D.1 EARTHWORK EXCAVATION AND BACK FILLING: 1.

1 SCOPE: This specification covers the general requirements of earthwork excavation in different materials, filling back around foundations and in plinths, conveyance and disposal of surplus spoils or stacking them properly as directed by Engineer and all operations covered within intent and purpose of this specification. APPLICABLE CODES: The following Indian Standard Codes, unless otherwise specified herein, shall be applicable. In all cases, the latest revision of the Codes shall be referred to. a) I.S.1200 Method of measurement of building and civil Engineering works. b) I.S.3764 Safety code for excavation work. DRAWINGS: Engineer will furnish drawings required to show area to be excavated/filled, sequence of priorities, etc. CONTRACTOR shall follow strictly such drawings. GENERAL CONTRACTOR will furnish all tools, plants, instruments, qualified supervisory personnel, labour, materials, any temporary works, consumables, any and everything necessary, whether or not such items are specifically stated herein for completion of the job in accordance with specification requirements. CONTRACTOR shall carry out the survey of the site before excavation and set properly all lines and establish levels for various works such as earthwork excavation, basement, foundations, plinth filling, roads, drains, cable trenches etc. Such survey shall be carried out by taking accurate cross sections of the area perpendicular to established reference/grid lines at 5m intervals or nearer as determined by ENGINEER based on ground profile. These shall be checked by ENGINEER and thereafter properly recorded. The excavation shall be done to correct lines and levels. This shall also include, where required, proper shoring to maintain excavation and also the furnishing, erecting and maintaining of substantial barricades around excavated areas and warning lamps at night for ensuring safety.

1.2

1.3.

1.4. 1.4.1

1.4.2.

1.4.3.

1.5.

CLEARING: The area to be excavated/ filled shall be cleared off fences, trees, plants, logs, stumps, bush, vegetation, rubbish, slush etc. and other objectionable matter. If any roots or stumps of trees are met during excavation, they shall also be removed. The material so removed shall be burnt or disposed off as directed by ENGINEER. Where fill is intended, the area shall be stripped of all loose/ soft patches, top soil containing objectionable matter/material before fill commence. PRECIOUS OBJECTS,RELICS,OBJECTS OF ANTIQUITY, ETC. All gold, silver, oil, minerals, archaeological and other findings of importance, trees cut or other materials of any description and all precious stones, coins, treasures, relics, antiquities and other similar things which may be found in or upon the SITE shall be the property of the OWNER. The CONTRACTOR shall duly preserve the same to the satisfaction of OWNER and from time to time deliver the same to such person or persons as OWNER may from time to time authorise or appoint to receive the same. EXCAVATION: Excavation work shall be carried out on mechanical equipments unless, in the opinion of Engineer, the work involved and time schedule permit manual work. Excavation for permanent work shall be taken out to such widths, lengths, depths and profiles as are shown on the drawings or such other lines and grades as may be specified by ENGINEER. Rough excavation shall be carried out to a depth of 150mm above the final level. The balance shall be excavated with special care. Soft pockets shall be removed even below the final level for extra excavation filled up with PCC 1:5:10/ sand filling as directed by ENGINEER. The final excavation if so instructed by ENGINEER, should be carried out just prior to laying the sand. Additional filling with PCC 1:5:10 or sand as directed by the Engineer will not be paid for. All excavation shall be done to the minimum dimensions as required for safety and working facility. Prior approval of Engineer shall be obtained by CONTRACTOR in each individual case, for the method he proposes to adopt for the excavation, including dimensions, side slopes, dewatering, disposal etc. This approval, however, shall not in any way relieve CONTRACTOR of his responsibility for any consequent LOSS or DAMAGE. The excavation must be carried out in the most expeditious and efficient manner. Side slopes shall be as steep as will stand safely for the actual soil conditions encountered. Every precaution shall be taken to prevent slips. Should slips occur, the slipped material shall be removed and the slope dressed to a modified stable slope. Removal of the slipped earth will not be paid for.

1.6.

1.7 1.7.1.

1.7.2.

1.7.3.

1.7.4. 1.8.0. 1.8.1

1.8.2.

Excavation shall be carried out with such tools, tackles and equipments as described herein before. FILL, BACK FILLING WITH RIVER SAND: MATERIAL: All fill material (i.e. River sand) will be subject to ENGINEERs approval. If any material is rejected by ENGINEER, the CONTRACTOR shall remove the same forthwith from the SITE at no extra cost to the OWNER. To the extent available, selected surplus spoils from excavated materials shall be used as backfill. Fill material shall be free from clods, salts, sulphates, organic or other foreign material. All clods of earth shall be broken or removed. Where excavated material is mostly rock, the boulders shall be broken into pieces not larger than 150 mm size, mixed with properly graded fine ,material consisting of murum or earth to fill up the voids and the mixture used for filling. FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS OF STRUCTURES, WALLS ETC. As soon as the work in foundations has been accepted and measured, the spaces around the foundations, structures, pits, trenches etc. shall be cleared of wall debris and filled with earth in layers not exceeding 15 cm. Each layer being watered rammed and properly consolidated, before the succeeding one is laid. Each layer shall be consolidated to the satisfaction of Engineer. Earth shall be rammed with approved mechanical compaction machines. Usually no manual compaction shall be allowed unless Engineer is satisfied that in some cases manual compaction by tampers cannot be avoided. The final backfill surface shall be trimmed and levelled to proper profile as directed by Engineer or indicated on the drawings. SAND FILLING IN PLINTH AND OTHER PLACES: At above places, back filling shall be carried out with river sand if directed by ENGINEER. The sand used shall be clean, medium grained and free from impurities. The filled-in-sand shall be kept flooded with water for 24 hours to ensure maximum consolidation. Any temporary work required to contain sand under flooded condition shall be to CONTRACTORs account. The surface of the consolidated sand shall be dressed to required level or slope. Construction of floors or other structures on sand fill shall not be started until ENGINEER has inspected and approved the fill. FILLING IN TRENCHES Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipe and drains have been tested and passed. The back filling material shall be properly consolidated by watering and ramming, taking due care that no damage is caused to the pipes. Where the trenches are excavated in soil, the filling from the bottom of the trench to the level of the centreline of the pipe shall be done by

1.8.3.

1.8.4.

1.8.5 1.8.5.1.

1.8.5.2.

1.8.5.3.

compaction, with the selected approved earth in layers not exceeding 8cms. Back filling above the level of the centreline of the pipe shall be done with selected earth by hand compaction or other approved means in layers not exceeding 15cms. In case of excavation of trenches in rock, the filling up to a level 30cms. above the top of the pipe shall be done with fine materials, such as earth, murram, etc. The filling up of the level of the centre line of the pipe shall be done by hand compaction in layers not exceeding 8cms. Whereas the filling above the centre line of the pipe shall be done by hand compaction or approved mechanical methods with broken rock filling of size not exceeding 15cms. mixed with fine material as available to fill up the voids. Filling of the trenches shall be carried simultaneously on both side of the pipe to avoid unequal pressure on the pipe. MEASUREMENT & PAYMENT: All excavation shall be measured nett. Dimensions for purpose of payment shall be reckoned on the horizontal area of the excavation at the base for foundations of the walls, columns, footings, tanks, rafts or other foundations/structures to be built, multiplied by the mean depth from the surface of the ground in accordance with the drawings. Excavation in side slopes will not be paid for. Contractor may make such allowance in his rates to provide for excavation in side slopes keeping in mind the nature of the soil and safety of excavation. Reasonable working space beyond concrete dimensions and shuttering where considered necessary, in the opinion of Engineer have to be done without any extra payment for additional excavation. Over-excavation shall be made good by Contractor with concrete of the same class as in the foundations at his cost. Payment for fill inside trenches, plinth or similar filling with selected excavated material will be made for only compaction as specified/directed. Cost of all other operations shall be deemed to have been covered in the rate quoted for excavation. Payment for this work will be made based on measurement of plinth/trench dimensions filled. The plinth ground levels shall be surveyed before hand for this purpose. If no compaction is specified /desired such filling will not be separately paid for. In such a event the fill shall be leveled/finished to the profile as directed at no extra cost. Back filling, plinth filling etc., with borrowed river sand will be paid for at rates quoted. The quoted rate shall include all operations such as clearing, excavation, lead and transport, fill, including all lead, lift, compaction etc., as specified. Actual quantity of consolidated river sand filling shall be measured and paid in cubic metres. Actual quantity of consolidated sand filling shall be measured and paid in cubic metres.

1.8.5.4.

1.9. 1.9.1.

1.9.2.

1.9.3

1.9.4.

1.9.5.

LEVELLING THE SITE: The SITE shall be levelled over the area of the building and for about 5metres width all around and the ground being sloped away from the building and suitably drained along its outer edges. D.2. DEWATERING

2.1. 2.2

2.3

2.4

This specification covers the general requirements of dewatering in general. All excavation shall be kept free of water. Grading in the vicinity of excavations shall be controlled to prevent surface water running into excavated areas. Contractor shall remove by pumping or other means approved by Engineer any water inclusive of rain water and subsoil water accumulated in excavation and kept all excavations dewatered until the foundation work is completed and back filled. Sumps made for dewatering must be kept clear of the excavations/trenches, required for further work. Method of pumping shall be approved by Engineer, but in any case, the pumping arrangement shall be such that there shall be no movement of subsoil or blowing in due to different head of water during pumping. Pumping arrangements shall be adequate to ensure no delays in construction. When there is a continuous in flow of water and quantum of water to be handled is considered in the opinion of Engineer, as large, well point system- Single stage or multistage, shall be adopted. Contractor shall submit to Engineer his scheme of well point system including the stages, the spacing, number and diameter of well points, headers, etc. and the number, capacity and location of pumps of approval. The cost of dewatering shall be included in the items rate itself. Unless separately provided for in the schedule of quantities, dewatering is deemed to have been included in the unit rates quoted. Wherever the Schedule is described with specific dewatering for items of works involved below Ground level, the rate quoted for the specific item should be inclusive of all dewatering charges of any type as may be required from the time of excavation, till the back filling is completed for the entire period of all operations for the structure concerned including excavation, mat concreting RCC including tying reinforcements, curing etc. NO SEPARATE PAYMENT WILL BE PAYABLE on whatsoever grounds including misjudgment of the nature of dewatering and idle periods. D.3. RAIN WATER DRAINAGE

3.1. 3.2.

