidly retains its shape and
position during concreting and that surface irregularities in the concrete are avoided.
f. Formwork shall be erected to such levels as to make allowance for anticipated deflection of the
formwork under load.
7.3.2 Preparation for Placing Concrete
Before the concrete lining is cast the CONTRACTOR shall thoroughly clean the invert, sides and
roof of the excavation of loose or unsound fragments of rock, mud, debris, standing water, oil and
any other foreign matter.
7.3.3 Transport of Concrete
Clause No. 1709 of the General Specification.
7.3.4 Placing of Concrete
a. Clause No. 1709 of the General Specification.

b. The CONTRACTOR shall submit full details of his proposed tunnel concrete placing methods,
including a description of the equipment to be used.
c. The method of placing concrete shall be such that the concrete is not introduced into the
formwork at a high velocity and shall be such that segregation of the concrete does not occur, the
concrete pump shall produce a continuous stream of concrete without air pockets.
d. The casting of the side beams and the structural invert shall be done in separate operations
before placing the inner lining arch of the tunnel. The method of placing concrete in the invert
shall be subject to review of the Authority Engineer.
e. The concrete beams on each side shall be used as abutments for the rails which are necessary
for moving the tunnel formwork. They shall be cured for at least 7 days before the formwork for
the inner lining arch is allowed to be placed.
f. Concrete shall be pumped into the formwork through suitable temporary openings.
g. Concrete in the walls and crown of tunnels shall be brought up in horizontal layers not
exceeding 50 cm, evenly distributed over the concreting section and
h. Maximum level differences shall not exceed the values as specified by the manufacturer of the
formwork.
i. Concrete shall not be pumped into the crown of the arch and allowed to flow down into the walls
and invert. Concrete shall be forced into all irregularities in the ground or initial support surface by
submersive vibrators to fill the void between that surface and the formwork.
j. Particular care shall be taken to ensure the complete filling of the crown of the tunnel arch. The
CONTRACTOR shall include with his details of tunnel concrete placing methods proposals for
satisfying this requirement. Air pockets in the tunnel roof shall be relieved by ventilation hoses
where necessary beyond the relevant stop-end of the formwork.
k. Cold joints in final lining shall be avoided where practicable. A standby concrete pump and
placement line shall be provided during concreting operations. In the event of continuous placing
being interrupted by equipment breakdown or for any other reason, the CONTRACTOR shall
thoroughly consolidate the concrete at such joints to a reasonably uniform and stable slope while
the concrete is plastic and any concrete which remains unconsolidated shall be removed.
l. Final lining for tunnels shall be cast in sections of 10 to 12 meters length measured along the
tunnel axis. Each section shall be cast in one continuous operation without interruption and
construction joints. All construction joints at the ends of the sections shall be perpendicular to the
gradient.
m. When the ambient temperature at the place of pouring is greater than 32 degrees Celsius, hot
weather concreting techniques as described in the American Concrete Institute Standard ACI
305R-77 shall be used.
n. For cold weather concreting refer to Section 1712 of the General Specification.
7.3.5 Compaction of Concrete for Final Lining
b. The concrete shall be compacted by vibrators anchored to the formwork and immersion
vibrators operated through the inspection openings in the formwork.
c. The operating time of the external vibrators shall be kept short in order to avoid segregation.
7.3.6 Removal of Formwork
b. Formwork shall be so designed as to permit easy removal without resorting to hammering or
levering against the surface of the concrete or injuring the concrete.
c. Any damages occurring during striking of the formwork shall be made good by the
CONTRACTOR during "rubbing up" as described in Clause No. 7.3.8 of this specification.
d. Form removal shall not be started until the concrete has attained strength so that most
unfavourable load conditions do not cause any damages to the structure. The strength of the
concrete shall be measured after removal of the stop-end shutter in the tunnel roof. The minimum
strength for removal of the formwork must satisfy the structural requirements for "dead load" of
the lining. This strength shall be checked by a Schmidt pendulum type hammer, or similar
approved, for low strength concrete, with a piston of 40 mm diameter. Prior to the commencement
of concreting works, the instrument shall be calibrated for each approved concrete mix under
particular application.
The following equipment or similar shall be used:
Manufacturer: Wykeham Farrance, Slough, England
Model No: WF 53932
7.3.7 Curing of Concrete
b. The sealing agent shall not interfere with the bonding of any subsequent surface treatment.
c. Curing can be omitted if the humidity and shrinkage measurements prove that no effect is
attained by curing measures.
7.3.8 Remedial Treatment of Surfaces
7.3.9 Contact Grouting
a. Prior to the commencement of inner lining works, the CONTRACTOR shall submit to the AE for
review full details of the working method and equipment to be used.
b. At all times the CONTRACTOR shall ensure that the grouting operation is under the direct
control of skilled and experienced operatives. The TUNNEL DESIGNER'S REPRESENTATIVE
will state the maximum pressures to be used reviewed by the Authority Engineer.
c. Grouting and ventilating pipes shall be positioned prior to concreting.
d. Upon completion of grouting, the CONTRACTOR shall cut off all surplus lengths of pipes and
make good the surface to the satisfaction of the Authority Engineer.
e. The CONTRACTOR shall provide to the AE as required, records of grouted areas, injection
pressures, grout consumption and mix details.
f. The AE will require tests to be carried out to confirm that the grout mix and its constituent
materials are in accordance with the specification. The CONTRACTOR shall carry out such tests
and submit the results for the Authority Engineer’s review when required.
g. Where dry premixes of grout of an acknowledged manufacturer are used, they shall be mixed
to the manufacturer's recommended water/solids ratio. All grout mixes shall be prepared using
high speed, high shearing action mixers.
h. The CONTRACTOR may choose to propose a method of concreting in order to eliminate
contact grouting of the tunnel lining. However, if the proposed method is agreed with the AE the
requirements of Clause No. 7.1.1e must still be met and the cast in holes used to check that the
tunnel lining is complete as directed by the Authority Engineer.
SECTION 8 – FILL MATERIAL, ANCILLARY CONCRETE AND CONCRETE PAVEMENT

8.1 Plain Cement Concrete
8.1.1 General
Section 1500 and 1700 of the General Specification shall apply.
8.2 Structural Cement Concrete
8.2.1 General
Section 1500 and 1700 of the General Specification shall apply.
8.3 Granular Sub-Base
8.3.1 General
Clause No. 401 of the General Specification shall apply.
8.4 Concrete Pavement
8.4.1 Dry Lean (Rolled) Concrete Base Course
8.4.1.1 General
Clause No.603 of the General Specification shall apply.
8.4.2 Concrete Pavement
8.4.1.1 General
Clause No.602 of the General Specification shall apply.
CLAUSE A-3 GROUTED DOWELS FOR SLOPE STABILITY AND PROTECTION WORKS
Sub-Clause A-3.1. Scope
This work shall consist of furnishing, drilling, installing, and grouting of dowels in conformity with
the dimensions, lines and grades shown on the plans, or as determined by the engineer. The
work shall generally be done in conformity to BS: 8006 Specifications.
Sub-Clause A-3.2. Material Property Requirements
Sub-Clause A-3.2.1 Dowel Rod
It shall be essentially a steel bar of 32 mm diameter and of required length inserted into a
predrilled hole and then grouted so that there is no empty space between the hole wall and the
dowel surface. The metal used for the production of the dowel shall conform to (BS4449:1997)
High Yield Deformed - Steel having a Yield strength of 460 MPa to 500 MPa, and a Rupture
strength of 600 MPa.
Sub-Clause A-3.2.2 Water
As per Appendix – 1800/III (All appendices have references to MORT&H Specifications for
Road and Bridge Works)
Sub-Clause A-3.2.3 Cement
As per Appendix – 1800/III
Sub-Clause A-3.2.4 Sand
Sub-Clause A-3.2.5 Admixtures
Sub-Clause A-3.2.6 Grout
Sub-Clause A-3.2.7 Equipment
The following equipment shall be used for the purposes of drilling and grouting dowels.
Sub-Clause A-3.3.1 Drilling Equipment
Drilling of holes is commonly done by a rotary or rotary percussion handheld or remotely operated
drill equipment. It must be capable of providing a stable drill hole having dimensions within the
permitted tolerance and which is free of obstructions or major protrusions so that the bar can be
inserted without undue resistance.
Sub-Clause A-3.3.3 Grout Mixer and Agitator
Sub-Clause A-3.3.3 Grout Pump
Sub-Clause A-3.3.3 Water Pump
Sub-Clause A-3.3.5 Grout Screen

Sub-Clause A-3.3.6 Connections and Air Vents
Sub-Clause A-3.4. Construction and Installation Requirements
Sub-Clause A-3.4.1 Drilling
The drill holes for rock dowels are commonly produced by a rotary or rotary percussion
mechanism with air or water used as flushing medium. The drilling machine or technology
employed may be handheld or remotely operated drill rigs. The diameter of drill hole shall be
minimum 25 mm larger than dowel diameter.
Sub-Clause A-3.4.2 Installation of Dowel
The boreholes are cleaned by flushing with compressed air or water. The dowel is inspected for
damages or corrosion, immediately prior to installation. The dowels of required lengths are
inserted into the hole till it touches the hole end.
Sub-Clause A-3.4.3 Grouting
Grout shall be injected to fill the hole completely. This will be ensured when the grout of the same
consistency comes out of the hole. In case the length of dowel protrudes from the hole, it shall be
covered by concrete by hand packing.
CLAUSE A-4 GROUTED ROCK BOLTS FOR SLOPE STABILITY AND PROTECTION WORKS
Sub-Clause A-4.1 Scope
This work shall consist of furnishing, drilling, installing, and grouting of rock bolts, in conformity
with the dimensions, lines and grades shown on the plans, or as determined by the engineer. The
work shall generally be done in conformity to the BS: 8006 Specifications.
Sub-Clause A-4.2 Material Property Requirements
Sub-Clause A-4.2.1 Mechanical Shell Anchor
It is a mechanically anchored bar 32 mm nominal diameter and 12 m long. With an expansion
shell anchor, a wedge attached to the shank is pulled into a conical shell forcing it to expand
against the walls of the drill hole.
The metal used for the production of the rock bolts shall conform to BS 4449:1997 High Yield -
Steel having Rupture Strength of 600 MPa.
The bar must be threaded at the proximal end to allow tensioning of the bolt and for a nut and
faceplate to be attached.
Sub-Clause A-4.2.2 Water
As per Appendix – 1800/III (All appendices have references to MORT&H Specifications for
Road and Bridge Works)
Sub-Clause A-4.2.3 Cement
Sub-Clause A-4.2.4 Sand

