MINISTRY OF ROAD TRANSPORT & HIGHWAYS SPECIFICATIONS FOR ROAD AND BRIDGE WORKS (Fifth Revision) Published By the Indian Roads Congress, on Behalf of the Govt. of India, Ministry of Road Transport & Highways Copies can be had from Indian Roads Congress, Jamnagar House, Shahjahan Road, New Dethi & Sector 6, R.K. Puram, Kama Koti Marg, New Delhi Prive Rs. 3,000/- Plus packing & postage chargesFirst Published Reprinted Reprinted Reprinted Reprinted Reprinted ‘Second Revision Reprinted Reprinted Reprinted Reprinted Reprinted Third Revision Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Fourth Revision Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Reprinted Fifth Revision April, 1973 November, 1975 May, 1978 September, 1981 October, 1983 April, 1986 February, 1988 ‘August, 1988 April, 1990 June, 1992 February, 1993 July, 1993, Apri, 1995 January, 1997 (Incorporates Corrigendum No.1 & 2 and Col. 12 & 15. 662) January, 1998 January, 1998 May, 1999 February, 2000 ‘September, 2000 (Section 700 “Geosynthetics’ Changed to “Geosynthetics and Reinforced Earth’) August, 2004 January, 2002 March, 2002 September 2002 November, 2002 March, 2003 June, 2003 July, 2003 December, 2003 May, 2004 September, 2004 April, 2005 October, 2005 March, 2006 September, 2006 March, 2007 ‘August, 2007 February, 2008 ‘August, 2008 November, 2008 March, 2009 June, 2009 December. 2009 March, 2010 July, 2010 April, 2013, (Rights of publication and Translation are reserved) Printed at: India Offset Press, A-1 Mayapuri Ind, Area Phase-1 New Delhi-11064 (1000 copies)PREFACE TO THE FIFTH REVISION This edition of the Specifications for Road and Bridge Works marks the Fifth Revision. In the last decade and a half, significant developments have taken place in the highways sector. The massive National Highways Development Projects (NHDP) undertaken by the Government of India is in progress involving execution of a large number of high value road projects. These require adoption of latest international practices so as to achieve technical execelience and the best quality. Concrete bridges have also undergone major changes with deveopment of new structural forms, new methods of computer based analysis and design and development of high strength materials, IRC:112 for concrete bridges based on the limit state method has come into force. Over the past few years, many IRC codes have also been completely revised necessitating extensive changes in the Ministry's specifications for road and bridge works ‘Some of the important additions in this revision of Specifications for Road and Bridge Works cover stone mastic asphalt, microsurfacing, sand asphalt base course, prefabricated vertical drains (PVD), natural geo textiles, geo cells for use in base and sub base in pavement and slope protection, variable message sign boards, soil nailing, cold applied retro-reflective paints, audible and vibratory pavement markings, solar powered road markers, traffic control & safety devices in construction zone, traffic impact attenuators and advance traffic management system. Some of the new areas covered in bridges include high performance concrete, HDPE sheathings, Pot-PTFE bearings, jack down method of well sinking, dynamic testing of piles and mechanically woven wire crates for gabions The Fifth Revision of the Specifications for Road and Bridge Works is the result of the concerted efforts of the officers of the Roads Wing and other professionals who contributed to the drafting of this document. | wish to express my