SCOPE: This scope covers the drainage of rainwater in excavated areas. Grading in the vicinity of excavation shall be such as to exclude rain/surface water draining into excavated areas. Excavation shall be kept clear of rain and such water as the CONTRACTOR may be using for his

work by suitably pumping out the same at no extra cost to the OWNER. The Scheme for pumping and discharge of such water shall be approved by the ENGINEER. D.4. CONCRETE AND ALLIED WORKS 4.1. SCOPE This Specification covers the general requirements for concrete to be used on jobs using on-site production facilities including requirements in regard to the quality, handling, storage of ingredients, proportioning, batching, mixing and testing of concrete and also requirements with regard to the quality, storage, bending and fixing of reinforcement. This also covers the transportation of concrete from the mixer to the place of final deposit and the placing, curing, protecting, repairing and finishing of concrete. The two parts viz. Specific Technical requirement for the project and this specification are complementary and are to be read together for correct interpretation of the provisions of this specification. Where requirement of the two sections conflict, those of Specific Technical requirement for the project shall govern. It shall be very clearly understood that the specifications given herein are brief and do not cover minute details. However ,all works all have to be carried out in accordance with the relevant standards and codes of practices or in their absence in accordance with the best accepted current Engineering practices or as directed by ENGINEER from time to time. The decision of ENGINEER as regards the specification to be adopted and their interpretation and the mode of execution of work shall be final and binding on CONTRACTOR and no claim whatsoever will be entertained on this account. APPLICABLE CODES AND SPECIFICATIONS All standards, tentative Specification, Specifications, Codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of discrepancy, between this Specification and those referred to herein, this Specification shall govern. MATERIALS I.S.8112 - Specification for 43 grade Ordinary Portland cement. I.S.1489 - Specification for Portland -pozzolana Cement. I.S.650 - Specification for standard sand for testing of cement. I.S.383 - Specification for coarse and fine aggregates From natural sources for concrete. I.S.2386 - Methods of test for aggregate for concrete (Parts I to VIII)

4.1.1.

4.1.2

4.2

(a) 1. 2. 3. 4. 5.

6. 7. 8. 9.

I.S.516 I.S.1199 I.S.3025 I.S.1139

10. 11. 12. 13. 14. (b) 1. 2. 3. (c) 1. 2. 3. 4. 5. 6.

I.S.1786 I.S.4990 I.S.2645 I.S.4461 I.S.4031

- Method of test for strength of concrete. - Method of sampling and analysis of concrete. - Method of sampling and testing (Physical and Chemical) of water used in industry. - Specification for hot rolled mild steel, medium tensile steel and high yield strength steel deformed bars for concrete reinforcement. - Specification for cold worked steel high strength deformed bars for concrete reinforcement. - Specification for plywood for concrete shuttering work. - Specification for integral cement water proofing compounds. - Cold worked steel bars for the reinforcement of concrete. - Methods of physical tests for hydraulic cement.

EQUIPMENT I.S.1791 - Specification for batch type concrete mixers. I.S.2505 - Specification for concrete / vibrators (immersion type) I.S.2750 - Specification for steel scaffoldings. CODES OF PRACTICE FOR CONCRETE I.S.456 Code of practice for plain and reinforced concrete. I.S.3935 Code of practice for construction. I.S.2751 Code of practice for welding of mild steel bars used for reinforced concrete construction. I.S.2502 Code of practice for bending and fixing of bars for concrete reinforcement. I.S.3558 Code of practice for use of immersion Vibrators for consolidating concrete. I.S.3414 - Code of practice for design and installation of joints in building. I.S.4014 - Code of practice for steel tubular (Part I & II) scaffolding. I.S.2571 - Code of practice for laying in-situ cement concrete flooring. I.S.1343 - Code of practice for pre stressed concrete.

7. 8. 9.

(c) CONSTRUCTION SAFETY 1. I.S.3696 - Safety code for scaffolds and ladders (Part I & II)

(e) 1. 2.

MEASUREMENT I.S.1200 - Method of measurement of building works. I.S.3385 - Code of Practice for measurement of Civil Engineering works. Note: In the event that state, city or other Government bodies have requirements more stringent than those setforth in this Specification, such requirements shall be considered part of this specification and shall supersede this Specification where applicable.

4.3.

4.3.1

MATERIALS FOR CONCRETE The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type Ordinary Portland cement, clean sand, natural coarse aggregate, clean water, and admixtures, if specially called for on drawings or specifications. The quality of materials, method, control, manufacture and transportation of all concrete irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portion of this specification. ENGINEER shall have the right to inspect the sources of materials, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and take quality control systems such an inspection shall be arranged of concrete work. CEMENT a) Unless otherwise specified in Section C or called for by ENGINEER/ OWNERS, cement shall be Portland cement conforming to not less than Grade 43 of relevant I.S. and in 50-kg bags. The use of bulk cement will be permitted only with the approval of ENGINEER. Changing of brands on type of cement within the same structure will not be permitted without approval of ENGINEER.

a) While purchasing cement or before commencing the work for every batch of cement consignments, the CONTRACTOR should satisfy himself about the quality of cement by conducting initial test on concrete cubes in the presence of the representative of the PURCHASER and only after establishing the suitability, the cement should be used on work. To have quick evaluation results, the above specimens should be cured by steam curing and tested immediately at CONTRACTORs cost at an approved laboratory. CONTRACTOR shall not be entitled to any claim of any nature on this account. 4.3.2 AGGREGATES a) `Aggregate in general designates both fine and coarse inert materials used in the manufacture of concrete. `Fine Aggregate is aggregate most of which passes through 4.75mm IS sieve. `Coarse Aggregate is aggregate most of which is retained on 4.75mm IS sieve.

b)

c)

d)

4.3.3.

i)

ii)

All fine and coarse aggregates proposed for the use in the work shall be subject to ENGINEER's approval and after specific materials have been accepted, the source of supply of such materials shall not be changed without prior approval of ENGINEER. STORAGE OF AGGREGATES All coarse and fine aggregates shall be stacked separately in stock piles in the material yard near the work site to avoid inter-mixing of different aggregates. Contamination with foreign materials and earth during storage and while heaping the materials shall be avoided. The aggregate must be of specified quality not only at the time of receiving at site but more so at the time of loading into mixer. Coarse aggregates shall be piled in layer not exceeding 1.20 metres in height to prevent coning or segregation. Each layer shall cover the entire area of the stockpile before succeeding layers are started. Aggregates that have become segregated shall be rejected. Rejected materials after remixing may be accepted, if subsequent tests demonstrate conformity with required gradation. SPECIFIC GRAVITY Aggregates having a specific gravity below 2.6 (Saturated surface dry basis) shall not be used without special permission of ENGINEER. FINE AGGREGATE Fine aggregate except as noted above, and for other than lightweight concrete shall consist of natural sand/manufactured sand to I.S.383. The sand shall be clean, sharp, hard, strong and durable and shall be free from dust, vegetable substances, adherent coating, clay alkali, organic matter, mica, salt, or other deleterious substances, which can be injurious to setting qualities/strength/durability of concrete. SCREENING AND WASHING Sand shall be prepared for use by such screening or washing, or both as necessary to remove all objectionable foreign matter while separating the sand grains to the required size fractions. FOREIGN MATERIAL LIMITATIONS The percentages of deleterious substances in sand delivered to the mixer shall not exceed the following.

Percent by weight Uncrushed Crushed i) Material finer than 75micron I.S. sieve 3.00 15.00 ii) Shale 1.00 -iii) Coal and lignite 1.00 1.00 iv) Clay lumps 1.00 1.00 v) Total of all the above substances including items (i) to (iv)for uncrushed 5.00 2.00 sand and items (iii) and (iv) for crushed sand ______________________________________________________________

iii) GRADATION Unless and otherwise directed or approved, the grading of sand be within the limits indicated hereunder: I.S.Sieve Designation grading Zone-I 10 mm 100 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron 90-100 60-95 30-70 15-34 5-20 0-10 Percentage passing for Zone-II Zone-III Zone-IV 100 100 100 90-100 75-100 55-90 35-59 8-30 0-10 90-100 85-100 75-90 60-79 12-40 0-10 95-100 95-100 90-100 80-100 15-50 0-15

shall

Where the grading falls outside the limits of any particular grading zone of sieves, other than 600 I.S. Sieve, by total amount not exceeding 5 percent, it shall be regarded as falling within that grading zone. This tolerance shall not be applied to percentage passing the 600 micron I.S. sieve or to percentage passing any other sieve size on the coarser limit of Grading Zone-I or the finer limit of Grading Zone-IV. Fine aggregates conforming to Grading Zone-IV shall be used unless mix designs and preliminary tests have shown its suitability for producing concrete of specified strength and workability. iv) FINENESS MODULUS The sand shall have fineness modulus of not less than 2.2 or more than 3.2. The fineness modulus is determined by adding the cumulative percentages retained on the following I.S. sieve sizes (4.75mm, 2.36mm, 1.18mm, 600 micron, 300 micron and 150 micron) and dividing the sum by 100. COARSE AGGREGATE Coarse aggregate for concrete, except as noted above and for other than lightweight concrete shall conform to I.S. 383. This shall consist of natural stone and shall be clean, and free from elongated, flaky or laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag, alkali, mica, organic matter of other deleterious matter. i) GRADING Coarse aggregate shall be either in single size or graded. In both cases, the grading shall be within following limits.

4.3.4.