Sub-Clause A-4.2.5 Admixtures
Sub-Clause A-4.2.6 Grout
Sub-Clause A-4.3 Equipment
The following equipment shall be used for the purposes of drilling and grouting anchored bolts.
Sub-Clause A-4.3.1 Drilling Equipment
Drilling of holes is commonly done by a rotary or rotary percussion handheld or remotely operated
drill equipment. It must be capable of providing a stable drill hole having dimensions within the
permitted tolerance and which is free of obstructions or major protrusions so that the bar can be
inserted without undue resistance.
Sub-Clause A-4.3.2 Grout Mixture And Agitator
Sub-Clause A-4.3.3 Grout Pump
Sub-Clause A-4.3.4 Water Pump
Sub-Clause A-4.3.5 Grout Screen
Sub-Clause A-4.3.6 Connections and Air Vents
Sub-Clause A-4.4 Construction and Installation Requirements
Sub-Clause A-4.4.1 Drilling
The drill holes for rock bolts are commonly produced by a rotary or rotary percussion mechanism
with air or water being used as flushing medium. The drilling machine or technology employed
may be handheld or remotely operated drill rigs.
Sub-Clause A-4.4.2 Installation of Rock bolt
The boreholes are cleaned by flushing with compressed air or water. The rock bolt is inspected
for damages or corrosion, immediately prior to installation.
The rock bolts are driven into the hole until the expansion shell reaches the hole end and an initial
tension is applied by tightening the bolt so that the wedge shaped blades are held stationary
against the hole wall. A steel plate 200 x 200 x 8mm thick with a conical washer shall be inserted
on to the bolt on the face of the rock. Rock bolts shall be tensioned either directly, using hydraulic
jacks or indirectly by applying a measured torque to the locking nut. The load is transferred from
the rock bolt via threaded nuts onto the face plate.
Sub-Clause A-4.4.3 Grouting
Grouting shall be injected through the grout inlet tube to fill the hole completely. This will be
ensured when the grout of the same consistency comes out the grout return tube.
Sub-Clause A-4.4.4 Stressing and Testing
The hydraulic jacks and pumping unit should be capable of tensioning the rock bolt tendon to not
less than 80% of characteristics of the shank. Typically, between 1% to 5% of the bolts should be
checked with hydraulic jack. The method of tensioning, the sequence of stressing and procedures
to be adopted for each stressing operation is as per specified or according to the Engineer.
Annex – I
(Schedule-D)
(Value Addition Works)
SPECIFICATIONS AND STANDARDS FOR CONSTRUCTION OF TUNNEL
1. Specifications and Standards
All Materials, works and construction operations shall conform to the Manual of Specifications and
Standards for Four-Laning of Highways (IRC: SP: 84-2019) and IRC: SP: 91-2019 with all
amendments till date published by IRC (referred to as “Manual” in this Schedule) and MORT&H
Specifications for Road and Bridge Works(5th revision). Where the specification for a work is not
given, Good Industry Practice shall be adopted to the satisfaction of the Authority‟s Engineer for
construction of the project t highway.
As regards, the work of utility shifting, the relevant specifications, relevant rules regulations and
acts of Utility Owning Department/ Agencies shall be applicable.
2. Deviations from Specifications and Standards
2.1 The terms “Concessionaire”, “Authority Engineer” and “Concession Agreement” used in the
Manual shall be deemed to be substituted by the terms “Contractor”, “Authority‟s Engineer” and
“Agreement/EPC Agreement” respectively.
2.2 Notwithstanding anything to the contrary contained in Paragraph 1 above, the following
Specifications and Standards shall apply to the Project Highway, and for purposes of this
Agreement, the aforesaid Specifications and Standards shall be deemed to be amended to the
extent set forth below:
Deviations from the Specifications and Standards
S. No. Clause Manual Provision Modified provision
No.
14.2.2 Cross-Section As Per Schedule-B and TCS as given in Annex-I of
1. (Tunnel) Schedule-B.
14.2.5 Number of Traffic As per Typical cross section for Tunnel as given in
2. Lanes Annex-I of Schedule-B.

(Tunnel)
14.2.6 Carriageway & As indicated in tunnel cross sections given in
3. Shoulders Annex-I of Schedule-B.
(Tunnel)
14.2.9 Vertical Alignment Vertical Alignment of Tunnel shall be as specified in
4. (Tunnel) Plan and Profile given in Annex- III, of Schedule A.
14.2.10 Horizontal Alignment Horizontal Alignment of Tunnel shall be as specified

5. (Tunnel) in Plan and Profile given in Annex- III, of Schedule
A.
14.8 Tunnel Illumination Tunnel Illumination shall be designed as per
6. (Tunnel) IRC:SP:91-2019
Section- Protection As specified in Appendix D – I of Schedule –D.

7. 13 Works/Tunnel Works
& Road works
S. No. Description
Specifications and Standards for Tunnel & Road Works
Tunnel Specifications (Annexure-I)
1.
Protection Works (Annexure-II)

2.
Annexure-I
TUNNEL SPECIFICATIONS
A. SPECIFICATIONS & STANDARDS OF CIVIL WORKS IN TUNNEL
General
The project road has twin tube unidirectional traffic tunnels accommodating two lanes for each
north bound and south bound carriageways. The tunnel will be provided with infrastructure for
accommodating lighting, firefighting, and other E&M arrangements as per manual requirements.
1. Scope of the Work
1.1. The work shall include but not be limited to:
a) Survey and setting out of the alignment.
b) Additional Exploratory Geotechnical Investigations along the alignment of the tunnels and cut
and cover portions etc., if necessary,
c) Excavation of open cuts in all types of soils and rock including provision of treatment such as
Soil Nailing, Rock Bolting, installation of Wire Netting, Shotcreting, Grouting etc. to the excavated
profile as and where necessary as per approved design, drawings and as directed by the
Engineer.
d) Tunnel Excavation in all types of soils and rock with concurrent Advance Probing and if and
where necessary, Grouting of the Strata ahead, Fore-poling, Shotcreting, Rock bolting and
Installation of Permanent Steel Supports with precast Lagging and Lean Concrete backpacking,
installation of Lattice Girder Supports embedded in reinforced Shotcrete, as and where necessary
as per approved design, drawings and as directed by the Engineer.
e) Concrete lining of the Tunnel where required and as directed by the Engineer.
f) Concrete inside Drains, Kerbs and Crash Barrier etc. in the Tunnels.
g) Installation of Furnishings such as Walkway Slabs, Hand Railing for the Walkways.
h) Design Supply, Erection, Testing and Commissioning of Mechanical, Electrical and Plumbing
Services.
2. Special Features of the Work
2.1 The EPC Contractor will employ controlled blasting techniques so as to avoid damage to
adjoining and overlaying structures, electric power lines, telephone lines, etc. In this respect,
The EPC Contractor will have to plan the tunnel excavation activities in such a manner that at no
stage the gap between any two faces under excavation will be less than 20 m.
The area lies in Seismic Zone No. IV as defined by IRC Codes.
3. Open Excavation
3.1 Excavation in Open Cuts and Tunnel Approach Cuts all types of strata shall be carried out as
per additional specifications.
4. Underground Excavation
4.1 Setting Out
The EPC Contractor shall establish at suitable points to the satisfaction of the Engineer,
permanent reference marks on the centre lines of tunnels etc. and their extensions at both the
ends as may be necessary. The permanent marks shall be inscribed on brass pegs set in
concrete blocks. Suitable permanent benchmarks shall be established near the portals.
As the work progresses, centre line marks shall be transferred on pegs, inserted into the roof of
tunnels at suitable locations and at convenient intervals to the satisfaction of the Engineer for
checking alignment, grades, levels etc. and also the dimensions of the excavated profiles.
The EPC Contractor shall at all times remain responsible for the sufficiency and accuracy of all
such benchmarks, central line pegs and reference points.
4.2 Accuracy of alignment, grades, levels etc.
a) Benchmarks and fixed reference points, with the value of the reduced levels and the
coordinates shall be fixed near the works area. Plan showing the position, coordinates, and levels
of the salient points of the various underground works shall need to be approved by the Engineer.
The EPC Contractor shall take all precautions to see that the control points fixed by him are not
disturbed by his work and shall make good the damage, if any, at his own cost. The EPC
Contactor shall excavate the tunnels, true to alignment, grades and levels and shall check them at
frequent intervals as the work progresses. The EPC Contractor shall provide at this own cost all
facilities like labour, special equipment and instruments etc. to the Engineer to check the
alignment, grades and level etc. whenever and anytime they are asked for. Such checking by the
Engineer or his representatives, shall not absolve the EPC Contractor from his responsibility of
maintaining the accuracy of the work. Any discrepancy or error detected during the course of
excavations and / or at the end of the work when the excavated bore/ faces meet shall be set right
by the EPC Contractor in a manner satisfactory to the Engineer without causing any harm to the
work already carried out. The EPC Contractor, shall at all times during execution of work, shall
have at the site of work, at least one electronic total station and two auto levels, duly calibrated
and in good condition, at the disposal of the Engineer, for proper control of line and level.
b) The EPC Contractor shall arrange to check the excavated profiles of the tunnels periodically to
ensure excavation to required profile and undercuts, if any, found within the boundary of minimum
excavation line, shall be immediately removed.
4.3 Proposed Method of Work
a) The EPC Contractor shall carry out the work of tunnelling by full face excavation or heading
and benching method or multi-drift method to suit rock conditions and to expedite the work and
minimize tunnel hazards. The EPC Contractor can carry out tunnel excavation in heading and
benching simultaneously with suitable lag, to expedite progress. EPC Contractor shall carry out
shotcreting, rock-bolting and installation of permanent steel supports with lagging and lean
concrete backpacking and installation of lattice girder supports along with their embedment in
reinforced Shotcrete simultaneously with the excavation, as per site requirements and as per
approved design, drawings and as directed by the Engineer. Therefore, the EPC Contractor
should deploy adequate plant and machinery, skilled labour, material etc. for such simultaneously
activities of tunnel excavation;
b) The EPC Contractor should plan his operations and carry them out in such a manner and in
such sequence that the entire work is completed within the lime targets laid down.
c) Geological mapping
Geological mapping shall be performed by qualified geologist to provide a documentation of rock
and rock mass condition encountered during excavation. Additionally, all exposed rock surfaces
of the open and underground excavations shall be washed down for inspection and geological
mapping. Exposed rock surfaces at the required excavation pay lines shall be mapped after
preparation but before shotcrete application. Tunnel and other underground faces shall be
mapped just before the start of drilling. The Contractor shall allow in his construction procedure
and schedule for the geological mapping of each tunnel face not less than 30 minutes.
The geological mapping shall include but not limited to the following information:
 excavation face
 tunnel meter
 geological unit
 intact rock:
- rock type and lithology description
- weathering and alteration degree
- uniaxial and unconfined compressive strength (from point load tests)
 rock mass:
- jointing degree
- geometry, orientation (strike and sip) and properties of discontinuities
- face condition (homogeneous or heterogeneous)
- water inflow
- over breaks (separated in geological and non-geological)
- ground response
- suspected pervious zone
 the RMR & Q values and the corresponding excavation class
 groundwater appearance
The Contractor shall provide lights, ladders, platforms and free access and shall assist the
Employer’s Representative to carry out inspection and geological mapping.
In case of sudden and unexpected changes of the geological conditions, the same shall be
informed immediately.
d) Blasting
Not less than 40 days prior to commencement of rock excavation in each area, the Contractor
shall submit, for review by the Employer’s Representative, details of the drilling and blasting
methods which he intends to use in that area. If, at any time in a specific area, a plan which has
been previously adopted does not produce conditions at the excavated rock face that conform to
the requirements of these Specifications, the Contractor shall submit a revised plan to the
Employer’s Representative before continuing excavation in adjacent areas.
The Contractor shall develop controlled blasting techniques, which will satisfy the excavation
requirements specified herein. In each different type of rock conditions, the Contractor's initial
blasts shall be performed as trials, and the burden, drill hole pattern and depth, explosive type
and quantity, blasting sequence and drill delay pattern shall be modified to achieve the
requirements specified herein.
Blasting means have to follow the licensing requirements and orders as well as the
manufacturer’s instructions.
Blasting operations shall be carried out only under the direction of an experienced operator. The
Contractor shall appoint one competent person to be responsible for the security of explosives.
Blasting shall be carried out carefully so as to avoid loosening or shattering rock beyond the
required line of excavation, and loose or shattered rock (where it does not contribute to stability of
the excavation) shall be removed by scaling down or other means before personnel will be
permitted to restart operations after blasting.
Notices of blasting operations shall be posted on site. Before each firing, the Contractor shall give
audible warning, clear the area and shall take positive measures to prevent personnel from
entering the danger area.
The Contractor shall monitor the results of blasting closely and, where it is proper to do so, shall
propose changes to his blasting operation for the agreement of the Employer’s Representative.
Under no circumstances shall any holes be charged until completion of all drilling operations at
the face.
After each blasting operation the tunnel drive shall be sufficiently ventilated to remove any nitrous
gases and the atmospheric conditions shall be constantly checked prior to personnel accessing
the excavated face.
No person shall be allowed to approach the face and no face operation shall commence until the
Contractor’s authorized person in charge of the operation has given permission after blasting
round.
As soon as practicable after blasting and without undue delay the Contractor shall erect such
support as may be necessary to safeguard the excavation and personnel.
The shot-firer must keep a record of the number of shots fired, their time of firing, type and
weights of explosives used, and the type and number of detonators used, together with a record
of the post-blast situation for each and every location. A copy of the record shall be available to
the Employer’s Representative at the end of every shift on which shots are fired.
e) Controlled perimeter blasting
Controlled perimeter blasting techniques shall be used to produce rock faces conforming to the
required excavation lines, slopes, elevations and dimensions shown on the drawings with a
minimum of disturbance to the rock at, or outside of, the excavation pay lines.
Drill holes for controlled perimeter blasting shall not be less than 42 millimetres in diameter and
shall be a single row of closely spaced holes drilled to a maximum depth of one round length
along the excavation pay lines and a spacing of 0.4 to 0.6 m depending on the ground condition.
The spacing of the perimeter holes may be modified on the basis of results obtained and in
agreement with the Employer’s Representative.
All blast holes within a distance of 5 meters normal to the excavation pay lines shall be less than
75 millimetres in diameter and shall be loaded in a manner and detonated in a sequence to
ensure that a minimum of damage will result to the face when the main charge is fired
f) Explosives
The Contractor shall use explosives only in circumstances where it is safe to do so having due
regard to the safety of persons, third-party property and the safety of the Works. Explosives shall
not be used without the agreement of the Employer’s Representative.
The Contractor shall obtain all necessary licenses and consents and shall provide secure storage
facilities for all explosives and equipment in accordance with Indian or International Standards
Code of practice for the safe use of explosives in the construction industry and the requirements
of the local Authorities and the Employer’s Representative.
Explosives shall be handled and used only by the Contractor’s duly authorized personnel. The
names and qualifications of such personnel shall be submitted to the Employer’s Representative
in writing in advance of any possible use of explosives.
At an early stage, in advance of the proposed use of explosives, the Contractor shall notify the
Employer’s Representative, third parties, statutory authorities and services which have an interest
in or are likely to be affected by blasting operations, of the general nature of the operation. The
Contractor shall subsequently give a minimum of 14 days‟ notice to the Employer’s
Representative and others described above of the proposed use of explosives. With this
notification the Contractor shall submit to the Employer’s Representative a detailed method
statement on all aspects of the proposed use of explosives, including the treatment of misfires.
The Contractor shall comply with the following documents in respect of the use of explosives:
 Indian Explosives Act 1884
 Indian Explosive Rules 2008 and further amendment in Jan.2009
 The Manufacture and Storage of Explosives Regulations 2005
 BS 5607:1998 Code of practice for the safe use of explosives in the construction industry
 Control of Explosives Regulations 1991
 Carriage of Explosives by Road. Road Traffic (Carriage of Explosives) Regulations 1996
 PD CLC/TR 50426:2004 Assessment of inadvertent initiation of bridge wire electro-explosive