gratitude to all of them and the Indian Roads Congress for undertaking the assignment of bringing out this publication. Feedback and suggestion for further improvement would be welcome from users of this edition Cee (C. Kandasamy) DG(RD) & SS 03-01-2013CONTENTS. Section No. Section Title/Clause No. Page No. 100 GENERAL 101 Introduction 1 102 Definitions 1 103 Materials and Test Standards 5 104 Sieve Designations 5 105 Scope of Work 6 106 Construction Equipment 10 107 Drawings 1 108 Site Information " 109 Setting Out " 110 Public Utilities 8 114 Precautions for Safeguarding the Environment 15 112 Arrangement for Traffic During Construction 19 113 General Rules for the Measurement of Works for Payment 22 114 Scope of Rates for Different tems of Work 24 115 Methodology and Sequence of Work 26 116 Crushed Stone Aggregates 28 117 Supply of Quarry Samples 28 18 Approval of Materials 28 119 Use of Surfaces by Traffic 28 120 Field Laboratory 29 121 Supply of Project Record 33 200 SITE CLEARANCE 201 Clearing and Grubbing 37 202 Dismantling Culverts, Bridges and Other Structures/ Pavements 39 300 EARTHWORK, EROSION CONTROL AND DRAINAGE 301 Excavation for Roadway and Drains 45 302 Blasting Operations 53 303 Presplitting Rock Excavation Slopes 56400 500 Contents 304 Excavation for Structures 305 Embankment Construction 306 Soil Erosion and Sedimentation Control 307 Turfing with Sods 308 Seeding and Mulching 309 Surface/Sub-Surface Drains 310 Preparation and Surface Treatment of Formation 311 Works to be Kept Free of Water 312 Water Courses at Culverts 313 Rockfill Embankment 314 Ground Improvement for Weak Embankament Foundation Using Geosynthetic Drains and Stone Columns. SUB-BASES, BASES (NON-BITUMINOUS) AND SHOULDERS 401 Granular Sub-Base 402 Lime Treated Soil for Improved Sub-Grade/Sub-Base 403 Cement Treated Soil and Cement-Flyash Treated Sub Base/Base 404 Water Bound Macadam Sub-Base/Base 405 Crushed Cement Concrete Sub-Base 406 Wet Mix Macadam Sub-Base/Base 407 Crusher-Run Macadam Base 408 Shoulders, Islands and Median 409 Cement Concrete Kerb and Kerb with Channel 410 Footpaths and Separators BASES AND SURFACE COURSES (BITUMINOUS) 501 General Requirements for Bituminous Pavement Layers 502 Prime Coat Over Granular Base 503 Tack Coat 504 Bituminous Macadam 505 Dense Bituminous Macadam 506 Sand Asphalt Base Course 507 Bituminous Concrete 508 Close-Graded Premix Surfacing/Mixed Seal Surfacing 59 63 7 79 82 85 89 90 90 91 92 109 112 116 121 129 131 136 139 142 143 149 166 168 170 174 183 188 192Contents: 509 Surface Dressing 194 510 Open-Graded Premix Surfacing 198 511 Seal Coat 205 512 Slurry Seal 207 513 Fog Spray 213 514 Micro-Surfacing 215 518 Stone Matrix Asphalt (SMA) 219 516 Mastic Asphalt 225 517 Crack Prevention Courses 231 518 Bituminous Cold Mix (Including Gravel Emulsion) 234 519 Recycling of Bituminous Pavement 242 520 Supply of Stone Aggregates for Pavement Courses 249 600 CONCRETE PAVEMENT 601 Dry Lean Cement Concrete Sub-Base 255 602 Cement Concrete Pavement 263 700 GEOSYNTHETICS 701 Geosynthetics for Road and Bridge Works 299 702 Geatextiles for Drainage, Separation and Erosion Control 302 703 Geogrid 307 704 Geocomposite Drains 309 705 Geocell for Slope Protection 312 706 Geosynthetic Mat 34 707 Natural Geotextile 316 708 Paving Fabrics/Glass Grids 318 800 TRAFFIC SIGNS, MARKINGS AND OTHER ROAD APPURTENANCES 801 Traffic Signs 325 802 Overhead Signs 335 803 Road Markings 338 804 Reflective Pavement Markers (Road Studs) and Solar Powered Road Markers (Solar Studs) 353 805 Distance Indicator Posts 356 806 Road Delineators 357900 1000 1100 807 808 809 810 an 812 813 814 815 816 Contents Boundary Stones Fencing Tubular Stee! Railing Structural Steel Railing Crash Barriers Road Traffic Signals Traffic Control and Safety Devices in Construction Zone Traffic Impact Attenuators Semi Automatic Toll Collection System Advanced Traffic Management Systems (ATMS) QUALITY CONTROL FOR ROAD WORKS 901 902 903 General, Control of Alignment, Level and Surface Regularity Quality Control Tests During Construction MATERIALS FOR STRUCTURES 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 General Sources of Materials Bricks Stones and Blocks Cast Iron Cement Coarse Aggregates Fine Aggregates Steel Water Timber Concrete Admixtures Reinforced and Prestressed Concrete Pipes Storage of Materials Tests and Standard of Acceptance PIPE FOUNDATIONS 1101 4102 1103 Description Subsurface Investigations Type of Piles 357 358 359 359 360 364, 366 371 372 381 415 417 421 439 439 439 440 440 440 442 443 443 4a7 449 449 451 451 453 457 457 4581200 1104 1105 1106 1107 1108 1109 1110 111 4112 4113 4114 1115 1116 117 1118 1119 Contents Materials. Test Piles Precast Concrete Piles Cast In Situ Concrete Piles Steel Piles Timber Piles Driving Equipment Driving Raker (Inctined) Piles Pile Tests Pile Cap Important Considerations, Inspection/Precautions for Different Types of Piles Tolerances Tests and Standards of Acceptance Measurements for Payment Rate WELL FOUNDATIONS 1201 1202 1203 1204 1205 1206 1207 1208 1209 1210 1211 1212 1213 1214 1215 1216 Description General Setting Out and Preparations for Sinking Cutting Edge Well Curb Floating Caissons Well Steining Well Sinking Bottom Plug Sand Filling Top Plug Well Cap Tolerances Tests and Standards of Acceptance Measurements for Payment Rate 458 459 459 461 465 466 466 467 470 470 472 472 474 475 475 475 479 479 479 480 481 482 483, 483 494 495 495 495 495 496 496 4971300 1400 1500 Contents. BRICK MASONRY 1301 1302 1303 1304 1305 1306 1307 1308 1309 1310 1311 1312 1313 1314 1315 1316 Description Materials Personnel Cement Mortar Soaking of Bricks Joints Laying Jointing Old and New Work Curing Scaffolding Equipment Finishing of Surfaces Coping for Wing/Return/Parapet Wall Acceptance of Work Measurements for Payment Rate STONE AND CONCRETE BLOCK MASONRY 1401 Description 1402 Materials 1403 Personnel 1404 Type of Masonry 1405 Construction 1406 Pointing 1407 Curing 1408 Scaffolding 1409 Weep Holes 1410 Jointing with Existing Structures 1411 Coping for Wing/Return/Parapet Walls 1412 Tests and Standard of Acceptance 1413 Measurements for Payment 1414 Rate FORMWORK 1501 Description 1502 Materials vi 501 501 501 501 502 502 502 503 503 503 504 504 505 506 506 506 509 509 509 509 509 515 515 515 515 516 516 516 516 516 519 5191600 1700 1503 1504 1505 1506 1507 1508 1509 1510 1811 1512 1513 Contents Design of Formwork Workmanship Lining of Formwork Precautions Preparation of Formwork Before Concreting Removal of Formwork Re-Use of Formwork Specialized Formwork Tests and Standards of Acceptance Measurements for Payment Rate STEEL REINFORCEMENT 1601 1602 1603 1604 1605 1606 1607 1608 1609 Description General Protection of Reinforcement Bending of Reinforcement Placing of Reinforcement Bar Splices Testing and Acceptance Measurement for Payment Rate STRUCTURAL CONCRETE 1701 1702 1703 1704 1705 1706 1707 1708 1709 1710 1711 1712 1713 Description Materials Grades of Concrete Proportioning of Concrete Admixtures Size of