-------------------------------------------------------------------------------------------------IS Percentage Passing for Percentage Sieve single aggregate of passing for Designominal size graded aggregate of nation nominal size ----------------------------------------------------------------------------------------------------40 20 16 12.5 10 40 20 16 12.5 mm mm mm mm mm mm mm mm mm ---------------------------------------------------------------------------------------------------63mm 100 ---- -100 ---40mm 85-100 100 --- -95-100 100 --20mm 0-20 85-100 100 -- -30-70 95-100 100 -16mm --85-100 100 ---90-100 10mm 0-5 0-20 0-30 0-45 85-100 10-35 25-55 30-70 40-85 4.75mm -0-5 0-5 0-10 0-10 0-10 0-10 0-10 0-10 2.36mm ----0-5 ----------------------------------------------------------------------------------------------------------The pieces shall be angular in shape and shall have granular or crystalline surfaces. Friable flaky and laminated pieces, mica and shale, if present, shall be only in such quantities that will not, in the opinion of ENGINEER, affect adversely, the strength and/or durability of concrete. The maximum size of coarse aggregate shall be 40mm for class A concrete and 20mm for class B concrete. The maximum size of coarse aggregate shall be the maximum size specified above but in no case greater than 1/4 of the maximum thickness of the member, provided that the concrete can be placed without difficulty so as to surround all reinforcement thoroughly and fill the corners of the form. For heavily reinforced concrete member, the nominal maximum size of the aggregate shall be 5mm less than the minimum clear distance between the reinforcing main bars or 5mm less than the minimum cover to the reinforcement whichever is smaller. The amount adherent shall not exceed 1% when determined by laboratory sedimentation tests as per I.S.2386. After 24 hours immersion in water, a previously dried sample shall not have gained more than 10% of its over dry weight in air, as determined by I.S.2386. ii) FOREIGN MATERIAL LIMITATIONS The percentage of deleterious substance in the aggregate delivered to the mixer shall not exceed the following : Percent by weight Uncrushed Crushed i) Material finer than 75 micron I.S.sieve ii) Coal and lignite iii)Clay lumps 3.00 1.00 1.00 3.00 1.00 --

iv) Soft Fragments v) Total of all the above substances 4.4. a)

3.00 5.00

---

b)

WATER Water used for both mixing of mortar / concrete and curing shall be free from injurious amounts of deleterious materials. Potable water is generally satisfactory for mixing of mortar / concrete and curing concrete. The relevant essential Water tests pertaining to access the suitability for construction standards shall have to be done before commencement of work. The suitability of water for making concrete shall be ascertained by the tests as specified in I.S.456 and other relevant standards. The sample of water taken for testing shall be typical of the water proposed to be used for concreting, due account being paid to seasonal variation. The sample shall not receive any treatment before testing other than that envisaged in the regular supply of water proposed for use in concrete. REINFORCEMENT SUPPLY The supply of steel shall be arranged by the contractor himself. Reinforcement if supplies are arranged by CONTRACTOR shall be either plain round mild bars Grade 1 as per IS.432 (Part 1) or medium tensile steel bars as per IS.432 (Part 1)and deformed bars as per IS:1786. Wire mesh or fabric shall be in accordance with IS 1566. Substitution of reinforcement will not be permitted except upon written approval from ENGINEER. No advance amounts shall be paid to the contractor towards purchase of steel. Note The tenderer, shall give details of Fe 415 grade.viz. sizes (diameter) available, necessary test reports and manufacturers certificate on the every consignment of steel that are brought to site shall be furnished to the Engineer then and there and approval of Engineer shall be obtained before proceeding the works.

4.5. i)

ii) a) b)

STORAGE The reinforcement shall not be kept in direct contact with the ground but stacked on top of an arrangement of timber sleepers or the like. If the reinforcing rods have to be stored for long duration, they shall be coated with cement wash before stacking and/or be kept under cover or stored as directed by ENGINEER.

c)

Fabricated reinforcement shall be carefully stored to prevent damage, distortion, corrosion and deterioration.

iii) QUALITY a) All steel shall be of Grade-I quality unless specifically permitted by ENGINEER. No re-rolled material will be accepted. If demanded by ENGINEER, CONTRACTOR shall submit the manufacturers test certificate for steel. Random tests on steel supplied by CONTRACTOR may be performed by OWNER as per relevant Indian Standards. All costs incidental to such tests shall be at "CONTRACTOR's expense. Steel not conforming to Specifications shall be rejected. b) All reinforcement shall be clean, free from grease, oil, and paint, dirt loose mill scale, loose rust, dust bituminous material or any other substances that will destroy or reduce the bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective rods shall not be used. All bars shall be rigidly held in position before concreting. No welding of rods to obtain continuity shall be allowed unless approved by ENGINEER. If welding is approved, the work shall be carried out as per I.S.2751 according to best modern practices and as directed by ENGINEER. In all cases of important connections, tests shall be made to prove that the joints are of the full strength of bars welded. Special precautions, as specified by ENGINEER, shall be taken in the welding of cold worked reinforcing bars and bars other than mild steel. iv) LAPS Laps and splices for reinforcement shall be as shown on the drawings. Splices in adjacent bars shall be staggered and the locations of all splices, except those specified on the drawings, shall be approved by ENGINEER. The bars shall not be lapped unless the length required exceeds the maximum available lengths of bars at site. BENDING Reinforcing bars supplied bent or in coils, shall be straightened before they are cut to size. Straightening of bars shall be done in cold and without damaging the bars. This is considered as a part of reinforcement bending fabrication work. All bars shall be accurately bent according to the sizes and shapes shown on the detailed working drawings/ bar bending schedules. They shall be bent gradually by machine or other approved means. Reinforcing bars shall not be straightened and re-bent in a manner that will injure the material. Bars containing cracks or splits shall be rejected. They shall be bent cold, except bars of over 25mm in diameter which may be bent hot if specifically approved by ENGINEER, Bars which depend for their strength on cold working, shall not be bent hot, shall not be heated beyond cherry red colour (not exceeding 845C) and after bending shall be allowed to

v) a)

b)

cool slowly without quenching. Bars incorrectly bent shall be used only if the means used for straightening and re-bending be such as shall not, in the opinion of ENGINEER, injure the material. No reinforcement shall be bent when in position in the work without approval, whether or not it is partially embedded in hardened concrete. Bars having kinks or bends other than those required by design shall not be used. vi) FIXING Reinforcement shall be accurately fixed by any approved means and maintained in the correct position shown in the drawings by the use of blocks, spacers and chairs as per IS.2503 to prevent displacement during placing and compaction of concrete. Bars intended to be in contact at crossing points shall be securely bound together at all such points with number 16 gauge annealed soft iron wire. The vertical distances required between successive layers of bar in beams or similar members shall be maintained by the provision of mild steel spacer bars at such intervals that the main bars do not perceptibly sag between adjacent spacer bars. COVER The cover to reinforcement shall be in accordance with IS 456-2000 and other relevant standards. INSPECTION Erected and secured reinforcement shall be inspected and approved by ENGINEER prior to placement of concrete.

vii)

viii)

4.6.

CONSISTENCY AND SLUMP a) The concrete mix proportions chosen should be such that the concrete is of adequate workability for the placing conditions of the concrete and can properly be compacted with the means available. Suggested ranges of workability of concrete measured in accordance with IS 1199 are given below: Placing Conditions Degree of Slump Workability (mm) Blinding concrete; Shallow sections; Very low See5.6.b below Pavements using pavers Mass concrete; Lightly reinforced Sections in slabs, Beams, walls, columns; Floors; Hand Low 25-75 placed pavements; Canal lining; Strip footings. Heavily reinforced sections in slabs, beams, walls, columns, slip formwork, Pumped Medium concrete.

50-100 75-100

Trench fill, In situ piling. Tremie concrete

High Very high

100-150 See 5.6.c below

b)

c)

NOTE: For most of the placing conditions, internal vibrators (needle vibrators) are suitable. The diameter of the needle shall be determined based on the density and spacing of reinforcement bars and thickness of sections. For tremie concrete, vibrators are not required to be used. In the 'very low" category of workability where strict control is necessary, for example pavement quality concrete, measurement of workability by determination of compacting factor will be more appropriate than slump (see. IS 1199) and a value of compacting factor of 0.75 to 0.80 is suggested. In the 'very high' category of workability, measurement of workability by determination of flow will be appropriate (see IS 9103) TESTING OF CUBES Arrangement shall be made by CONTRACTOR to have the cubes tested in an approved laboratory at his expense, with the prior consent of the ENGINEER. SAMPLING FOR STRENGTH OF CONCRETE At least 6 test cubes of each class of concrete shall be made for every 15 cu.m. concrete or part thereof. At least one sample shall be taken from each shift. Such samples shall be drawn on each day for each type of concrete. Of each set of 6 cubes, three shall be tested at 7 days age and three at 28 days age. The laboratory test results shall be tabulated and furnished to ENGINEER. ENGINEER will pass the concrete if the acceptance criteria as per clause 16 of IS: 456-2000 are met with. NOMINAL / DESIGN MIX CONCRETE Concrete grade shall be designated on drawings. Concrete in the works shall be "DESIGN MIX CONCRETE or "NOMINAL MIX CONCRETE. Design mix is preferred to nominal mix. If design mix concrete can not be used for anyreason on the work for Grades M20 or lower, nominal mixes may be used with permission from Engineer. CONCRETE grade above M20 shall be DESIGN MIX CONCRETE. DESIGN MIX CONCRETE For Design Mix Concrete, the mix shall be designed according to IS: 10262 and SP: 23 to provide the grade of concrete having the required workability and characteristic strength not less than appropriate values given in IS: 456. The design mix shall in addition be such that it is cohesive and does not segregate and should result in dense and durable concrete and also capable of giving the finish as specified. For liquid retaining structures, the mix shall also result in water tight concrete. The CONTRACTOR shall exercise great care while

4.7.