devices by radio- frequency radiation. Guide Quarries (Explosives) Regulations 1988, as far as it
is relevant to tunnel works
g) Blasting Vibrations
For structures in the proximity of blasting, the peak particle velocity shall be measured at the
locations immediately adjacent to the structure nearest to the face being blasted or any other
location where it is necessary to limit vibration.
Vibration monitoring proposals shall be submitted to the Employer’s Representative for his
agreement.
The measurement of peak particle velocity shall be obtained from instruments capable of
measuring along three orthogonal axes, one of them shall be aligned parallel to the centre line of
the excavation and another shall be vertical. The Contractor has to provide supports for the
measuring instrument if so, required by the manufacturer’s instructions.
The measurements of the particle velocities shall be the responsibility of the Contractor. Copies of
the readings in an agreed form shall be supplied to the Employer’s Representative.
Prior to the commencement of blasting in any location, the Contractor shall demonstrate using
test firings, or by other means, that neither the peak particle velocities given in the particular
Standards and Specifications will be exceeded.
The maximum allowable blasting vibrations shall be defined by the Contractor for every influenced
structure with reference to the applicable Standards and Specifications for the relevant structure.
The allowable blasting vibrations shall be approved by the Employer’s Representative prior to any
blasting operations.
The Contractor shall maintain accurate records of all blasting and excavating operations and at
the end of each shift he shall provide the Employer’s Representative. The forms shall bear the
signatures of the Contractor's and the Employer’s Representative certifying that records are
accurate and complete and include but not limited to the following:
 length of tunnel excavated, and theoretical volume of solid material excavated.
 quantity of any rock support installation.
 occurred rock falls, zones of instability and logs of pilot holes.
 water inflow at the head and rate of discharge at the tunnel portal.
 unusual occurrences and all delays with reasons for these.
Holes drilled in swelling ground shall be conducted without water. Determination of Excavation
and Support and Prediction of System Behaviour.
For the final determination of the excavation and support method, it must be checked if the
ground conditions conform to the design assumptions. When the observed conditions
conform to the predicted ones, stipulations in the framework plan must be followed when
determining the construction measures.
In case of a deviation exceeding the specified tolerance in the framework plan, the designer must
be informed to allow for an adaptation of the prediction, based on new findings. The designer
shall agree with the required additional measures in due time and update the framework plan
accordingly.
The final decisions on the applied construction measures are based on the design and additional
information gained during construction. The goal is a safe and economical construction.
h) Check of System Behaviour
The actual deformation in the supported area and in the final stage shall be compared to the
predicted behaviour, and checked, whether the behaviour is within the specified limits of the
warning criteria. Additional measurements or evaluations may be required.
Deviations between the expected and the observed behaviours must be analysed and
documented.
In case the assumptions regarding the influencing factors are inappropriate, the parameters must
be modified. The modifications must be supported by appropriate data and analyses and
documented in an updated framework plan.
In case the ground quality is better than predicted, the geotechnical model must be revised. In
case of a significant deviation, the criteria for the determination of excavation and support must be
modified.
In case the ground quality is worse than predicted and warning levels exceeded, contingency
measures according to the safety management plan must be implemented, and excavation and
support shall be adjusted accordingly. This can be done for example by additional bolting,
installation of a temporary invert, etc. In some cases, the installation of a stronger support in the
following rounds may be enough to achieve the target.
In case of significant deviations, the geotechnical model has to be revised and the criteria for the
determination of excavation and support have to be modified. This generally requires that the
framework plan is updated.
The following parameters need to be monitored in the tunnel:
i. Geometrical Parameters:
1. Face Extrusion (horizontal displacement)
2. Surface settlement
3. Surface rotation
4. Extrusion of the ground ahead of tunnel face
5. Displacement in bore hole
6. Convergence in side wall & crown
7. Crack Monitoring
8. Deformation of permanent lining
ii. Mechanical properties:
1. Force (arch base, anchoring rod, rock bolt)
2. Stress in support/lining
iii. Hydraulic Properties:
1. Piezometric levels
Fig- Typical cross section with Instrumentation for Monitoring

Table- Measurement Parameters with corresponding Instrument
iv. Face Extrusion & of Ground ahead of tunnel face-It is meant to identify the
extent and condition of the de-stressed zone ahead of the tunnel face.
Fig- Extrusion Measurement
Fig- Incremental Extensometer with

Optical targets for Longitudnal & radial deformation
Fig- Typical Graph for the Extrusion measurement &

distance from the face of excavation.
v. Settlement & Displacements- The settlement of the ground surface and
displacements in the tunnel shall be presented in graphical form.
Fig- Typical Displacement History Plot

(Austrian Society of Geomechanics 2005)
Fig- Typical Deflection curve for tunneling (Austrian

Society of Geomechanics 2005)
Fig-Typical Trend line plot with a major Fault zone
Fig- Typical plot of S crown – S Sidewall

(displacement difference) for tunnel with Faults
The trend line will give an overview of the displacement development along the
tunnel axis for given excavation component. The presence of a weak zone or
major discontinuity ahead of the face of tunnelling tends to increase the
displacement over several readings. The trend line should be used to identify
any potential zone of weakness and discontinuity; accordingly, the support
measures and excavation sequence needs to be planned in accordance with
the technical specifications.
vi. Convergence Measurement- The monitoring of convergence is done with
help of optical targets mounted on the tunnel wall immediately after the
excavation. To determine the convergence the readings of the
deformation of each target over a cross section should be plotted with
respect to time. The convergence data shall be used in studying the
integrated effects of stresses, strains and curvature. The displacement is
observed over several cross sections at regular interval.
Fig-Optical targets to measure convergence
Fig- a) Distance Vs Time, b) Convergence Vs Time, c) Convergence Vs Distance

Table- Measurement Parameters with
corresponding frequency and spacing range of instr.
vii. The Ground Response Curve- The GRC has to be developed based upon
the observed values and it shall be compared with the theoretical values.
The support interaction with the ground response shall be plotted.
Following is the set of GRC based upon theoretical calculations and
geotechnical data obtained from investigation at site for the reference purpose.
The same shall be modified and updated based upon the ground response
obtained during the tunnel excavation through specified monitoring and

instrumentation.
Fig- Ground Response Curve: Poor Rock mass

(RMR) with overburden of 25 meters
Fig - Ground Response Curve: Poor Rock mass

Fig- Ground Response Curve: Poor Rock mass

Fig - Ground Response Curve : Fair Rock mass

Fig - Ground Response Curve : Fair Rock mass

Ground-support interaction curves to be developed based upon the convergence
data obtained from instrumentation & monitoring.
Fig - Ground support Interaction curve

i) Probing Ahead
Where required the Contractor shall be responsible for probing ahead of the tunnel
face in order to prove or investigate the ground.
The selection of plant for probing shall be agreed with the Employer‟s Representative
and shall take the probable nature of the ground ahead and its water-bearing
capacity into account.
Probing shall be carried out in such way to allow modification of the excavation and
support according to the encountered ground conditions. The number of probes, the
diameter of drilling, their positions in the face and angles with respect to the tunnel
drive shall be governed by the actual ground conditions and the machinery in use.
Construction of Balance work and Value Addition Works of Four Laning of part of Ramban to Banihal Page D-
The maximum probed distance ahead of the face shall be governed by the ground
conditions and the degree of uncertainty with distance.
The diameter of probe holes shall be not less than 38 mm.
5. Construction Material
Sand/gravels and boulders are available in abundance in the vicinity of site. Quarries will be
required to be set up at suitable locations when the construction work is actually taken up.
All other material like cement, steel, construction machinery and equipment will have to be
brought from outside and transported via roads.
The current survey and the potential increase in underground constructions (and tunnels in
particular) foreseen for the future to answer the Increasing demand for infrastructures, will
involve a huge amount of tunnel muck , which, if not re-used. has to be dumped, with high
costs concerning both the impact on the territory and the project itself. In tunneling
excavation, two very important aspects have to be taken into account the dumping of the
excavated material and the opening of new quarries to supply raw materials.
A solution that could be proposed to minimize these relevant environmental problems is the
recycling, or reusing, of the muck from tunnel excavations which can be employed as
aggregates for concrete, for bituminous conglomerates, for road construction, or for raw
materials for industry. Tunnel muck can be used: in its natural form, as obtained from the
excavation, treated in plants, treated or in its natural form with addition of other materials or
as raw material for industrial products (not very common use).
Tunnel muck is more frequently used as:
 Refilling material
 Material for reliefs
 Road construction
 Concrete
 Raw material for industrial production.
The properties considered to determine the final use vary according to its final use and refer,
as far as the physical aspect is concerned, to the size distribution, the maximum dimension,
the shape and the density, whereas from the chemical point of view, they concern the
presence of some reactive minerals. Before muck can be used as concrete aggregates, it
must have suitable properties: as far as the Petro graphic properties are concerned, the
presence of a significant quantity of brittle minerals (clay, gypsum, talc), of very hard
minerals (garnet) and of foliated and fibrous minerals (mica, graphite, asbestos), should be
avoided, whereas, as far as the chemical properties are concerned, high solubility (chloride,
Sulphate, gypsum), low resistance to decay (anhydrite, pyrite) and alkali reactivity have a
negative effect.
Tunnel muck should be considered as a valuable resource after treatment. It can be used for
different purposes. This would lead not only to environmental benefits but also those of an
economic nature. The D&B Contractor has to be carried out survey and evaluation of
construction materials including water with reference to relevant IS codes and doing
chemical analysis to determine the aggressiveness of the water to concrete. The muck
removed and after treatment will be utilizes as construction material providing to meet the
requirement as per specification given below.
5.1 Aggregates
Aggregates shall comply with the requirements of IS 383. As far as possible, preference
shall be given to natural aggregates.
5.2 Coarse Aggregates
Coarse aggregates for all classes of concrete shall conform to the requirements of ARE:
383. It shall be furnished in two separate sizes: either the 20mm down and or the 38mm
down to No.4 sieve.
Beside aggregates other construction material listed below shall meet the following
requirements:
5.3 Fine Aggregates
Fine aggregates shall conform to the requirements of IS: 383 or as required to meet the
design requirements. Water absorption shall be less than 3% by weight.
5.4 Cement
The cement used shall be any of the following and the type selected should be appropriate
for the intended use
 33 Grade ordinary Portland cement conforming to IS: 269
 53Grade ordinary Portal cement conforming to IS: 12269
 Rapid hardening Portland cement conforming to IS: 8041
 Portland slag cement conforming to IS: 455
 Portland Pozzolana cement (fly ash based) conforming to IS: 1489 (Part 1)
 Portland Pozzolana cement (calcined day based) conforming to IS: 1489 (Part 2)
 Hydrophobic cement conforming to IS: 8043
 Low heat Portland cement confirming to IS: 12600
 Sulphate resisting Portland cement confirming to IS: 12330
5.5 Water
Water to be used for mixing and curing concrete and mortar shall be fresh and dissolved or
suspended matter, which may be harmful and shall comply with the requirements of IS: 456.
5.6 Admixtures
The consent of the Engineer shall be obtained prior to using any admixture in any concrete
mix. Admixtures shall conform to IS: 9103.
5.7 Reinforcement
 The reinforcement shall be any of the following:

 Mild steel and medium tensile steel bars conforming to IS: 432 (Part 1)
 High strength deformed steel bars conforming to IS: 1786
 Hard-drawn steel wire fabric conforming toIS:1566
 Structural steel conforming to Grade A of IS: 2062
6. Shotcreting
General Shotcrete is mortar or concrete conveyed through a hose and projected at high
velocity on to a surface. Shotcrete is classified into dry mix and wet mix according to mixing
and working method. Shotcrete, for this work, shall be defined as spraying premixed
Portland cement concrete as per approved design with admixtures including micro silica and
additives (i.e. water reducing agents/ thixotropic agent, acceleration etc.) from a spray
nozzle by means of compressed air using wet shotcrete machine. Shotcrete shall be applied
in accordance with relevant ACI/ASTM/EF/NARC specifications/ guidelines.
a) The provisions contained in IS:9012-1978 shall generally apply. The work consists of
provision and application of shotcreting to excavated profile of the open cuts and the tunnels.
All Shotcrete will be reinforced of thickness as specified unless otherwise ordered by the
Engineer. shotcrete shall be applied on excavated periphery of the tunnels of the open cuts
at locations as directed by the Engineer with EPC Contractor’s supply of materials,
machines, equipment, tools and labour necessary for mixing and applying the shotcrete.
b) Cement: The Cement used shall be low alkali Portland cement with the prior approved of
the engineer-in-charge.
c) Aggregates: Sand and shotcrete shall comply with the requirements given in IS: 383-
1970. Coarse aggregate when used shall comply with the requirements of IS 383-1970.
d) Water: Water used for shotcrete shall conform to the requirements of IS: 456-1978.
e) Reinforcement: Reinforcing bars shall comply with the requirements of IS: 432 (Part 1) -
1966.
6.1 Shotcrete Process
Dry Mix Process
In this process, a mixture of cement and moist sand is conveyed through the delivery hose to
a nozzle where most of the mixing water is added under pressure.
The process consists of the following steps:
The cement and moist sand are thoroughly mixed;
 The cement sand mixture is fed into a special mechanical feeder or gun referred to in this
standard as delivery equipment.
 The mixture is forced into the delivery hose by a feed wheel or distributor;
 The mixed material is carried in suspension by compressed air through the delivery hose
to a nozzle, which is filled inside with a perforated manifold through which water is
introduced under pressure and intimately mixed with the other ingredients.
 The mortar is jetted form the nozzle at high velocity on to the surface to be provided with
shotcrete.
6.2 Wet Mix Process
In this process, all the ingredients including water are mixed before they enter the delivery
hose. It consists of the following steps:
All the ingredients (including mixing water) are thoroughly mixed;
 The mortar or concrete is introduced into the chamber of the delivery equipment:
 The mixture is forced into the delivery hose and conveyed compressed air or other
means to a nozzle.
Additional air is injected at the nozzle to increase the velocity and improve the shooting
pattern; and the mortar or concrete is jetted from the nozzle at high velocity on to the surface
to be shotcreted.
6.3 Material
Ingredients of shotcrete shall include cement, aggregate, admixtures, micro silica and steel
fibers. Specified of ingredients are given below.
a) Cement: Low alkali cement is recommended.
b) Aggregate
Aggregate shall conform to requirement of relevant IS Code or as directed by the Engineer.
The aggregates size shall not exceed 10mm. The gain size distribution of aggregate shall be
as under:
Sieve size Percentage passing through sieve
(mm) Minimum Maximum
10 100 100
8 90 100
4 73 100
2 55 90
1 37 72
0.5 22 50
0.25 11 26
0.125 4 12
The aggregate shall be well graded and no fraction, shall constitute more than 30% of the
total mass.
c) Admixtures
Only proven admixtures which meet the requirement of the specification on field trails and
satisfactory performance on other projects already constructed in India and elsewhere shall
be used to unsure a homogeneous mix and better dispersions of various constituents of
shotcrete. A two components system to control the consistency shall be used to ensure good
workability and low rebound. The admixture system shall produce slump killing effect and
thixotropic consistency thus adhering in thick layers without tricking and subsequently
reducing the rebound. The EPC Contractor shall submit along with the design a certificate
for satisfactory performance of admixtures and chemical compatibility between two

components, from the manufacture.
Admixture shall be of following types:
I) Water reducing/ thixotropic agents: -
These agents shall be added at the batching plant/ concrete mixer to keep the Shotcrete/
mix workable during transportation and to ensure pumpability at an acceptable low W/C
ratio. The chloride contents shall not exceed 0.1% by weight.
II) Accelerators:
Accelerators shall meet the following requirements:
 Only liquid alkali free accelerators shall be used.
 Water glass (sodium silicate) shall not be used unless n a modified base form
approved by the Engineer.
 Only the minimum quantity of the accelerator necessary shall be permitted in
normal shotcrete operations subject to maximum doges of 5-6% by weight of
cementitious material.
 Accelerators should have pH values less than 12.
 Accelerators shall be selected such that at the chosen dosage for use in the works,
he decreases in strength at 28 days compared with the base concrete without any
accelerators shall not exceed 10%. There shall be no further reduction in strength of
the shotcrete mix between 28 and 90 days.
d) Micro Silica (Silica fumes)/ Metakaoline
Micro silica/ Metakaoline produced manufactured only by suppliers as approved by the
Engineer shall be used for the work. The dose of silica fumes shall be 5 to 7% of cement
weight subject to site trials. Silica fumes shall have bulk density between 500 to 700 kg per
cum. Few important requirements are reproduced below for guidance:
Chemical requirements
I) Chemical requirements
S. No. Property % Age Min Frequency
of testing or as
Directed by the
Engineer
1 SiO2 >85 Lot or 100 MT
2 SiO3 <1 Lot or 100 MT
3 Loss on ignition 6 Lot or 100 MT
II) Physical requirements
S. No. Property % Min Frequency of

Age testing or as Directed
by the Engineer
1 Accelerated pozzolanic activity 85 Lot or 100 MT
index with Portland cement at
7 days (Min % age of control)
2 Increase in drying shrinkage of 5 Lot or 100 MT
mortar bars at 28 days (Max %
age joints)
3 Reactivity with cement 80 Lot or 100 MT
reduction of mortar expansion
at 14 days (min % age)
Metakaoline shall confirm to ASTM C 618 Class – N Pozzolana specifications.

e) Steel fibre
Steel fibre produced/ manufactured only by suppliers as approved by the Engineer shall be
used for the work. No balling of steel fibres should occur at the time of mixing and
shotcreting. The dose of steel fibre shall be such as to achieve a min of 750 J energy
absorption subject to site rails. The EPC Contractor shall submit test certificate from a
reputed laboratory/ supplier for all ingredients brought and intended to be used in shotcrete /
SFRS by him. The Engineer may however get he samples of these materials tested
independently at EPC Contractor’s won cost. The cost of such test shall be borne by the
EPC Contractor.
6.4 Strength criteria
The final product shall meet the strength criteria as per relevant EFNARC/ACI standards.
The strength requirements for SFRC/plain shotcrete are given below.
a) Steel fibre reinforced shotcrete:
The Shotcrete shall meet the following strength requirements:
I) Compressive strength on cylindrical cores
(i) 3 days 10Mpa
(ii) 7 days 18 Mpa
(iii) 28 days 25 Mpa
II) Flexural Strength 28 days: 3.8 Mpa
III) Toughness 28 days: 2.4 Mpa
b) Plain wet shotcrete: The mix shall be designed to give the following strength
requirements.
I) Compressive strength on cylindrical cores