Coarse Aggregates Equipment Batchinh, Mixing, Transporting, Placing and Compaction Construction Joints Concreting Under Water Concreting in Extreme Weather Protection and Curing Finishing vi 519 519 521 521 522 522 523 523 524 524 524 527 527 527 527 528 529 531 531 532 535 535 535 538 543 544 545 546 550 551 552 553 555Contents 1714 Concrete with Blended Cements or Mineral Admixtures 555 1715 High Performance Concrete 556 1716 Tolerances 558 1717 Tests and Standards of Acceptance 558 1718 Measurements for Payment 562 1719 Rate 562 1800 PRESTRESSING 1801 Description 565 1802 General 565 1803 Materials 565 1804 Testing of Prestressing Steel and Anchorages 568 1805 Workmanship 568 1806 Supervision 572 1807 Tensioning Equipment 872 1808 Post Tensioning 573 1809 Grouting of Prestressed Tendons 574 1810 Pre-Tensioning 575 1811 Protection of Ends 579 1812 Safety Precautions During Tensioning 579 1813 Surface Preparation 879 1814 Transportation Storage and Handling of Precast Girders 580 1815, Tolerances 581 1816 Tests and Standards of Acceptance 581 4817 Measurements for Payment 581 1818 Rate 582 1900 STRUCTURAL STEEL 1901 Description 585 1902 General 585 1903 Materials: 585 1904 Fabrication 589 1905 Erection 605 1906 Painting 614 1907 Tests and Standards of Acceptance 618 1908 Measurements for Payment 619 1909 Rate 620 vill2000 2100 2200 2300 Contents BEARINGS 2001 Description 2002 General 2003 Steel Bearings 2004 Special Bearings 2005 Elastomeric Bearings 2006 Pot Bearings 2007 Inspection and Testing 2008 Test and Standards of Acceptance 2009 Measurements for Payment 2010 Rate OPEN FOUNDATIONS 2101 Description 2102 Materials 2103 General 2104 Workmanship 2105 Tests and Standards of Acceptance 2106 Tolerances 2107 Measurement for Payment 2108 Rate SUBSTRUCTURE 2201 Description 2202 Materials 2203 General 2204 Piers and Abutments 2205 Pier Cap and Abutment Cap 2206 Dirt Wall, Return Wall and Wing Wall 2207 Tests and Standards of Acceptance 2208 Tolerances in Concrete Elements 2209 Measurements for Payment 2210 Rate CONCRETE SUPERSTRUCTURE 2301 Description 2302 Materials 623 623 624 631 633 648 659 659 659 660 663 663 663 663 666 666 666 666 669 669 669 669 670 671 671 671 672 672 675 6752400 2500 2303 2304 2305 2306 2307 2308 2309 2310 Contents General Reinforced Concrete Construction Prestressed Concrete Construction Cast In-Place Voided Slabs Tolerances Tests and Standards of Acceptance Measurement for Payment Rate 675 675 676 682 682 683 683 684 SURFACE AND SUB-SURFACE GEOTECHNICAL INVESTIGATION 2401 2402 2403 2404 2405 2406 2407 2408 2409 2410 2411 2412 2413 2414 2415 Description Extent and Number of Bores Depth of Bores Detailed Investigation Detailed Investigation for Bridge Foundations Resting on Rock Boring Records of Boring and Trial Pits Methods of Sampling Procedure for Taking Samples Preservation, Handling and Labelling of Samples Tests for Investigation of Shallow Foundations of Bridges ‘Tests for Investigation for Deep Foundations of Bridges, Testing of Material for Foundations of Guide Bunds and High Embankments Measurements for Payment Rate RIVER TRAINING WORK AND PROTECTION WORK 2501 2502 2503 2504 2505 2508 Description Guide Bund Apron Pitching/Revetment on Slopes Rubble Stone/Cement Concrete Block Flooring Over ‘Cement Concrete Bedding Dry Rubble Flooring x 687 687 688 688 689 692 692 694 694 696 697 697 698 698 700 703 703 704 709 711 7122600 2700 2800 2507 2508 2509 2510 Contents Curtain Wall and Flexible Apron Tests and Standards of Acceptance