i)

ii)

a)

designing the concrete mix and executing the works to achieve the desired result.The minimum cement content for different grades of Concrete for RCC / P.C.C works shall be as per IS 456-2000 or as specified in the drawings/schedule. It shall be CONTRACTOR's sole responsibility to carry out the mix designs in a reputed Institution / Research Institute at his own cost. He shall furnish to ENGINEER atleast 30 days before concreting operations, a statement of proportions proposed to be used for the various concrete mixes and the strength results obtained. The strength requirements of the concrete mixes ascertained on 150mm cubes as per IS: 516 shall comply with the requirements of IS: 456. CONSISTENCY Slump tests shall be carried out as often as demanded by ENGINEER and invariably from the same batch of concrete from which the test cubes are made. Slump tests shall be done immediately after sampling. ADMIXTURES Admixtures may be used in concrete only with the approval of ENGINEER based upon evidence that, with the passage of time, neither the compressive strength nor its durability reduced. Calcium chloride shall not be used for accelerating setting of the cement for any concrete containing reinforcement, or embedded steel parts. When calcium chloride is permitted to be used, such as in mass concrete works, it shall be dissolved in water and added to mixing water in an amount not to exceed 1 percent of the weight of the cement in each batch of concrete. When admixtures are used, the designed concrete mix shall be corrected accordingly. Admixtures shall be used as per manufacturers instructions and in the manner and with the control specified by ENGINEER. No extra cost will be paid for admixtures. Water Proofing Agent Where specified and approved by ENGINEER, water proofing agent conforming to IS.2645, shall be added in quantity specified by Engineer. TESTS Engineer if he so desires may order tests to be carried out on cement, sand, coarse aggregate, water in accordance with the relevant Indian Standards. Tests on cement shall include fineness test test for normal consistency test for setting time test for soundness test for tensile strength test for compressive strength test for heat of hydration (by experiment and by calculations) in accordance with IS: 269.

(b)

4.8.

4.9.

i) ii) iii) iv) v) vi) vii)

Tests on sand shall include. i) Sieve test ii) test for organic impurities. iii) Decantation test for determining clay and silt content iv) specific gravity test v) test for unit weight and bulkage factor vi) test for sieve analysis and fineness modulus. Tests on coarse aggregate shall include. Sieve analysis specific gravity and unit weight of dry, loose and clodded aggregate. Soundness and alkali aggregate reactivity. Petrographic examination. Deleterious materials and organic impurities. Test for aggregate crushing value. Any or all these tests would normally be ordered to be carried out only if ENGINEER feels the materials are not in accordance with the specifications or if the specified concrete strengths are not obtained and shall be performed by CONTRACTOR or at an approved test laboratory If the test cubes of the work do not give the stipulated strengths, ENGINEER reserves the right to ask CONTRACTOR to dismantle such portions of the work, which in his opinion are unacceptable and re-do the work to the standard stipulated at CONTRACTORs cost. The unit rate for concrete shall be all-inclusive, including making preliminary mix design and test cubes, works-cubes, testing them as per Specification, slump tests, optional tests, etc. complete. LOAD TEST ON MEMBERS OR ANY OTHER TESTS: In the event of any work being suspected of faulty materials or workmanship or both, ENGINEER requiring its removal and reconstruction may order, or CONTRACTOR may request that it should be load tested in accordance with the following provisions. i) The test load shall be 125 percent of the maximum superimposed load for which the structure was designed. Such test load shall not be applied before 56 days after the effective hardening of concrete. During the test, struts strong enough to take the whole load shall be placed in position leaving a gap under the members. The test load shall be maintained for 24 hours before removal. ii) If within 24 hours of the removal of the load, the structure does not show a recovery of atleast 75 percent of the maximum

i) ii) iii) iv) v) vi) vii)

b)

c)

deflection shown during the 24hours under load, the test loading shall be repeated after a lapse of atleast 72hours. The structure shall be considered to have failed to pass the test if the recovery after the second test is not atleast 75 percent of the maximum deflection shown during the second test. If the structure is certified as failed by the ENGINEER, the cost of the load test shall be borne by the CONTRACTOR. iii) Any other tests, e.g. taking out in an approved manner concrete cores, examination and tests on such cores removed from such parts of the structure as directed by ENGINEER, sonic testing etc. shall be carried out by CONTRACTOR if so directed. UNSATISFACTORY TESTS Should the results of any test prove unsatisfactory, or the structure shows signs of weakness, undue deflection or faulty construction CONTRACTOR shall remove and rebuild the member or members involved or carry out such other remedial measures as may be required by ENGINEER/ OWNER. CONTRACTOR shall bear the cost of redoing, unless the failure of the member or members to fulfil the test conditions is proved to be solely due to faulty design. 4.10. (a) PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL INSPECTION AND APPROVAL Before the concrete is actually placed in position, the inside of the formwork shall be inspected to see that they have been cleaned and oiled. Temporary openings shall be provided to facilitate inspection, especially at bottom of columns and wall forms, to permit removal of saw dust, wood shavings, binding wire, rubbish, dirt etc. Openings shall be placed or holes drilled so that these materials and water can be removed easily. Such openings/ holes shall be later suitably plugged. The various trades shall be permitted ample time to install drainage and plumbing lines, floor and trench drains, conduits, hangers, anchors, inserts, sleeves, bolts, frames, and other miscellaneous embedments to be cast in the concrete as indicated on the drawings or as is necessary for the proper execution of the work. CONTRACTOR shall co-operate fully with all such agencies, and shall permit the use of scaffolding, formwork etc. by other trades at no extra cost. All embedded parts, inserts etc. supplied by OWNER or CONTRACTOR shall be correctly positioned and securely held in the forms to prevent displacement during depositing and vibrating of concrete. All anchor bolts shall be positioned and kept in place with the help of properly manufactured templates unless specifically waived in writing by ENGINEER. The use of all such templates, fixtures etc. shall be deemed to be included in the rates. Slots, openings, holes, pockets etc. shall be provided in the concrete work in the positions indicated in the drawings or as directed by ENGINEER.

(b)

(c)

(d)

(e)

(f) (g)

(h)

(i)

Reinforcement and other items to be cast in concrete shall have clean surfaces that will not impair bond. Prior to concrete placement all work shall be inspected and approved by ENGINEER and if found unsatisfactory, concrete shall not be poured until after all defects have been corrected at CONTRACTORs cost. Approval by ENGINEER of any and all materials and work as required herein shall not relieve CONTRACTOR from his obligation to produce finished concrete in accordance with the drawings and Specifications. RAIN OR WASH WATER No concrete shall be placed in wet or on a water-covered surface. Any concrete that has been washed by heavy rains shall be entirely removed, if there is any sign of cement and sand having been washed away from the concrete mixture. To guard against damage, which may be caused by rains, the works shall be covered with tarpaulins immediately after the concrete has been placed and compacted before leaving the work unattended. Any water accumulating on the surface of the newly placed concrete shall be removed by approved means and no further concrete shall be placed thereon until such water is removed. To avoid flow of water over/ alround freshly placed concrete, suitable drains and sumps shall be provided. BONDING MORTAR Immediately before concrete placement begins, prepared surfaces except formwork, which will come in contact with the concrete to be placed shall be covered with a bonding mortar. TRANSPORTATION All buckets, containers, or conveyer used for transporting concrete shall be mortar-tight. Irrespective of the method of transportation adopted, concrete shall be delivered with the required consistency and plasticity without segregation or loss of slump. However, chutes shall not be used for transport of concrete without the written permission of Engineer and concrete shall not be re-handled before placing. RETEMPERED OR CONTAMINATED CONCRETE Concrete must be placed in the final position before it becomes too stiff to work. On no account water shall be added after the initial mixing. Concrete, which has become stiff or has been on taminated with foreign materials shall be rejected and disposed off as directed by ENGINEER. CLEANING OF EQUIPMENT All equipment used for mixing, transporting and placing of concrete shall be maintained in clean condition. All pans, buckets, hoppers, chutes, pipelines and other equipment shall be thoroughly cleaned after each period of placement.

(j)

4.11 a)

b)

c)

4.12 a)

b)

c)

d)

PROCEDURE FOR PLACING OF CONCRETE: ENGINEERS APPROVAL OF EQUIPMENT & METHODS Before any concrete is placed, the entire placing programme, consisting of equipment, layout, proposed procedures and methods shall be submitted to ENGINEER for approval if so demanded by ENGINEER and no concrete shall be placed until ENGINEER's approval has been received. Equipment for conveying concrete shall be of such size and design as to ensure a practically continuous flow of concrete during depositing without segregation of materials considering the size of the job and placement location. TIME INTERVAL BETWEEN MIXING AND PLACING Concrete shall be placed in its final position before the cement reaches its initial set and concrete shall normally be compacted in its final position within thirty minutes of leaving the mixer, and once compacted it shall not be disturbed. AVOIDING SEGREGATION Concrete shall, in all cases, be deposited as nearly as practicable directly in its final position, and shall not be re-handled or caused to flow in a manner which will cause segregation, loss of materials, displacement of reinforcement, shuttering or embedded inserts or impair its strength. For locations where direct placement is not possible, and in narrow forms, contractor shall provide suitable drop and "Elephant Trunks to confine the movement of concrete. Special care shall be taken when concrete is dropped from a height, especially if reinforcement is in the way, particularly in columns and thin walls. PLACING BY MANUAL LABOUR Except when otherwise approved by Engineer, concrete shall be placed in the shuttering by shovels of other approved implements and shall not be dropped from a height more than 1.0metre or handled in a manner, which will cause segregation. PLACING BY MECHANICAL EQUIPMENT The following specification shall apply when placing of concrete by use of mechanical equipment is specifically called for while inviting bids or is warranted considering the nature of work involved. The control of placing shall begin at the mixer discharge. Concrete shall be discharged by a vertical drop into the middle of the bucket or hopper and this principle of vertical discharge of concrete shall be adhered to throughout all stages of delivery until the concrete comes to rest in its final position. TYPE OF BUCKETS Central-bottom-dump buckets of a type that provides for positive regulation of the amount and rate of deposition of concrete in all dumping position, shall be employed.

e) i)

ii)

iii)

f)

4.13.