(i) 3 days 7 Mpa
(ii) 7 days 15 Mpa
(iii) 28 days 20 Mpa
II) Flexural Strength 28 days: 3 Mpa
6.5 Mix design
The EPC Contractor shall submit mix design to meet the strength as specified for prior
approval of the Engineer prior to commencement of shotcrete/ SFRS. Mix design should
give following details.
Ordinary Portland cement (Low alkali Kg
cement is recommended) (Minimum
cement contents as per IS 456, 2000
for durability)
Micro silica/ Metakaoline Kg
Natural fine aggregate Kg
Crushed coarse aggregate Kg
Crushed fine aggregate Kg
Steel fibers Kg
Water reducer/ thixotropic agent Kg
Accelerator -
W/C ratio -
Slump -
Density (Wet) -
Compressive strength on cylindrical 3 days/ 7 days/ 28 days
cores
Equivalent cubes strength 28 days
Flexural strength 28 days
Toughness 28 days
6.6 Test procedure
Tests of SFRS/ shotcrete shall be carried out as per relevant ASTM/ JSCE/EFNARC
standard or as directed by the Engineer. All equipment for testing shall be arranged by the
EPC Contractor at his own cost. Some of the tests of the shotcrete/ SFRS are given below
for guidance.
a. Compressive strength
The specimen cylindrical cores measuring minimum 75 mm dia or as directed by Authority
Engineer or concrete cubes of 100 mm size shall be drilled/sawn/extracted out of prepared
test panels. Panels for testing shall be at least 600 x 600 mm in size and shall be of
thickness as per design. The panel shall be prepared by shotcreting into vertical Moulds
which shall be constructed of steel or other non-water absorbent material and shall have
side splayed out Moulds at 15 degrees to prevent the entrapment of rebound.
b. Flexural strength and energy absorption
Flexural strengths and energy absorption shall be measured in accordance with Japanese
standard JSCE/ASTM/EFNARC standards. The beam shall be cut out from splayed panels.
The beam shall be stored in water for a minimum of 3 days after sawing and immediately,
before testing and kept moist during testing. The test panel for energy absorption shall
correspond to EFNARC or SIA standard.
6.7 Placing equipment
EPC Contractor should use only wet shotcrete machine with Robot arm which can spray
shotcrete efficiently even in overhead positions. The machine should be able to place
shotcrete & SFRS as per design mix.
The air supply system shall be capable of supplying air at the pressure and volumes needed
for the efficient operation of the machine. No air supply system shall be used that delivers air
contaminated by oil or that is incapable of maintaining constant pressure.
In addition, a separate air hose and blowpipe shall be available to remove dust & rebound
during shotcrete application.
6.8 Method of application
a) Only wet mix method shall be used for the purpose spraying shotcrete.
b) Water cement ratio shall be 0.45 (maximum) by weight of Cementitious material.
c) The workability shall be measured by slump test and should be between 10 to 15 ems.
The slump shall also be checked after interval of 15 minutes which should be within
prescribed limits. The shotcrete older than 2 hours and having slump not within prescribed
limits shall not be used unless treated with hydration control additives. If SFRS is used, the
spread shall be 40-55 cm.
d) The requited workability shall be ensured before transporting the mix for execution at
batching plants/transit mixer itself.
(e) Surface shall be suitably prepared by scaling followed by cleaning with compressed air
and water under pressure through nozzle. All surfaces shall be wet and clean at the time of
applying shotcrete.
(f) Before filling the mix in the hopper of the shotcrete machine; slurry shall be mixed and put
into the concrete hose.
(g) The application procedure of Shotcrete shall be developed in the field to give minimum
rebound, minimum shrinkage etc. to the satisfaction of the Engineer.
(h) The nozzle shall be held at a predetermined distance of approximately one meter but in
no case greater than 1.5 meter from the surface to be covered and positioned so that the
stream of flowing material shall be applied at right angles to the surface to be covered.
Nozzle shall be held in steady motion so that the shotcrete is applied uniformly to build up
the required thickness of layer. Acceptable shotcrete shall consist of dense and uniform
concrete without rebound inclusions segregation or ·discernible weakness of bond between
layers. The nozzle men shall apply shotcrete with a uniform consistency in order to maximize
binding cohesion and density, minimize rebound and segregation and prevent sagging of
applied shotcrete.
(i) Shotcrete shall always be started from the bottom to avoid rebound material getting
locked in. Shotcrete will be applied in a single layer of 50 mm' thickness or successive
multiple layers of 50 mm thickness as per directions of the Engineer.
(j) Before laying a new layer over a previously laid layer, the previously laid layer shall be
allowed to take its initial set and loose materials from the surface shall be removed.
(k) Care shall be taken to ensure that no air pockets are formed behind the shotcrete.
(l) All applied shotcrete shall be kept wet tor at least 7 days or have internal curing agent to
ensure proper curing of the shotcrete. Sufficient air shall be added at the nozzle to get good
compaction and higher compressive strength.
(m) All necessary precautions shall be taken to ensure that there is no damage to the
instruments installed in rock and to ensure that the drainage holes do not get plugged.
6.9 Proficiency of workmen
Nozzle man shall have had previous experience in the application of shotcrete on at least
two projects of comparable nature and shall Work under immediate supervision of a foreman
or instructor with at least five years of experience. Proficiency of workmen will be checked by
the Engineer before allowing them to work.
6.10 Control of water
Water flow and seepage shall be controlled in such a manner that detrimental effects are
completely and permanently eliminated. The EPC Contractor may drain such water by pipes,
chases or other appropriate methods approved by the Engineer.
6.11 Safety Measures
Alkali hydroxides and other chemicals contained in shotcrete admixtures are moderately
toxic and can cause skin and respiratory irritation unless adequate safety measures and
undertaken. In applying shotcrete containing toxic admixtures, the nozzle men should have
air to breath, which shall be free of toxic or objectionable material. Gloves and necessary
protective clothing shall be worn to protect against dermatitis.
7. Rock bolting
7.1. General
Rock bolts are the active type of support and improve the inherent strength of the rock mass
which acts as the reinforced rock arch whereas, the conventional steel rib supports are the
passive supports and supports the loosened rock mass externally. All rock bolts should be
grouted very carefully in its full length. There are many types of rock bolts and anchors which
may also be used on the basis of past experience and economy. Rock Bolt is classified into
Point-anchored type and Face-anchored type etc.
Within two months of completion of the additional Exploratory Geotechnical Investigations,
the EPC Contractor shall submit to the Engineer, the designs of all supporting systems for
the tunnels including Rock bolting, for his approval, The Rock Bolts shall be SN-Bolts, PG-
Bolts [post-grouted or injection bolts], 180 Bolts [injection bore-bolts], Swellex Rock bolts
[friction anchored rock bolts] of International Standards or Full Column Resin Grouted Rock
bolts as IS13517:1992. EPC Contractor will prepare Working Drawings for the approved
design. The approved drawings will be adopted for construction.
All pull out tests shall be carried out as per relevant IS codes. All testing shall be carried out
in the presence of the Engineer or his representative. The Engineer reserves the right to ask
for pull out tests in any location where he deems them necessary. If during the testing, any
rock bolt fails due to improper workmanship or defective material, the Engineer may order
testing of all the adjacent rock bolts and all rock bolts so failing shall be replaced and re-
tested by the EPC Contractor at his own cost.
7.2. Materials
7.2.1 Bolt
Alternative materials shall be subject to agreement with the Engineer.
 High strength deformed steel bar to IS:432 (Part 1)-1966, or threaded bar of steel
grades 500/600 N/mm2 or 670/800N/mm2.
 Hollow steel bar of the self-drilling type, grade 500/600N/mm2
 Slit steel tube with a tapered distal end, or folded steel tube which \is expanded
upon installation using high-pressure water injection
 Glass-fiber-reinforced resin rods, solid or hollow
 Only item (a) can be de-bonded effectively for active support applications.
Steel bars shall be grade 500 N/mm², deformed type 2 bars complying with BS 4449.
Threaded parts of bars, nuts and seating shall comply with the requirements of BS 4190.
Face plates shall be of a dish shape in steel to the appropriate standard and shall have a
hemispherical seating with centralized slot to suit dimensions of the rock dowels.
Rock bolts shall be installed according to the length, direction, placement, and number as
per approved design drawings for each relevant Excavation Class unless otherwise
determined by the Employer’s Representative. Rock bolt length, direction, placement and
number shall be adjusted to the Ground Type.
Comprehensive records about details of the installation of rock bolts during drivage, such as
reference number, grout consistency, drilling depth, length, inclination and type of rock bolts,
deviations from the theoretical position, type and time of grouting, time of tightening, special
observations, details of tests carried out, geological ground condition, etc. shall be kept for
each rock bolt and round by the Contractor and countersigned by the Employer’s
supervisory personnel. Copies of these records should be submitted to the Employer’s
Representative.
The trademark of rock bolts and anchors to be installed shall be approved by the Employer’s
Representative. A quality assessment is required unless common anchor steel and anchor
plates were used. The Contractor’s construction execution shall comply with the
manufacturer's specifications and recommendations regarding drilling, installing, testing and
maintenance of rock bolts. The characteristic bearing capacity of the anchor plate and the
connection between the anchor and anchor plate shall be equal to the characteristic bearing
capacity (according to BS EN 1537) of the anchor steel.
The diameter of the drillings and the drilling technique shall be adjusted to the anchor type
and Ground Type. Holes for the installation of bolts shall be drilled straight and with an
accuracy of ±10°.
The drilling hole shall be flushed and cleaned with compressed air or water immediately prior
to the installation of the bolt. The used technique shall be adjusted on the Ground Type (e.g.
bore holes drilled in swelling ground no water flushing is permitted).
The water pressure during drilling may have an inadequate impact on the surrounding
ground (e.g. decrease of mechanical strength properties) due to this the water pressure may
be reduced or dry drilling may be conducted as directed by the Employer’s Representative.
Unless instructed otherwise, rock bolts shall be installed and tensioned prior to the
excavation of the next bench or round excavation. The tension force shall be determined by
the Employer’s Representative after completion of the initial testing program.
The Contractor shall provide torque wrenches of a type acceptable to Employer’s

Representative. All impact and torque wrenches shall be calibrated once every month.
The grouted hole shall be completely filled with grout. This shall be done by filling the drilled
hole from the bottom of the hole and withdrawing the grout slowly, always maintaining the
hose embedded in the grout. A regular surface shall be provided to seat the face plate by
trimming rock surfaces or forming pads of quick-setting mortar. Where mortar pads are
required, they shall be of adequate thickness and extend beyond the face plate by 25 mm all
round at that thickness before being chamfered at 45°. Care shall be taken to ensure that
the mortar does not interfere with the installed bolt.
7.3 Cement for grout
Cement for grout for rock-bolts where required shall conform to the requirements of Indian
Standards as detailed in IS: 456. Cement grout shall have a water/cement ratio
commensurate with the product, either thixo-tropic grouts or pumpable grouts and shall
achieve the characteristic strength Admixtures containing chlorides shall not be used. Other
admixtures including plasticizers and expanding agents shall be used only with the
Engineer's agreement.
7.4 Face plate
Rock-bolts shall have face plates which shall be of a dish shape in steel to tile appropriate
standard and shall have a hemi-spherical seating with centralized slot to suit the dimensions
of the rock-bolts.
7.5 Aggregates
Sand for cement grout shall comply with the requirements given in IS: 383-1970.
7.6 Resin grouts
Full details of resin-based grouts where required shall.be submitted to the Engineer for his
approval. Resin grouts shall be tested in accordance with BS 6319.
7.7 Testing of Rock-bolt
Conducing pull-out test on rock bolts shall comply with the requirements of IS: 11309-1985.
Drill holes shall have diameters recommended by the supplier or as proposed by the
Contractor and submitted to the Engineer.
Bolts and anchors shall be thoroughly cleaned and be free from loose rust, seal, dirt grease
or any other coating before they are inserted into the drill holes. Bolts shall normally be
grouted in over the entire lengths with grout consisting of cement and water with or without
the addition of sand. The grouting shall be carried out in a manner so as to prevent
formations of voids or air pockets.
The composition of the grout and the grouting procedures shall be submitted to the
Engineer.
8. Various Supports
8.1 Types of Support Systems
There are following types of support systems used in construction of tunnels, these are used
based on the class of rock mass.
a) Reinforcement – Wire Mesh
Cutting of reinforcement for better placing due to edges is permitted; hence additional
reinforcement in these sections is required.
Welded wire mesh fabric shall be installed in surface excavations in conjunction with
sprayed concrete, as shown on the drawings, or as directed by the Employer’s
Representative. Chain link fabric may be used for surface applications if previously approved
by the Employer’s Representative.
Welded wire mesh fabric shall conform to the requirements of IS: 4948 and shall have a
mesh size of 150 x 150 x 6 mm as shown on the drawings, or as required by the Employer’s
Representative.
The diameter of additional steel bars shall be limited to 14 mm according to Austrian
Guideline “Sprayed Concrete”. The characteristic yield strength of the welded wire mesh
shall be 500 N/mm².
Welded wire fabrics shall be installed in such way so that it follows as close as possible the
irregularities of the excavation surface or previous layers of shotcrete. It shall be firmly fixed
to prevent vibration and change of position during spraying of shotcrete. The use of wooden
pegs or pins for attaching the wire mesh to the rock surface shall not be permitted. Welded
wire fabrics shall be installed in the longest practical length. The overlap for welded wire
fabrics applied in the shotcrete lining shall be at least twice the pitch distance in
circumferential direction. In longitudinal direction, the overlap shall be at least one pitch
distance for the first layer of fabric and at least twice the pitch distance for the second layer
of fabric.
A minimum concrete cover at the tunnel side of 4.0 cm of all wire mesh layers shall be
provided.
b) Lattice Girder
Steel arches or lattice girders shall be installed to maintain the designed shape of the
opening and if necessary, provide an immediate support at the working face over the length
of the last excavation completed. The lattice girder mainly functions as reinforcement. If
necessary, the installation of steel arches or lattice girders shall also prevent ground loss
and shall improve load distribution.
For the application of support arches and lattice girders the following shall be considered:
- axial stress and bending moment in the steel arch ribs induced by the ground loads
- lateral stability and bracing of steel arches or lattice girders
- method of installing the steel arches or lattice girders
- method of blocking and spacing of blocking points
- bearing capacity of the ground at the toe of the arch ribs
- the stand-up time of the unsupported part of the excavation
- the groundwater regime and permeability of the ground