Measurements for Payment Rate EXPANSION JOINTS 2601 2602 2603 2604 2605 2606 2607 2608 2609 2610 2611 2612 2613 2614 2615 Description General Performance Requirements Filler Joints Reinforced Elastomeric Joint Single Strip/Box Seal Joint Modular Strip/Box Seal Expansion Joints Asphaltic Plug Joint Compression Seal Joint {installation of Expansion Joints Testing and Acceptance Standards Tests and Standards of Acceptance Measurements for Payment Rate WEARING COAT AND APPURTENANCES 2701 2702 2703 2704 2705 2706 2707 2708 2769 Description Wearing Coat Railings and Crash Barrier Approach Slab Drainage Spouts Weep Holes Tests and Standards of Acceptance Measurements for Payment Rate REPAIR OF STRUCTURES 2801 2802 2803 Description General Sealing of Cracks by Injection of Epoxy Resin xi 712 713 713 713 723 723 724 725 726 728 730 732 734 736 744 744 748 748 748, 751 751 752 754 754 755 755 755 756 759 759 7592900 3000 2804 2805 2806 2807 2808 2809 2810 2811 2812 2813 2814 2815 Contents Replacement of Spalled Concrete by Epoxy Mortar/Polymer Mortar Epoxy Bonding of New Concrete to Old Concrete Cement Grouting Guniting/Shotcreting Protective Surface Coating of Concrete by Acrylic Elastomeric Coating Protective Surface Coating of Concrete by Patented Systems of Coating Replacement of Bearings Repair and Replacement of Wearing Coat External Prestressing ‘Tests and Standards of Acceptance Measurements for Payment Rate PIPE CULVERTS 2901 2902 2903 2904 2905 2906 2907 2908 2909 2910 2911 Scope Materials Excavation for Pipe Bedding for Pipe Laying of Pipe Jointing Backfilling Headwalls and Other Ancillary Works Opening to Traffic Measurement for Payment Rate MAINTENANCE OF ROAD 3001 3002 3003 3004 3005 General Restoration of Rain Cuts Maintenance of Earthen Shoulders Bituminous Work in Connection with Maintenance and Repair Maintenance of Cement Concrete Road xi 766 769 769 77 773 775 776 776 777 778 773 779 783 783 783 784 784 785, 785 786 786 786 786 789 789 790 791 7973100 3200 APPENDICES Appendix 1 Appendix 2 Appendix 3 Appendix 4 Appendix Contents REINFORCED EARTH 3101 Scope 3102 Design 3103 Reinforcing Element 3104 Earth Fill 3105 Facia Material 3106 Construction Details 3107 Reinforced Soil Slopes 3108 System Responsibility, Performance Bond 3109 Measurement for Payment 3110 Rate SOIL NAILING 3201 Scope 3202 Nail Installation Methods 3203 Construction Materials 3204 Facing Types 3205 Construction Sequence 3206 Geotechnical Aspects 3207 Analysis of Failure Modes 3208 Initial Design Considerations 3209 Other Design Considerations 3210 Field Pullout Testing 3211 Measurement for Payment 3212 Rates 3213, References List of IRC Publications Referred to in the Specifications List of Indian and Foreign Standards Referred to in the Specifications Method of Sieving for Wet Soils to Determine the Degree of Pulverisation Anti-Stripping Agents Used for Bituminous Materials and Mixes 1200/1-1 History of Sinking of Well 1200/1-2 Plan of Well Nos. 1200/2 __‘Tiltaand Shift in Well Nos. xii 801 801 201 804 805 807 810 811 812 812 821 821 821 822 823 823 824 824 825 826 827 827 829 831 833 847 848 855 856 857Appendix Appendix Appendix Appendix 1500/1 1700/1 18001 1800/2 1800/3 1800/4 2800 Contents Information to be Supplied by the Manufacturers of Proprietary Systems Specification for Construction Joints Tests on Sheathing Ducts Prestressing Report Specifications for Grouting of Post-Tensioned Cables in Prestressed Concrete Bridges Grouting Record xiv 859 861 864 871 873 882 883100 GENERAL