4.14.

4.15.

OPERATION OF BUCKET In placing concrete in large open area, the bucket shall be spotted directly over the position designated and then lowered for dumping. The open bucket shall clear the concrete already in place and the height of drop shall not exceed 1.00m. The bucket shall be opened slowly to avoid high vertical bounce. Dumping of buckets on the swing in any manner, which results in separation of ingredients or disturbance of previously placed concrete, will not be permitted. PLACEMENT IN RESTRICTED FORMS Concrete placed in restricted form by barrow, buggies, cars, short chutes or hand shovelling shall be subject to the requirements for vertical delivery of limited height to avoid segregation and shall be deposited as nearly as practicable in its final position. CHUTING Where it is necessary to use transfer chutes, specific approval of Engineer must be obtained to type, length, slopes, baffles, vertical terminals and timing of operations. These shall be so arranged that an almost continuous flow of concrete is obtained at the discharge and without segregation .To allow for the loss of mortar against the sides of the chutes, the first mixes shall have less coarse aggregate. During cleaning of chutes, the waste water shall be kept clear of the forms. Concrete shall not be permitted to fall from the end of the chutes by more than 1m.Chutes when approved for use shall have slopes not flatter than 1vertical:3 horizontal and not steeper than 1vertical:2 horizontal. Chutes shall be of metal or metal lined and of rounded cross section .The slopes of all chute sections shall be approximately the same .The discharge end of the chutes shall be maintained above the surface concrete in the forms. PLACING CONCRETE IN LAYERS Concreting, once started, shall be continuous until the pour is completed. Concrete shall be placed in successive horizontal layers of uniform thickness ranging from 150 to 900 mm as directed by Engineer. These shall be placed as rapidly as practicable to prevent the formation of cold joints or planes of weakness between each succeeding layer within the pour. The thickness of each layer shall be such that it can be deposited before the previous layer has stiffened. The bucket leads or other units of Deposit shall be spotted progressively along the face of the layer with such overlap as will facilitate spreading the layer to uniform depth and texture with a minimum of shovelling. Any tendency to segregation shall be corrected by shovelling stones into mortar rather than mortar on to stones. Such a condition shall be corrected by redesign of mix or other means, as directed by Engineer. BEDDING OF LAYERS The top surface of each pour and bedding planes shall be approximately horizontal unless otherwise instructed.

4.16.

4.17.

4.18.

4.19.

4.20.

4.21.

4.22. a)

b)

COMPACTION Concrete shall be compacted during placing, with approved vibrating equipment until the concrete has been consolidated to the maximum, practicable density, is free of pockets of coarse aggregate and fits rightly against all form surfaces, reinforcement and embedded fixtures. Particular care shall be taken to ensure that all concrete placed against the form faces and into corners of forms or against hardened concrete at joints is free from voids or cavities. The use of vibrators shall be consistent with the concrete mix and caution exercised not to over vibrate the concrete to the pointing that segregation result. STONE POCKETS AND MORTAR PONDAGES The formation of stone pockets or mortar pondages in corners and against faces of forms shall not be permitted. Should these occur, they shall be dug out, reformed and refilled to sufficient depth and shape for thorough bonding, as directed by ENGINEER. PLACEMENT INTERVAL Except when placing with slip forms, each placement of concrete in multiple lift work, shall be allowed to set for atleast 24 hours after the final set of concrete and before the start of a subsequent placement. SPECIAL PROVISION IN PLACING When placing concrete in walls with openings, in floors, of integral slab and beam construction and other similar conditions, the placing shall stop when the concrete reaches the top of the opening in walls or bottom horizontal surface of the slab, as the case may be. Placing shall be resumed before the concrete in place takes initial set, but not until it has had time to settle as determined by ENGINEER. PLACING CONCRETE THROUGH REINFORCING STEEL When placing concrete through reinforcing steel, care shall be taken to prevent segregation of the coarse aggregate. Where the congestion of steel make placing difficult it may be necessary to temporarily move the top steel aside to get proper placement and restore reinforcing steel to design position. BLEEDING Bleeding or free water on top of concrete being deposited into the forms, shall be a cause to stop the concrete pour and the conditions causing this defect corrected before any further concreting is resumed. CONSTRUCTION JOINTS AND KEYS Concrete shall be placed without interruption until completion of the part of the work between predetermined construction joints, as specified herein after. Time lapse between the pouring of adjoining units shall be as specified on the drawing or as directed by ENGINEER. If stopping of concreting becomes unavoidable anywhere, a properly formed construction joint shall be made where the work is stopped. Joints shall be either vertical or horizontal, unless shown otherwise on drawings.

4.23

4.24.

4.25.

4.26.

4.27.

In case of an inclined or curved member, the joints shall be at right angles to the axis of the member. Vertical joints in walls shall be kept to a minimum. Vertical joints shall be formed against a stop board: horizontal joints shall be level and wherever possible arranged so that the joint lines coincide with the architectural features of the finished work. Battens shall be nailed to the formwork to ensure a horizontal line and if directed, shall also be used to form a grooved joint. For tank walls and similar work, joints shall be formed as per I.S.3370.Concrete that is in the process of setting shall not be disturbed or shaken by traffic either on the concrete itself or upon the shuttering. Horizontal and vertical construction joints and shear keys shall be located and shall conform in detail to the requirements of the plans unless otherwise directed by ENGINEER. Where not described, the joint shall be in accordance with the following. BEAM AND SLAB JOINTS Concrete in a beam shall be placed throughout without a joint but if the provision of a joint is unavoidable the joint shall be vertical and at the centre or within the middle third of the span unless or otherwise shown on drawings. Where a beam intersects a girder, the joints in the girder shall offset a distance equal to twice the width of the beam and additional reinforcement provided for shear. The joints shall be vertical throughout the full thickness of the concrete member. All joints in a slab shall be vertical and parallel to the principal reinforcement. Where it is unavoidably at right angles to the principal reinforcement, the joint shall be vertical and at the middle of the span. JOINT IN LIQUID RETAINING STRUCTURES Vertical construction joints in water tight construction will not be permitted unless indicated on the drawings. Where a horizontal construction joint is required to resist water pressure, special care shall be taken in all phases of its construction to ensure maximum water tightness. DOWELS Dowels for concrete work, not likely to be taken up in the near future, shall be wrapped in tar paper and burlap. MASS FOUNDATIONS Mass foundations shall be poured in lifts not exceeding 1.5m in height unless otherwise indicated on the drawings or approved by Engineer. TREATMENT OF CONSTRUCTION JOINTS ON RESUMING CONCRETING A drier mix shall be used for the top lift of horizontal pours to avoid laitance. All laitance and loose stones shall be thoroughly and carefully removed by wire brushing/backing and surface washed. Just before concreting is resumed, the roughened joint surface shall be thoroughly cleaned and loose matter removed and then treated with a thin layer of cement grout of proportion specified by Engineer and worked well into the surface. The new concrete shall be well worked against the prepared face before the grout mortar sets. Special care shall

4.29. i)

ii)

iii)

be taken to obtain thorough compaction and to avoid segregation of the concrete along the joint plane. CURING, PROTECTING, REPAIRING AND FINISHING CURING All concrete shall be cured by keeping it continuously damp for the period of time required for complete hydration and hardening to take place. Preference shall be given to the use of continuous sprays, or ponded water, continuously saturated coverings of sacking, canvas, hessian or other absorbent materials, or approved effective curing compounds applied with spraying equipment capable of producing a smooth, even textured coat. Extra precautions shall be exercised in curing concrete during cold and hot weather as outlined herein after. The quality of curing water shall be the same as that used for mixing concrete. Certain types of finish or preparation for overlaying concrete must be done at certain stages of the curing process and special treatment may be required for specific concrete surface finish. CURING WITH WATER Fresh concrete shall be kept continuously wet for a minimum period of 10 days of placing of concrete, following a lapse of 12 to 14hours after laying concrete. The curing of horizontal surfaces executed during winds shall however begin immediately the concrete has hardened. Water shall be applied to unformed concrete surfaces, within 1hour after concrete has set. Water shall be applied to formed surfaces immediately upon removal of forms. Quantity of water applied shall be controlled so as to prevent erosion of freshly placed concrete. CONTINUOUS SPRAYING Curing shall be assured by use of ample water supply under pressure in pipes, with all necessary appliances of hose, sprinklers and spraying devices. Continuous fine mist spraying or sprinkling shall be used unless otherwise specified or approved by ENGINEER. ALTERNATIVE CURING METHODS Wherever in the judgement of ENGINEER, it may be necessary to omit the continuous spray method, covering of clean sand or other approved means such as wet gunny bags which will prevent loss of moisture from the concrete, may be used. No type of covering will be approved which would stain or damage the concrete during or after the curing period. Covering shall be kept continuously wet during the curing period. CURING EQUIPMENT All equipment and materials required for curing shall be on hand and ready for use before concrete is placed. PROTECTING FRESH CONCRETE Fresh concrete shall be protected from the elements, from defacements and damage due to construction operations by leaving forms in place for an ample period as specified later in this specification. Newly placed

iv)

v)

vi)

vii)

viii) a)

b)

c)