Lattice girders shall consist of three primary bars, connected by stiffening elements to the
manufacturer‟s design or as shown on the drawings. They shall be designed so as to:
- facilitate sprayed concrete penetration into and behind the girder, thereby
minimizing the creation of projection shadows and/or voids
- provide good-quality bonding between the steel and sprayed concrete, to form a
composite structure acting as a continuous reinforced concrete lining
- make allowance for the specified tolerances including convergence
c) Steel Ribs
Steel ribs provide an immediate support of the excavation after installation and shall
subsequently act as reinforcement and load distributing members for the shotcrete lining.
Steel ribs are required as support for forepoling elements, which are installed in advance of
the excavation. During the entire construction period, they will contribute as load bearing
members within the shotcrete lining.
The steel ribs shall be manufactured to meet the geometrical requirements for the
excavation geometries for each Excavation Class including the relevant tolerances.
Prior to the beginning of the work the complete fabrication details, installation procedures
and layout, details of joints, rib connections, rib spacers, geometry etc. and certificates of
compliance of the materials shall be submitted to the Employer’s Representative for
approval.
The fabrication and installation of structural steel support shall conform to the latest edition
of the following Indian Standards or, where not covered by these Standards, to the
equivalent International Standards:
- IS: 800 Code of practice for general construction in steel
- IS: 808 Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle
Sections
- IS: 816 Code of practice for use of metal arc welding for general construction in mild
steel
- IS: 2062 Steel for general structural purposes
Rib splices shall be welded or connected with bolted plates. Splices shall not reduce the
section moment of resistance. Where possible all connections shall be welded, and all field
connections shall be bolted.
Arches, base plates, ties and connections shall be formed from steel with the characteristic
in accordance to reinforced concrete standards. Arches shall be rolled to suit the
dimensional requirements of the Contract. Welding shall conform with BS EN 1011-1. Holes
for ties, struts and any bolted connections shall be drilled. No burning will be allowed
whether for temporary Works items or permanent elements. Threaded tie rods and struts
shall be of adequate length to suit arch centres and allow 25 mm projection each end
beyond the nut. Where arches are to be provided as part of the Contractor’s obligation for
support the Contractor shall provide dimensional details of the arches, calculations regarding
imposed loads and design and such other information that the Employer’s Representative
may reasonably request.
Galvanized arches, where required, shall be treated in accordance with BS EN ISO 1461. All
components, including the rods, fish plates, nuts and bolts, shall be galvanized.
d) Forepoling
To support the excavation roof (tunnel crown) forepoling elements are installed if required at
the upper part of the tunnel excavation face. Forepoling shall be applied in rock and soil
conditions which tend to produce over break, collapses or material inflows immediately
following excavation. Forepoling shall be applied locally or systematically, as the
circumstances require for the safety of the works and for preventing over break. The
installation of forepoling always requires the erection of steel ribs. They shall be driven from
the supporting frame in a slightly upwardly inclined direction at the crown of the heading and
should penetrate at least half a set beyond the next excavation cycle.
Forepoling shall be applied as shown on the approved detail design drawings by the
Contractor or as instructed by the Tunnel Designer‟s Representative and/or the Employer‟s
Representative.
Forepoling shall be properly supported by the steel rib and the shotcrete above the steel rib.
Therefore, the shotcreting of the gap between steel rib and the shotcreted sealed rock
surface along the area of forepoling shall be completed after the installation of forepoling.
Spacing between consecutive forepoling pipes or bars around the crown of the excavation
profile shall not exceed the maximum distance specified on the approved design drawings
and shall be reduced if the actually prevailing geological conditions at the tunnel face require
to do so.
Great care shall be taken to prevent the disturbance of face boards and supports in general
during the fore poling cycle.
e) Lagging
Steel Lagging (sheet piles) shall be employed mainly in weak ground with low cohesion with
the purpose of preventing a collapse of material during and immediately after excavation.
The use of lagging will always require the erection of steel ribs.
Steel lagging sheets with a thickness of 4 to 6 mm shall be used.
Lengths shall be in accordance with the round length of excavation and the support
requirements beyond the face as defined by the drawings or directed by the Employer’s
Representative.
Voids and gaps behind the lagging sheets shall be either filled with shotcrete or by contact
grouting with a suitable cement mortar.
Lagging sheets shall be driven at distances shown on the approved detail design drawings.
They shall be driven in advance of excavation of the respective round to a depth extending a
minimum length of 0.5 meters beyond the face of the subsequently round length into the
ground.
f) Yielding Elements
Large deformations occurring during tunnel excavation in rock with unfavourable

characteristics shall be managed with yielding elements.
The primary tunnel lining shall be divided into segments by means of longitudinal gaps. To
make better use of the lining capacity, yielding elements (LSC – Lining Stress Controller or
equivalent) consisting of multiple steel pipes in a concentric assembly with a total length of
app. 510 mm are installed in the deformation gaps in the circumferential direction.
The yielding elements shall be used to achieve controlled ductility of the tunnel lining in order
to prevent overstressing. To allow a smooth initial load development, special provisions have
to be foreseen (predetermined breaking points at the ends of the load tube).
In order to optimize the bearing capacity of the shotcrete lining, a multi-stage system may be
used in agreement with the Employer’s Representative, where the bearing capacity of the
element unit is increased stepwise.
It shall be possible to adjust the bearing load of the yielding elements to the actual ground
conditions (e.g. variation of steel cylinders of LSC).
Installation shall be done prior to any shotcreting. The elements shall be fixed to the wire
mesh or to steel ribs. The elements shall be protected to ensure functionality after primary
lining installation prior to shotcreting.
The elements shall have proper contact to the shotcrete lining to transfer the lining forces.
8.1.1 Material
Structural steel sections for tunnel supports shall conform to IS: 800-2007
8.2 Permanent Steel Supports
Permanent Steel Supports are those erected during the excavation of tunnel and left in place
forming part of the finished tunnel. These supports shall be provided as and where required
and as ordered by the Engineer.
8.3 After completion of the additional Exploratory Geotechnical
Investigations, the EPC Contractor shall submit to the Engineer, the designs of all supporting
systems for the tunnels including, installation of Permanent Steel Supports made of Rolled
Steel Joists embedded in Concrete Lining and Lattice Girder Supports embedded in
reinforced Shotcrete etc. to suit the Clear Sections of the Tunnels and the Connecting
Passages, for his approval.
8.4 Fabrication of Permanent Steel Supports
All materials and steel required for the fabrication and installation of permanent steel
supports shall be arranged by the EPC Contractor. The supports shall be fabricated by cold
bending according to drawings approved by the Engineer.
Permanent Steel Supports fabricated out of R.S. Joists and Lattice Girder Supports
fabricated out of M. S. Rounds shall be fabricated by cold bending to the shape indicated in
the relevant drawing approved by the Engineer and the butt I junction plates etc. shall then
be welded on. When finished, the supports shall be true and free from all kinks, twisted, etc.
and shall not be defective or strained in any manner. The fabrication of the supports shall be
carried out in accordance with the provisions of the Indian Standard Code I.S. 800-1956 and
Codes applicable to Lattice Girders.
No painting of any sort is to be carried· out on the steel support.
8.5 Erection of Supports
a) The support shall be erected as per the approved drawings and under the instructions of
the Engineer, whose decision in regard to the spacing at which the arch ribs and posts are to
be erected will be final.
b) In zones where the supports have to be used for supporting the roof of the tunnel, it may
be desirable from the technical point of view to carry out the breakout to full section in two or
multiple operations (a) break-out of the Heading in one or more operations and (b)
deepening of the Heading by Benching in one or more operations. These types of break-out
will be amenable to easy erection of the supports and avoid hazards.
c) Where excavation of the heading is carried out by advancing Central Drift followed by
widening to full section of the heading, Arch of the Central Drift will be supported using
segments of the arch rib held in place by installation of temporary verticals, and bottom
struts. The segment of the arch rib will have a cover plate on both ends so as to facilitate its
extension to form a full arch rib. When excavation for widening of the advancing central drift
to full section of the heading is carried out, the segments of the arch ribs erected previously
in the heading and now falling within the area where the sides have been blasted will get
exposed. An extension segment of the arch rib will be attached at each of the two, now
exposed ends so as to form a full arch rib. Other end of these extension pieces will be made
to rest and fixed onto a wall beam laid on each side of theheading. In case of Supports
fabricated 'out of R.S; Joists, concrete lagging planks will be placed over the extrados of the
supports and the annular gap between the tunnel periphery and the lagging will be packed
with backfill concrete. In case of Lattice Girder Supports, the girders will be embedded in
reinforced Shotcrete, as directed by the Engineer. Next cycle of excavation of the heading
will be resumed.
d) When the break out is achieved by dividing face in two or more parts as aforesaid, it will
be necessary to install wall beam on both sides of the heading to correct line and level and
secure it in position on timber packing. The wall beam will act as a girder for supporting the
arch ribs when, during bench excavation; some arch ribs get underpinned. The strength of
the wall beams will depend on its \ ·. design and load bearing capacity when it is
underpinned during bench blasting and till verticals are erected below it. Length of bench
advance will thus depend on the load bearing capacity of the wall beams. New pieces of
wall-beams laid on either side shall be connected loose to the previously laid wall-beams by
means of splice plates, bolts, nuts and washers etc. Arch ribs shall then be guyed up,
aligned, leveled and connected to the previously erected arch ribs by means of tie-roads with
double nuts.
e) Provision of the wall beam will be obligatory where tunneling is carried out by heading and
benching method or multi-drift method. The EPC Contractor will have to design the wall
beams and splicing and get it approved from the Authority Engineer.
f) As soon as the arch ribs are erected, they shall be firmly blocked against rock surface at
points not exceeding the spacing as shown in the approved drawing using timber packing
and wedges. Blocking work shall be progressed from the lower most point of the arch ribs
towards the crown in a systematic manner. The packing shall then be driven tight so as to
close the gap if any, at the crown of the support, to introduce the "Prestress" in the ribs. As
soon as two consecutive supports are erected, crown bolts, tie rod bolts and the gusset bolts
on the post plates etc., shall be tightened.
9. Concrete Back Packing
Temporary shuttering will be fixed on the intrados of the steel supports and the annular
space between the shuttering and intrados of shotcrete shall be tightly filled with M 25 grade
backfill concrete. In case of Lattice Girder Supports, the girders will be embedded in
reinforced Shotcrete, as directed by the Engineer.
10. Lining of Tunnel
10.1 General
In NATM or step excavation tunnel, initial stress is supported first with shotcrete (rock bolt)
and inner lining is designed to take on many roles such as strain management, improvement
of durability support and waterproofing sheet protection.
The requirements for concrete lining of tunnels shall be carefully drafted as the conditions for
lining tunnels are quite different from those of other cement concrete works. Requirements of
lining of tunnels are special on account of curvature, thin sections and difficulties in
placement and compaction in restricted spaces.
All the requirements for coarse and fine aggregates, cement, water, and concrete grading
and corresponding strength in accordance with IS: 456-2000 shall apply.
The work of Tunnel Lining involves providing and installing concrete lining of invert of the
tunnels and invert of the connecting tunnels / passages for embedding the permanent steel
supports and at other places and locations as per the approved design and drawings of
supporting system and as directed by the Engineer, Suitable weep holes with 100 mm dia
PVC pipes shall be provided in the lining. The cement to be used in the lining concrete shall
be low alkali cement.
Before the lining work is commenced at any location of the tunnel, the Engineer will inspect
the location to ensure that the excavation has been carried out properly and space for lining
of thickness as per approved design and drawings is available and all temporary tunnel
supports and other materials which cannot be allowed to be buried in the lining have been
removed.
10.2 Stages in Lining of the Tunnel
Lining of the tunnel can be carried out in single stage or can be divided in two parts, as
follows:
a) Lining in vertical sides up to the springing of the arch roof as shown in the relevant
drawing approved for construction.
b) Lining of arch roof of the tunnel.
10.3 Steel form work for lining
a) Steel shutters of approved type shall be used for lining. If the lining is cast in two parts,
shuttering for lining in sides can be conventional and for lining arch the shuttering will be in
the form of travelling collapsible telescopic shutter. If the lining in overt is cast in one
operation, the shuttering will be in the form of travelling collapsible telescopic shutter. The
EPC Contractor should submit his method of lining of the tunnel and the designs for steel
forms proposed to be used by him in lining the side walls and the roof area of the tunnel.
These proposals with such modifications as may be necessary will be approved by the
Engineer. The EPC Contractor shall then be required to manufacture the forms and erect
them in the approach cuts the tunnel in at suitable places as decided by the Authority
Engineer for his inspection. The forms shall be used only after approval by the Engineer.
The forms shall be so designed as to limit surface irregularity to the maximum of 6 mm in a
length of 2400 mm. If the lining is cast in two parts, the profile of the forms for the side wall
lining and the arch lining shall be accurately gauged so as to avoid any irregularity at the
cold joints in concrete. If any irregularity is noticed in the joints, the EPC Contractor will be
required to dress up the irregularity by rubbing it down with abrasives. The steel forms shall
be sufficiently rigid with suitable type of collapsing arrangements to enable smooth stripping
of the form without any shock to the newly laid concrete. If the lining is cast in two parts,
forms for the side lining of the tunnel will be allowed to be stripped after 18 hours after the
last batch of concrete is laid in position therein. Earlier stripping will require the approval of
the Engineer.
b) Sufficient number of widows of suitable size shall be provided in the forms in the forms to
enable pouring of the concrete, in situ vibrating the concrete for consolidation and inspection
of the work during the progress of concreting.
c) Form construction
 In a form structure, amount of concrete placed, placement length and placement
speed must be considered each time with the form structure.
 Form must be designed and produced to have good mobility; access shaft should
be installed in order to check the concrete placement conditions.
 Form must not exceed 15m in length for constructability and stability.
 When removing form, measures must be taken
 Form must not be removed until the concrete crown strength can stand a load and
it must be removed after concreting compressive strength is revealed to be over 3
MPa.
 Form track must move the form stably and be installed solidly so as to prevent
settlement when placing or moving concrete. ·
10.4 Placement of Concrete
a) Tunnel lining will be commenced from a convenient location with a sufficient lag behind
the face under excavation.
b) All concrete to be placed in lining of tunnel shall confirm to I.S. Code 456-2000. Grade of
the concrete shall be as per approved design and grade. Low alkali cement shall be used for
concreting lining works where necessary and as ordered by the Engineer.
c) Except areas where Sprayed Water-proofing membrane is to be provided, all surfaces
with which the concrete lining will come in contact shall be thoroughly washed with jet of
water and compressed air and brushed and cleaned to the satisfaction of the Engineer.
d) In-situ concrete lining in the sides and in the arch roof of the tunnel shall be placed in
position by concrete pump of approved type and vibrated and consolidated by use of
immersion type vibrators operated through the windows and with form vibrators attached to
the steel forms used for lining of the tunnel. The vibrators shall be positioned and moved
during the progress of concreting, so as to ensure perfect consolidation of the concrete in
the roof.
e) While concrete in the roof of the tunnel is being placed by concrete pumps, the EPC
Contractor will be required to provide for air slugging of the freshly laid concrete to ensure
satisfactory consolidation of the concrete in the arch roof.
f) In order to improve workability and other properties of concrete, use of plasticizers,
airentraining agents and other admixtures as per approved design will be permitted, if the
Engineer is satisfied regarding their need.
g) No construction joints are required to be provided in the lining of the tunnel, but cold joints
i.e. joints between the successive pours or between side walls and arch roofs shall be
treated as follows.
I). Cold joints less than 24 hours old shall be scrapped with wire brush and cleaned of
laitance/scum etc. and flushed with mortar of the same strength as the concrete mix in the
lining and immediately before fresh concrete is placed.
II). Cold joints which are more than 24 hours old shall be chipped for a depth of about 25
mm., washed, brushed, cleaned and flushed with mortar of the same strength as the
concrete mix in the lining before the placement of the fresh concrete.
Ill) The number of cube tests to be carried out should as per IS 456: 2000.
IV) A joint record in the form as approved by the Engineer shall maintained to record the
consumption of cement.
h) Concrete Lining Forms will have to remain in position for minimum 18 hours from the time
last batch of concrete is placed.
i) After concrete lining has aged for over 28 days, Backfill Grouting and Contact/ Pack
Grouting will have to be carried out as per the directions of the Engineer.
j) Suitable embedment, as directed by the Engineer, will have to be fixed in the concrete
lining for installation of permanent Lighting & Ventilation System and for installation of
Service Lines such as cables, firefighting water line etc.
k) 100 mm dia PVC pipes will have to be fixed in the concrete lining to serve as weep holes.
Number of such pipes and their location will be as directed by the Engineer.
10.5 Compaction
Concrete should be thoroughly compacted and fully worked around the reinforcement,
around embedded fixtures and into comers of the formwork. Concrete shall be compacted
using mechanical vibrators complying with IS: 2505, IS: 2506, IS: 2514 and IS: 4656. Over
vibration and under vibration of concrete are harmful and should be avoided. Vibration of
very wet mixes should also be avoided.
Whenever vibration has to be applied externally, the design of formwork and the disposition
of vibrators should receive special consideration to ensure efficient compaction and to avoid
surface blemishes.
10.6 Curing
Curing is the process of preventing the loss of moisture from the concrete whilst maintaining
a satisfactory temperature regime. The prevention of moisture loss from the concrete is
particularly important if the water cement ratio is low, if the cement has a high rate of
strength development, if the concrete contains granulated blast furnace slag or pulverized
fuel ash. The curing regime should also prevent the development of high temperature
gradients within the concrete.
The rate of strength development at early ages of concrete made with super-sulphated
cement is significantly reduced at lower temperatures. Super-sulphated cement concrete is
seriously affected by inadequate curing and the surface has to be kept moist for at least
seven days
10.7 Materials
10.7.1 Cement
The cement used shall be any of the following and the type selected should be appropriate
for the intended use;
 33. Grade ordinary Portland ·cement conforming to IS: 269
 Rapid hardening Portland cement conforming to IS: 8041
 Portland slag cement conforming to IS: 455
 Portland Pozzolana cement (fly ash based) conforming to IS: 1489(Part 1)
 Portland Pozzolana cement (calcinied clay based) conforming to IS: 1489(Part 2)
 Hydrophobic cement conforming to IS: 8043
 Low heat Portland cement confirming to IS: 12600
 Sulphate resisting Portland cement confirming to IS: 12330
10.7.2 Aggregates
Aggregates shall comply with the requirements of IS 383. As far as possible, preference
shall be given to natural aggregates.
10.7.3 Coarse Aggregates
Coarse aggregates for all classes of concrete shall conform to the requirements of ARE:
383. It shall be furnished in two separate sizes; either the 20mm down and or the 38rnm
down to No.4 as called for in the Specification.
10.7.4 Fine Aggregates
Fine aggregates shall conform to the requirements of IS: 383 or as required to meet the
design requirements. Water absorption shall be less than 3% by weight.
10.7.5 Water
Water to be used for mixing and curing concrete and mortar shall be fresh and dissolved or
suspended matter which may be harmful and shall comply with the requirements of IS: 456.
10.7.6 Admixtures
The consent of the Engineer shall be obtained prior to using any admixture in any concrete
mix. Admixtures containing chlorides or other corrosive agents shall not be used. Admixtures
shall conform to IS: 9103.
10.7.7 Reinforcement
 The reinforcement shall be any of the following
 Mild steel and medium tensile steel bars conforming to IS: 432(Part 1)
 High strength deformed steel bars conforming to IS: 1786
 Hard-drawn steel wire fabric conforming to IS: 1566
 Structural steel conforming to Grade A of IS: 2062
11. Pressure Grouting of Rock Mass/ Strata
11.1 For strengthening and stabilization treatment of the rock mass in the Open Cuts and the
Tunnels, Pressure Grouting with plain cement slurry or mortar, with addition of suitable
additives, as directed by the Engineer, will have to be carried out at locations as required
and as directed by the Engineer.
11.2 Grouting will be commenced with a grout mix of 1cement: 10water by weight at a
pressure of minimum 2 Kg. /Sq. Cm. If the grout is seen to flow freely into the hole, the grout
shall be progressively thickened by increasing the cement content or by adding fine sand,
saw-dust and other additives., as directed by the Engineer and the grouting pressure
progressively increased up to 7 Kg./Sq.Cm. and the grouting continued till refusal.
12. Tunnel Portals
12.1 The Tunnel Portal shave to be designed by the EPC Contractor. The EPC Contractor
will prepare working drawings for the Portals, tunnels, box tunnel structures and submit them
to the Authority Engineer for his approval.
12.2 Concrete of the Portal Walls will be minimum M 25 grade Reinforced Cement Concrete.
12.3 100 mm, dia. EW Pipes running through the stem of the Portal Walls will be fixed in a 2
m. x 2 m. pattern, to serve as Weep Holes.
12.4 Facade of the Portal should provide with, 'v' grooves, flutings etc. and should have
space for name plates for inserting name of the tunnel.
13. Backfilling and Compacting Selected Fill Material behind Concrete Portal Walls
Space between the excavated surface of the Approach Cuts and rear face of the Portal
Walls will be backfilled with selected hand packed rubble topped with earth cushion as
shown in the drawing approved for construction and as directed by the Engineer.
14. Firefighting system
The firefighting system as defined in MEP section shall be followed.
15. Construction of In-situ Kerbs, Crash Barriers, Side Drains and Pre-cast Concrete
Slabs for Drain-cover/ Walkway:
15.1 Crash Barriers and Kerbs shall be constructed with M-45 grade concrete and with TMT
Fe 500 grade reinforcement conforming to IRC: 21. Floor and Side Walls of the side drains
are to be provided in-situ concrete of minimum M20 grade as per approved drawings: Pre-
cast concrete slabs of minimum M 25 grade area to be provided over the drains to serve as
drain cover/ walkway slabs.
15.2 Concrete in the kerbs, crash barriers and side walls of the drain shall be laid using
forms of approved type. The form shall be erected carefully to ensure perfect line and level
for the alignment of the drain wall and smooth finish.
15.3 In-situ Concrete for Drains, Kerbs and Crash Barriers:
I). Concrete of the drain walls adjacent to the sides of the tunnel shall abut against the
shotcrete or concrete lining installed on tunnel sides, as the case may be. Concrete in floor
of the drains will be laid on excavated invert.
II). 100 mm N.B. PVC Pipes running through the inner drain walls kerbs and crash barriers
will be fixed at 5m spacing, to serve as drainpipes. Wherever provided, the down-take pipes
fixed in the overt of the tunnel will be embedded in the drain concrete.
Ill). Suitable embedment, as directed by the Engineer will have to be fixed in the concrete for
installation of fire water lines, walkway slabs and pipe hand-railing etc.
16. Treatment of Seepage Water
In order to tap seepage water and lead it to the side drains, in certain areas of the tunnel, the
Engineer may order installation of half round PVC Pipes100 mm. dia. clinging to the
excavated periphery of the overt of the tunnels using 'U' clamps. Lower end of the pipes will
be terminated into the side drains. The pipes will later be embedded in shotcrete placed as
an initial support.
19. Dewatering
The Contractor shall design, furnish, maintain and remove temporary works for protecting
the Works under construction against flood flows in rivers and creeks, and design, furnish,
operate, maintain and dismantle the temporary dewatering facilities required to remove
water from construction activities and from natural surface flow or groundwater seepage
from working areas on the surface as well as in the tunnel.‟
The Contractor‟s working methods and systems shall be designed to control ground and
surface water to permit the construction of shafts, tunnels, breakouts and portal structures.
Where dewatering operations are used, they shall be kept to the minimum necessary for the
execution of the Works. If, at any time, during construction, the inflow of water increases
more than the installed pumping capacity, the Contractor shall be required to install
additional pumping facilities and perform additional sealing as required by the Employer‟s
Representative. The dewatering system shall include a system for identifying ingress of soil
material during the dewatering operation.
In planning temporary pumping systems, the Contractor shall take due consideration of
water quality, pressure, quantity and variations in water levels.
Settlement ponds and other measures shall be provided so as to ensure that potentially
contaminated or polluted matter from the execution of the Works is nowhere released into
creeks, rivers or the ground.
The Contractor will be held responsible for all damage caused by his dewatering procedures
or the lack of such, and he shall reinstate or repair disturbed ground or structures to their
original condition or as otherwise approved.
Plant shall be delivered to site and maintained in good working order. Plant and pipe work
shall be fitted with appropriate valves, controls and gauges. Each dewatering well shall be
capable of individual adjustment and being shut down and isolated from the rest of the
system. Appropriate standby equipment and spares shall be maintained on site at all times.
20. Submittals
The EPC Contractor shall submit the following documentation with his preliminary design:
a) Preliminary design of tunnel supporting systems based on the available geotechnical data
and to suit the finished section of the tunnels.
b) Proposal for carrying out additional Geological Investigations, if any,
c) Detailed Methodology of Construction of all the Major Items of Work including Planned
Cycles of Work, Progress per Cycle, Progress per Day and per Month so as to complete all
the Tunnel Works within stipulated contract period including mobilization and months of rainy
season.
d) Detailed List of Plant, Machinery and Equipment proposed to be employed for execution
of the works with their capacity, immediate availability and arrangements for procurement.
e) Chart showing Manpower proposed to be employed month-wise.
21. The EPC Contractor shall submit the following documentation after award of the
work:
a) Commence all the additional Exploratory Geotechnical Investigations etc. within one
month of Award of Work and submit to the Engineer results of the geotechnical observations
within two months thereafter.
b) Based on the data obtained in the original and the additional geotechnical explorations,
design all the open cuts, cut and cover sections and all supporting. systems for the tunnels
including Rock bolting, Shotcreting installation of Permanent Steel Supports made of Rolled
Steel Joists embedded in Concrete Lining and Lattice Girder Supports embedded in
reinforced Shotcrete etc. to suit the Clear Sections of the Tunnels and the Connecting
Passages and design the ground stabilization and ground improvement systems, fore-poles
including pipe-fore-poles etc. to suit the final Clear Sections of the Tunnels and the
Connecting Passages and submit to the Engineer, all these designs for his approval, within
two months of completion of the additional Exploratory Geotechnical Investigations and
prepare Working Drawings on the basis of the approved design. Only the approved drawings
will be adopted for construction.
c) Thereafter, within a period of 30 days, prepare and submit to the Engineer for his approval
a complete scheme detailing his proposed method of Tunnelling (full face or top heading and
benching or multi-drift etc.), the pattern of holes and the charge, the type of explosives, the
methods of providing permanent and temporary - supports if required, the cycle of operation
and the rate of progress expected, the manner in which it is proposed to minimize over-
break, the nature of protective devices to minimize hazards to labour, equipment etc.
22. The EPC Contractor shall submit the following documentation during the work:
a) The EPC Contractor shall submit to the Authority Engineer and Ministry of Road Transport
and Highways [MORTH], three sets of cross sections of the Tunnels and the Connecting
Tunnels and approach cuts taken at an interval as decided by the Engineer, indicating the
tunnel profiles as actually excavated with the supporting and other treatment rendered and
duly signed by EPC Contractors, Authority Engineer & MORTH‟s representative. The EPC
Contractor shall prepare and submit to Authority Engineer & MORTH CDs containing
Connecting sections etc. as above, plotted on AutoCAD. The completion drawings of the
tunnels showing all aspects of the work shall also be submitted to the MORTH in the form of
AutoCAD Drawings. All the documentations etc. so submitted will be property of the MORTH
and no payment shall be made for preparing and submitting the same.
b) The EPC Contractor shall submit to the MOTH, three sets booklets of final bill as per
directives of the Engineer; containing all relevant details of up-to-date work done, typed on
computer in MS Excel / Words formats, jointly signed by EPC Contractors and MORTHs
representative. The submitted booklets will be property of the MORTH EPC Contractor shall
also submit CD for the same. No payment shall be made for submitting such booklets and
CD.
23. Prevention & Mitigation of tunnelling hazards
23.1 The EPC Contractor shall at all times adopt such methods of work as will ensure
structural safety and the safety of labour working in the Tunnel.
23.2 In the use of explosives for blasting, the EPC Contractor shall strictly abide by the
provisions in Indian Explosives Act and the Metaliferrous Mines Regulations and Rules
thereunder, as well as the relevant provision of the Act and Rules as may be enacted and
laid down by the State and Central Government from time to time in respect of such works
The EPC Contractor s' attention is specially drawn to relevant conditions of General
Conditions of Contract.
23.3 If at any time during the work, the Engineer finds the methods of safety arrangements,
in-adequate or unsafe, the EPC Contractor shall take immediate corrective measures to set
them right as per the provisions of relevant Acts or Rules and as directed by the Engineer.
The Engineer's directions in the matter shall in no way absolve the EPC Contractor of his
responsibility to adopt appropriate safety arrangements for safe working methods.
23.4 Roof and sides of the excavated tunnels sections shall be rendered with necessary safe
and sturdy supporting arrangements. The exact locations from where support work is
considered necessary will be as per decision of the Engineer which in this regard will be
final.
23.5 Should any hazards occur the EPC Contractor should notify the Engineer immediately
and the Engineer or Committee of MORTH's Authority Engineers as may be decided by the
MORTH, will inquire into the circumstances, leading to the hazarded and assess the extent
of responsibility evolving on the EPC Contractor. The EPC Contractor shall give all
reasonable assistance and full information to the Engineer/the Inquiry Committee appointed
for this purpose by MORTH. The findings of the Engineer shall be final and binding on the
EPC Contractor. The committee will consist of two experienced tunnelling engineers & one
Expert Geologist and one Geotechnical Expert.
23.6 In the case of hazards for which the responsibility does not rest with the EPC
Contractor, wholly or partly, as adjudged from the findings of the committee, the EPC
Contractor shall be entitled to an extension of time as in the opinion of the Engineer is
necessary and also to the payment wholly or partly, as may be judged by the MORTH for the
restoration work rates to be mutually negotiated between the MORTH and the EPC
Contractor. The EPC Contractor shall also be under obligation to expeditiously carry out the
restoration work.
23.7 In the case of hazards, for which the responsibility rests with the EPC Contractor, the
EPC contractor shall carry out at his own cost, the restoration work and such other works as
temporary supports, hand packing, plugging with concrete, provision of extra or new
permanent supports etc., as considered necessary by the Engineer. The EPC Contractor
shall always keep sufficient ready stock of supports to meet the emergencies likely to be
caused during tunnel hazards.
24. Expansion joints
Expansion joints must be constructed at intervals of 20-30m within 50m of the tunnel entry
and exit, and at intervals of 20-60m inside the tunnel. Additional expansion joints can be
constructed at the changing sections, sudden stratum change sections, steel and plain
concrete junctions and so on. Sealant must be applied after spreading primer paste.
Codes of Practice / Acts I/ Rules to be followed for Tunnelling Work
The following Codes/ Acts/ Rules and their revised/ updated versions, if any, will be
applicable to the tunnelling work. This list is not exhaustive and all other relevant Codes
/Acts I Rules and their revised I updated versions, if any, will be deemed to be applicable to
the tunnelling work;
IS 5878 1971 [Part 1] Precision Survey
and Setting out.
IS 5878 1971 [Part II, Section 1]
Underground Excavation
in Rock, Section Drilling
and Blasting.
Unden:1round Excavation
in Rock;
Section 2, Ventilation, Lighting, Mucking and Dewatering.
Underground Excavation
in Rock, Section 3,
Tunneling Methods for
Steeply Inclined Tunnels,
Shafts and Underground