concrete shall be protected by approved means such as tarpaulins from rain, sun and winds. Steps as approved by Engineer shall also be taken to protect immature concrete from damage by debris, excessive loading vibration, abrasion or contact with other materials etc. that may impair the strength and or durability of the concrete. Workman shall be warned against and prevented from disturbing green concrete during its setting period. If it is necessary that workmen enter the area of freshly placed concrete, ENGINEER may require that bridges be placed over the area. REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE Immediately after the shuttering is removed, the surface of concrete shall be very carefully gone over and all defective areas called to the attention of ENGINEER who may permit patching of the defective areas or also reject the concrete unit either partially or in its entirety. Rejected concrete shall be removed and replaced by CONTRACTOR at no additional expense to owner. Holes left by form bolts etc. shall be filled up and made good with mortar composed of one part of cement to one and half parts of sand passing 2.36 mm IS sieve after removing any loose stones adhering to the concrete. Mortar filling shall be struck off flush at the face of the concrete. Concrete surfaces are finished as described under the particular items of work. Superficial honey combed surface and rough patches shall be similarly made good immediately after removal of shuttering, in the presence of ENGINEER and superficial water and air holes shall be filled in. The mortar shall be well worked into the surface with a wooden float. Excess water shall be avoided. Unless instructed otherwise by ENGINEER, the surface of the exposed, concrete placed against shuttering shall be rubbed down immediately on removal of shuttering to remove fine or other irregularities, care being taken to avoid damaging the surface. Surface irregularities shall be removed by grinding. If reinforcement is exposed or the honey combing occurs at vulnerable position e.g. ends of beams and columns it may be necessary to cut out the member completely or in part and reconstruct. The decision of Engineer shall be final in this regard. If only patching is necessary, the defective concrete shall be cut out till solid concrete is reached (or to a minimum depth of 25mm) the edges being cut perpendicular to the affected surface or with a small under cut if possible. Anchors, tees or dovetail slots shall be provided whenever necessary to attach the new concrete securely in place. An area extending several centimetres beyond the edge and the edges and the surfaces of the prepared voids shall be saturated with water for 24 hours immediately before the patching material is placed.

d)

USE OF EPOXY The use of epoxy for bonding fresh concrete used for repairs will be permitted upon written approval of ENGINEER. Epoxies shall be applied in strict accordance with the instructions of the manufacturer. METHOD OF REPAIR Small size holes having surface dimension about equal to the depth of the hole, holes left after removal of form bolts, grout insert holes and slots cut for repair of cracks shall be repaired as follows. The holes to be patched shall be roughened and thoroughly soaked with clean water until absorption stops. A 5mm layer of grout of equal parts of cement and sand shall be well brushed into the surface to be patched, followed immediately by the patching concrete, which shall be well consolidated with a wooden float and left slightly proud of the surrounding surface. The concrete patch shall be built upon weather conditions, it shall be worked off flush with a wooden float and a smooth finish obtained by wiping with hessian, a steel trowel shall be used for this purpose. The mix of patching shall be of the same materials and in the same proportions as that used in the concrete being repaired, although some reducing in the maximum size of the coarse aggregates may be necessary and the mix shall be kept as dry as possible. Mortar filling by air pressure (guniting) shall be used for repair of areas to large and/or too shallow for patching with mortar. Patched surfaces shall be given a final treatment to match the colour and texture of the surrounding concrete. White cement shall be substituted for ordinary cement, if so directed by ENGINEER to match the shade of the patch with the original concrete. CURING OF PATCHED WORK The patched areas shall be covered immediately with an approved non staining, water-saturated material such as gunny bags, which shall be kept continuously, wet and protected against sun and wind for a period of 24 hours. Thereafter, the patched area shall be kept wet continuously by a final spray of sprinkling for not less than 10days. APPROVAL BY ENGINEER All materials, procedures, and operations used in the repair of concrete and also the finished repair work shall be subject to the approval of ENGINEER. All fillings shall be tightly bonded to the concrete and shall be sound, free from shrinkage cracks after the fillings have been cured and dried. FINISHING This specification is intended to cover the treatment of concrete surface of all structures. Areas requiring special finish not covered by this specification shall be clearly indicated on the drawings and special specifications shall be furnished. FINISH FOR FORMED SURFACES The type of finish for formed concrete surfaces shall be as follows, unless otherwise specified by the ENGINEER. For surface against which backfill

e)

f)

g)

ix) a)

b)

c)

d)

e)

f)

or concrete is to be placed, no treatment is required except repair of defective areas. For surface below grade which will receive water proofing treatment the concrete shall be free of surface irregularities, which would interfere with proper application of the waterproofing materials which is specified for use.Unless specified, surface which will be exposed when the structure is in service shall receive no special finish, except repair of damaged or defective concrete, removal of fins, and abrupt irregularities, filling of holes left by form ties and rods and clean up of adhering debris. Surfaces which will be exposed to the weather and which would normally level shall be sloped for drainage, unless the drawing specifies a horizontal surface or shows the slope required, the tops of narrow surfaces show the slope required, the tops of narrow surfaces such as stair treads, walls, curbs, and parapets shall be sloped across the width approximately 1 in 3. Broader surfaces such as walkways, road, parking areas and platforms shall be sloped about 1 in 50. Surfaces that will be covered by backfill or concrete, subfolders to be covered by backfill or concrete, sub-floors to be covered with concrete topping, terrazzo or quarry tile, and similar surfaces shall be smooth screeded and levelled to produce even surfaces. STANDARD FINISH FOR EXPOSED CONCRETE Exposed concrete shall mean any concrete, other than floors or slabs, exposed to view upon completion of the job. Unless otherwise specified on the drawings, the standard finish for exposed concrete shall be smooth finish. A smooth finish shall be obtained with the use of lined or plywood forms having smoothed and even surfaces and edges. Panels and form linings shall be of uniform size and be as large as practicable and installed with closed joint. Upon removal of form the joint marks shall be smoothed off and all blemishes, projections etc. removed leaving the surfaces reasonably smooth and unmarred. INTEGRAL CEMENT CONCRETE FINISH When specified on the drawings an integral cement concrete finish of specified thickness for floors and slabs shall be applied either monolithic or bonded, as specified on the drawings, as per IS 2571. The surfaces shall be compacted and then floated with a wooden float or power floating machine. The surface shall be tested with a straight edge and any high and low spots eliminated. Floating or trowelling of the finish shall be permitted only after all surface water has evaporated. Dry cement or mixture of dry cement and sand shall not be sprinkled directly on the surface of the cement finish to absorb moisture or to stiffen the mix. RUBBED FINISH A rubbed finish shall be provided only on exposed concrete surfaces as specified on the drawings. Upon removal of forms, all fins and other projections in the surfaces shall be carefully removed, offsets levelled and voids and/or damaged sections immediately saturated with water and repaired by filling with concrete or mortar of the same composition as was

g)

used in the surface. The surfaces shall then be thoroughly wetted and rubbed with carborundum or other abrasive. Cement mortar may be used in the rubbing, but the finished surfaces shall not be brush coated with either cement or grout after rubbing. The finished surfaces shall present a uniform and smooth appearance. PROTECTION All concrete shall be protected against damage until final acceptance by ENGINEER/OWNER. FORM WORK The formwork shall consist of shores, bracing, sides or beams and columns bottom of slabs, etc., including ties, anchors, hangers, inserts etc. complete which shall be properly designed and planned for the work. False work shall be so constructed that vertical adjustments can be made to compensate for take up and settlements. Wedges may be used at the top or bottom of timer shores, but not at both ends, to facilitate vertical adjustment or dismantling of a formwork. Only steel scaffolding and steel centering materials should be used for all RCC works. DESIGN OF FORMWORK The design and engineering of the formwork as well as its construction shall be the responsibility of CONTRACTOR. If so instructed, the drawings and/or calculations for the design of the form work shall be submitted to ENGINEER's approval and thereon. Such approval shall not however relieve contractor of the full responsibility for the design and construction of the form work. The design shall take into account all the loads vertical as well as lateral that the forms will be carrying including live and vibration loadings. TOLERANCES Tolerance is a specified permissible variation from lines, grade or dimension given in drawings. No tolerances specified for horizontal or vertical building lines or footings shall be construed to permit encroachment beyond the legal boundaries. Unless otherwise specified, the tolerances on the shapes, lines and dimensions will be permitted as per I.S. 456:2000. TYPE OF FORM WORK Form work may be of timber, plywood, metal, plastic or concrete. For special finishes the formwork may be lined with plywood, steel sheets, oil tempered hard board, etc. Sliding forms and slip forms may be used with the approval of ENGINEER. FORMWORK REQUIRERMENTS Forms shall conform to the shapes, lines, grades and dimensions including camber of the concrete as called for on the drawings. Ample studs, walers, braces, ties, straps, shores, etc. shall be used to hold the forms in proper position without any distortion whatsoever until the

4.30. i)

iii)

iii)

iv)

v) a)

b)

c)

d)

e)

f)

g)

concrete has set sufficiently to permit removal of forms. Forms shall be strong enough to permit the use of immersion vibrators. In special cases, form vibrators may also be used. The shuttering shall be close boarded. Timber shall be well seasoned, free from sap, shakes, loose, knots, worm holes, warps or other surface defects in contact with concrete. Faces coming in contact with the concrete shall be free from adhering grout, plaster, paint, projecting nails, split, or other defects, joints shall be sufficiently tight to prevent loss of water and fine materials from concrete. Plywood shall be used for Exposed Concrete surfaces. Where called for, Sawn and wrought timer may be used for unexposed surfaces. Inside faces of forms for concrete surfaces, which are to be rubbed, finish shall be planed to remove irregularities or unevenness in the face. Formwork with linings will be permitted. All new and used form timber shall be maintained in a good condition with respect to shape, strength, rigidity, water tightness, smoothness and cleanliness of surfaces. Form timber unsatisfactory in any respect shall not be used and if rejected by ENGINEER shall be removed from the site. Shores supporting successive storeys shall be placed directly over those below or be so designed and placed that the load will be transmitted directly to them. Trussed supports shall be provided for shores that cannot be secured on adequate foundations. Formwork, during any stage of construction showing signs of distortion or distorted to such a degree that the intended concrete work will not conform to the exact contours indicated on the drawings shall be repositioned and strengthened. Poured concrete affected by the faulty formwork, shall be removed entirely and the formwork corrected prior to placing new concrete. Excessive construction camber to compensate for shrinkage, settlement etc. that may impair the structural strength of members will not be permitted. Forms for substructure concrete may be omitted when in the opinion of ENGINEER the open excavation is firm enough to act as the form. Such excavations shall be slightly larger than required by the drawings to compensate for irregularities in excavation and to ensure the design requirements. h) Forms shall be so designed and constructed that their removal will not damage the concrete. Face formwork shall provide true vertical and horizontal joints conforming to the architectural features of the structure as to location of joints and be as directed by ENGINEER. i) Where exposed smooth or rubbed concrete finishes are required the form shall be constructed with special care so that resulting concrete surfaces require a minimum finish.