Power Houses
IS 5878 1971 [Part III] Underground
Excavation in Soft Strata.
IS 5878 1971 [Part IV] Tunnel Supports.
IS 5878 1971 [Part V] Concrete Lining
IS 5878 1971 [Part VI] Grouting.
IS 4081 1967 Safety Code for Blasting
and other related Blasting
Operations.
IS 4756 1978 Safety Code for Tunneling
Work.
IS 9103 1979 Admixtures for Concrete.
IS 9012 1978 Recommended Practice
for Shotcreting
IS 3764 1966 Safety Code for
Excavation Work.
IS 4138 1977 Safety Code for Working
in Compressed Air.
IS 7293 1974 Safety Code for Working
with Construction
Machinery.
IS 823 1964 Code of Practice for
Manual Metal Arc
Welding of Mild Steel.
Manual Metal Arc
Welding for General
Construction in Mild Steel
IS 1566 1967 Hard-drawn Steel Wire
Fabric for Concrete
reinforcement.
Training and Testing of
Metal Arc Welder
[Revised]
IS 226 1975 Structural Steel [Standard
Quality].
IS 456 2000 Code of Practice for Plain
and Reinforced Concrete.
IS 4086 1967 Methods of Tests for
Distributors.
IS 1893 1975 Criteria for Earthquake
Resistant Design of
Structures.
IS 1200 1971 [Part XXV] Method of
Measurement of Building
and Civil Engineering
Works.
IS 1200 1971 [Part XXV] Method of
Measurement of Building
and Civil Engineering
Works - Tunneling

Structural Safety of
Buildings.
Building Bye-laws.
IS 800 2007 Code of Practice for Use
of Structural Steel in
General Building
Construction
Indian Explosives Act.
Indian Explosive Rules.
IRC-SP-91 2019 Guidelines for Road
Tunnels
IRC-SP:84 2019 Manual of Specifications
and Standards for Four
Lining of Highways
through Public Private
Partnership
Note: Latest version of the above specifications shall be used.

Schedule D From Section 7

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National Highways Authority of India Request for Proposal – Bid Documents

SECTION 7 - INNER LINING CONCRETE

a. Clause No. 1709 of the General Specification.

SECTION 8 – FILL MATERIAL, ANCILLARY CONCRETE AND CONCRETE PAVEMENT

As per Appendix – 1800/III

Sub-Clause A-4.2.4 Sand

2. Lanes Annex-I of Schedule-B.

14.2.10 Horizontal Alignment Horizontal Alignment of Tunnel shall be as specified

Section- Protection As specified in Appendix D – I of Schedule –D.

Protection Works (Annexure-II)

 PD CLC/TR 50426:2004 Assessment of inadvertent initiation of bridge wire electro-explosive

Fig- Typical cross section with Instrumentation for Monitoring

Fig- Extrusion Measurement

Fig- Incremental Extensometer with

Fig- Typical Graph for the Extrusion measurement &

Fig- Typical Displacement History Plot

Fig- Typical Deflection curve for tunneling (Austrian

Fig-Typical Trend line plot with a major Fault zone

Fig- Typical plot of S crown – S Sidewall

Fig-Optical targets to measure convergence

Fig- a) Distance Vs Time, b) Convergence Vs Time, c) Convergence Vs Distance

obtained during the tunnel excavation through specified monitoring and

Fig- Ground Response Curve: Poor Rock mass

Fig - Ground Response Curve: Poor Rock mass

Fig- Ground Response Curve: Poor Rock mass

Fig - Ground Response Curve : Fair Rock mass

Fig - Ground Response Curve : Fair Rock mass

Fig - Ground support Interaction curve

 The reinforcement shall be any of the following:

for satisfactory performance of admixtures and chemical compatibility between two

II) Physical requirements

S. No. Property % Min Frequency of

Metakaoline shall confirm to ASTM C 618 Class – N Pozzolana specifications.

I) Compressive strength on cylindrical cores

The Contractor shall provide torque wrenches of a type acceptable to Employer’s

- the groundwater regime and permeability of the ground

Large deformations occurring during tunnel excavation in rock with unfavourable

Shafts and Underground

IS 1905 1980 Code of Practice for

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