vi)

vii)

BRACINGS, STRUTS AND PROPS Shuttering shall be braced, strutted, propped and so supported that it shall not deform under weight and pressure of the concrete and also due to the movement of men and other materials. Bamboo shall not be used as props or cross bearers.The shuttering for beams and slabs shall be so erected that the shuttering on the sides of the beams and under the soffit of slabs can be removed without disturbing the beam bottoms. Repropping of beams shall not be done except when props have to be reinstated to take care of construction loads anticipated to be in excess of the design load. Vertical props shall be supported on wedges or other measures shall be taken where by the props can be gently lowered vertically while striking the shuttering. If the shuttering for column is erected for the full height of the column, one side shall be left open and built up in sections as placing of concrete proceeds or windows may be left for pouring concrete from the sides to limit the drop of concrete to 1.0m or as directed by ENGINEER. MOULD OIL Care shall be taken to see that the faces of formwork coming in contract with concrete are perfectly cleaned and two coats of mould oil or any other approved materials applied before fixing reinforcement and placing concrete such coating shall be insoluble in water, non-staining and not injurious to the concrete. It shall not become flaky or be removed by rain or wash water. Reinforcement and/or other items to be cast in the concrete shall not be placed until coating of the forms is complete. Adjoining concrete surfaces shall also be protected against contamination from the coating material. CHAMFERS AND FILLETS All corners and angles exposed in the finished structure shall be formed with mouldings to form chamfers or fillets on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise specified, shall be 20mm x 20mm. Care shall be exercised to ensure accurate mouldings. The diagonal face of the moulding shall be planed or surfaced to the same texture as the forms to which it is attached. VERTICAL CONSTRUCTION JOINT CHAMFERS Vertical construction joints on faces, which will be exposed at the completion of the work, shall be chamfered as above except where not permitted by ENGINEER for structural or hydraulic reasons. WALL TIES Wire ties passing through the walls shall not be allowed. In their place bolts passing through sleeves shall be used.

viii)

ix)

x)

xi)

REUSE OF FORMS Before reuse, all forms shall be thoroughly scrapped, cleaned, nails removed, holes that may leak suitably plugged and joints examined and when necessary, repaired and the inside retreated to prevent adhesion, to the satisfaction of ENGINEER. Warped timber shall be resized. CONTRACTOR shall equip himself with enough shuttering to complete the job in the stipulated time. REMOVAL OF FORMS The stripping time for forms shall be in accordance with clause 11.3 of IS 456-2000. CONTRACTOR shall record on the drawing or a special register the date upon which the concrete is placed in each part of the work and the date on which the shuttering is removed therefrom. In no circumstances shall forms struck until the concrete reaches a strength of atleast twice the stress due to self weight and any construction/erection loading to which the concrete may be subjected at the time of striking formwork. In normal circumstances (generally where temperatures are above 20 oC) forms may be struck after expiry of the following periods: -----------------------------------------------------------------------------------Type of Form work Minimum Period Before Striking Form work. ----------------------------------------------------------------------------------a) Vertical formwork to columns, walls,beams 16-24 hours b) Soffit formwork to slabs 3 days (Props to be refixed immediately after removal of formwork) c) Soffit formwork to beams 7 days (Props to be refixed immediately after removal of formwork) d) Props to slabs: 1) Spanning up to 4.5m 7 days 2) Spanning over 4.5m 14 days e) Props to beams and arches: 1) Spanning up to 6m 14 days 2) Spanning over 6m 21 days

xii)

Striking shall be done slowly with utmost care to avoid damage to raises and projections and without shock or vibration by gently easing the wedges. If after removing the form work, it

4.31. i)

ii)

iii)

iv)

is found that timber has been embedded in the concrete, it shall be removed and made good as specified earlier. Reinforced temporary opening shall be provided, as directed by ENGINEER to facilitate removal of formwork which otherwise may be in accessible. Tie rods, clamps, form bolts, etc. which must be entirely removed from walls or similar structures shall be loosened not sooner than 24 hours nor later than 48 hours after the concrete has been deposited. Ties, except those required to hold forms in place, may be removed at the same time. Ties withdrawn from walls and grade beams shall be pulled towards the inside face. Cutting ties back from the faces of walls and grade beams will not be permitted. For liquid retaining structures no sleeves for through bolts shall be used nor shall through bolts be removed. The bolts, in this case, shall cut at 25mm depth from the surface and then the hole shall be made good by sand cement mortar of the same proportions as the concrete just after striking the form work. FOUNDATION BEDDING, BONDING AND JOINING All surfaces upon or against which concrete will be placed shall suitably prepared by thoroughly cleaning, washing, dewatering,as may be indicated in the plans or directed by ENGINEER, to meet the various situations encountered in the work. Prior to construction of form work for any item where soil will act as bottom form, approval shall be obtained form ENGINEER as to the suitability of the soil. PREPARATION OF EARTH STRATA OF FOUNDATIONS All earth surfaces upon which or against which concrete is to be placed shall be well compacted and free form standing water, mud or debris. Soft yielding soil shall be removed and replaced with suitable earth well compacted as directed by ENGINEER where specified, lean concrete shall be provided on the earth stratum for receiving concrete. The surface of absorptive soils against which concrete is to be placed shall be made moisture thoroughly so that no moisture will be drawn from the freshly placed concrete and later shall help to cure the concrete. PREPARATION OF CONCRETE SURFACES The preparation of concrete surfaces upon which additional concrete is to be placed later, shall preferably be done by scarifying and cleaning while the concrete is between its initial and final set. This method shall be used wherever practicable and shall consist of cutting the surface with picks and stiff brooms and by use of an approved combination of air and water jet as directed by ENGINEER. Great care shall be taken in performing this work to avoid removal of too much mortar and the weakening of the

v) a)

b)

c)

d)

surface by loosening of aggregate. When it is not practicable to follow the above method, it will be necessary to employ air tools to remove laitance and roughen the surface.The final required result should be a pitted surface from which all dirt, unsound concrete laitance and glazed mortar have been removed. BONDING TREATMENT (MORTAR) After rock or concrete surfaces upon which new concrete is to be placed have been scarified, cleaned, and wetted as specified herein, they shall receive, a bonding treatment, immediately before placement of the concrete. The bonding medium shall be a coat of cement-sand mortar. The mortar shall have the same cement- sand proportions as the concrete, which shall be placed on it. The water-cement ratio shall be determined by placing conditions and as approved by ENGINEER. Bonding mortar shall be placed in sufficient quantity to completely cover the surface about 10mm thick for rock surface and about 5mm thick for concrete surfaces. It shall be brushed or broomed over the surface and worked thoroughly into all cracks, crevices and depressions. Accumulations or puddles of mortar shall not be allowed to settle in depressions and shall be brushed out to a satisfactory degree, as determined by ENGINEER. Mortar shall be placed at such a rate that it can be brushed over the surface just in advance of placement of concrete. Only such area shall be covered with concrete before initial set in mortar taken place. The amount of mortar that will be permitted to place to any one time, or the area, which it is to cover, shall be in accordance with ENGINEER's directions. CLEANING AND BONDING FORMED CONSTRUCTION JOINTS Vertical construction joints shall be cleaned as specified above or by other methods approved by ENGINEER. In placing concrete against formed construction joints, the surfaces of the joints, where accessible, shall be coated thoroughly with the specified bed joint bonding mortar immediately before they are covered with concrete or by scrubbing with wire brooms dipped into the fresh concrete. Where it is impracticable to apply such a mortar coating, special precautions shall be taken to ensure that the new concrete is brought into intimate contact with the surface of the joint by careful paddling and spading with aid of vibrators and suitable tools. EXPANSION AND CONTRACTION JOINTS Provision shall be made for expansion and contraction in concrete by use of special type joint located as shown on the drawing. Contraction by joint surfaces shall be treated as directed by the specification on the drawing or as directed by ENGINEER.

vi)

vii)

4.32. a) b) c)

d)

e)

f)

4.33. i)

ii)

iii)

4.34. i)

ii)

HOT WEATHER REQUIREMENT All concrete work performed in hot weather shall be in accordance with I.S: 456 except as herein modified. Admixture may be used only when approved by ENGINEER. Adequate provisions shall be made to lower concrete temperatures by cool ingredient, eliminating excessive mixing, preventing exposure of mixers and conveyors to direct sunlight and the use of reflective paint on mixers etc. The temperature of the freshly placed concrete shall not be permitted to exceed 38 C. Consideration shall be given to shading aggregate stockpiles from direct rays of the sun and sprayings stockpiles with water, use of cold water when available, and burying insulating shading and/or painting white the pipe lines and water storage tanks and conveyance. In order to reduce loss of mixing water the aggregates, wooden forms, sub-grade, adjacent concrete and other moisture absorbing surfaces shall be well wetted prior to concreting placement and finishing shall be done as quickly as possible. Extra precautions shall be taken for the protection and curing of concrete. Consideration shall be given to continuous water curing and protection against high temperatures and drying hot winds for a period of atleast 7days immediately after concrete has set and after which normal curing procedures may be resumed. PLACING CONCRETE UNDER WATER Under all ordinary conditions all foundations shall be completely dewatered and concrete placed in the dry. However, when concrete placement under water is necessary, all work shall conform to IS.456 and the procedure shall be as follows: METHOD OF PLACEMENT Concrete shall be deposited under water by means of tremies, or drop bottom buckets of approved type. DIRECTION, INSPECTION AND APPROVAL All works requiring placement of concrete under water shall be designed, directed and inspected with due regard to local circumstance and purposes. All under water concrete shall be placed according to the plans or specifications and as directed and approved by ENGINEER. PRECAST CONCRETE Pre-cast units shall comply with I.S: 456 and with the following requirements: All pre-cast units shall be cast on a suitable bed or platform with firm foundation and free from wind. CONTRACTOR shall be responsible for the accuracy of the level or shape of the bed or platform. A suitable serial number and the date of casting shall be impressed or painted on each unit. STRIKING FORMS

iii)

iv)

4.35.

4.36. i) ii)

iii)

iv)

a)

b)

Side shutters shall not be struck in less than 24 hours after depositing concrete and no pre-cast unit shall be lifted until the concrete reaches strength of at least twice the stress to which the concrete may be subjected to at the time of lifting. PRECAST UNITS The lifting and removal of precast units, that shall be undertaken without causing shock, vibration or undue bending stresses to or in the units. Before lifting and removal takes place, CONTRACTOR shall satisfy ENGINEER or his representative that the methods he proposes to adopt for these operations will not over stress or otherwise affect seriously the strength of the precast units. The reinforced side of the units shall be distinctly marked. CURING All precast work shall be protected from the direct rays of the sun for atleast 7 days after casting and during that period each unit shall be kept constantly watered or preferably be completely immersed in water if the size of the unit so permits. Otherwise curing practice as given in clause D 5.29 shall be followed. SLOTS OPENING ETC. Slots, openings, or holes, pockets etc. shall be provided in the concrete work in the positions indicated in the drawings or as directed by ENGINEER. Any deviation from the approved drawings shall be made good by CONTRACTOR at his own expense without damaging any other work. Sleeves, bolts, inserts etc. shall also be provided in concrete work where so specified. INSPECTION All materials workmanship and finished construction shall be subject to the continuous inspection and approval of ENGINEER. All materials supplied by CONTRACTOR and all work or construction performed by CONTRACTOR rejected as not in conformity with the specifications and drawings shall be immediately replaced at no additional expense to the OWNER. Approvals of any preliminary materials or phase work shall in no way relieve the CONTRACTOR from the responsibility of supplying concrete and or producing finished concrete in accordance with the specifications and drawings. All concrete shall be protected against damage until final acceptance by OWNER or his representative. CLEAN-UP Upon the completion of concrete work, all forms, equipment construction tools, protective covering and any debris resulting from the work shall be removed from the premises. All debris i.e., empty containers, scrap wood etc. shall be removed to "Dump" daily or as directed by ENGINEER.

c) The finished concrete surfaces shall be left in a clean condition satisfactory to ENGINEER. 4.37. ACCEPTABLE CRITERIA Any concrete work shall satisfy the requirements given below individually and collectively for it to be acceptable. a) Properties of constituent materials b) Characteristic compressive strength c) Specified mix proportions d) Minimum cement content e) Maximum free water /cement ratio f) Workability g) Temperature h) Density of fully compacted concrete i) Curing j) Tolerances in dimensions k) Tolerances in levels l) Durability m) Surface finishes n) Special requirements such as i) Water tightness ii) Resistance to aggressive chemicals iii) Resistance to freezing and thawing iv) Improved fire resistance v) Wear resistance vi) Resistance to early thermal cracking The ENGINEER s decision as to the acceptability or otherwise of any concrete work shall be final and binding on the CONTRACTOR. For work not accepted, the ENGINEER may review and decide whether remedial measures are feasible so as to render the work acceptable. The ENGINEER shall in that case direct theCONTRACTOR to undertake and execute the remedial measures. These shall be expeditiously and effectively implemented by the CONTRACTOR. Nothing extra shall become payable to the CONTRACTOR by the OWNER for executing the remedial measures. 4.38. MODE OF MEASUREMENT AND PAYMENT i)The unit rate for concrete work under various categories shall be all inclusive and no claims for extra payment on account of such items as leaving holes, embedding inserts, etc. shall be entertained unless separately provided for in the schedule of quantities. No extra claim shall also be entertained due to change in the number, position and/or dimensions of holes, slots or openings, sleeves, inserts or on account of any increased lift or scaffolding etc. All these factors should be taken into consideration while quoting the unit rates. Unless consideration while quoting the unit rates. Unless provided for in the schedule of quantities the

rates shall also include fixing inserts in all concrete works, whenever required. ii)Payments of concrete will be made on the basis of unit rates quoted for the respective items in the schedule of quantities. No deduction in the concrete quantity will be made for the reinforcement, inserts etc. and opening less than 1/20 of a sq.m. in area where concrete is measured in sq.m and 1/150 cu.m. Where concrete is measure in cu, Metres. Where no such deduction for concrete is made, payment for shuttering work provided for such holes, pockets etc. will not bemade. Similarly the unit rates for concrete work shall be inclusive or exclusive of shuttering as provided for in the schedule of quantities. Where formwork is paid for separately, it shall be very clearly understood that payment for formwork is inclusive of form work, shuttering, shoring, propping, scaffolding etc. complete. Payment for beams will be made for the quantity placed on the depth being reckoned from the underside of the slabs and length measured as the clear distance between supports. Payments for columns shall be made for the quantity based on height reckoned upto the underside of slabs. The unit rate for precast concrete members shall include form work, mouldings, finishing, hoisting and setting in position including setting mortar, provision of lifting arrangement etc. complete. Only if reinforcement is used it shall be measured and paid for separately under item rate. GRANULAR SUBBASE

D.5. 5.1

IRC Codes Some of the relevant IS/IRC Codes and special publications for the road works are listed here. Only latest codes shall be referred. IRC -14 1977 Recommended practice for 2cm thick bitumen & tar carpets IRC -15 1981 Std. spec. & code of practice for construction of concrete roads. IRC -16 1989 Spec. For priming base course with bituminous primers. IRC -17 1965 Tentative spec. For single coat bituminous surface dressing. IRC -18 1977 Std. spec. & Code of practice for water bound macadam. IRC -19 1977 Std. spec. & Code of practice for water bound macadam. IRC -20 1966 Recom. practice for bituminous penetration macadam (full grout). IRC -21 2000 Std. spec. & code of practice for road bridges. Sec 3: Cement concrete (plain & reinforced). IRC -23 1966 Tentative spec. for two coat bituminous surface dressing. IRC -27 1967 Tentative spec. for bituminous macadam (base & binder course).

IRC -27 1967 Tentative spec. for bituminous macadam (base & binder course). IRC -29 1988 Specification for bituminous concrete (asphaltic concrete) for road pavement IRC -34 1970 Recommendations for road construction in waterlogged areas. IRC -35 1997 Code of practice for road markings.(with paints) IRC -36 1970 Recom. practice for the construction of earth embankments for road works. IRC -37 1901 Guidelines for the design of flexible pavements. IRC -42 1972 Proforma for record of test values of locally available pavement construction materials. IRC -43 1972 Recom. practice for tools, equipment & appliances for concrete pavement construction. IRC44 1976 Tentative guidelines for cement concrete mix design for pavements (for non air entrained &continuously graded concrete. IRC57 1974 Recom. Practice for sealing joints in concrete pavements. IRC -58 2002 Guidelines for design of rigid pavements for highways IRC -59 1976 Tentative guidelines for design of graded cement concrete mixes for road pavements. IRC -61 1976 Tentative guidelines for construction of cement concrete pavements in hot weather. IRC -77 1979 Tentative guidelines for repair of concrete pavements using synthetic resins IRC -78 1981 Std. spec. & code of practice for road bridges.Sec.7Foudations&sub structures. IRC -79 1981 Rec. practice for road delineators IRC -81 1997 Guidelines for strengthening of flexible road pavements using Benkelman beam deflection technique. IRC -82 1982 Code of practice for maintenance of bituminous surface of highways IRC -84 1983 Code of practice for curing of cement concrete pavements IRC -87 1984 Guide lines for the design and erection of falsework for road bridges. IRC -89 1997 Guidelines for design and construction of river training & control works for road bridges. IRC -90 1985 Guidelines for selection operation & maintenance of bitumen hot mix plant. IRC -94 1986 Spec. for dense bituminous macadam IRC -95 1987 Spec. for semi-dense bituminous concrete IRC -99 1988 Tentative guidelines on the provision of speed breakers for control of vehicular speed on minor roads. IRC109 1997 Guide lines on wet mix macadam SP:11 1988 Hand book of quality control for construction of roads & runways

SP:29 1994

Directory of indigenous manufacturers of road/bridge construction machinery SP:30 1993 Manual on economic evaluation of highway projects in India SP:34 1989 General guidelines about the equipment for bituminous surface dressing SP:42 1994 Guidelines on road drainage SP:47 1998 Guidelines on quality system for road bridges (plain, reinforced, prestressed and composite construction) SP:49 1998 Guidelines for the use of dry lean concrete as sub bas e for the rigid pavement. SP:51 1999 Guidelines for load testing of bridges IS 1201 1998 Method of testing Tar & Bituminous materials IS 1202 1998 Method of testing Sp. Gravity of Tar & Bituminous IS 1203 1999 Method of testing penetration of Tar & Bituminous IS 1205 1978 Method of testing softening point of Tar & Bituminous IS 1208 1978 Method of testing ductility of Tar & Bituminous IS 1209 1978 Method of testing flash point and fire point of Tar & Bituminous IS 1211 1978 Method of testing water content of Tar & Bituminous IS 1212 1978 Method of testing loss on heating Tar & Bituminous materials IS 1216 1978 Method of testing solubility in carbon di sulphide of Tar & Bituminous materials IS 73 1992 Paving bitumen IS 6509-1985 Code of practice for installation of joints in concrete pavements 5.2 General This work shall consist of laying and compacting well-graded material on prepared subgrade in accordance with the requirements of these Specifications. The material shall be laid in one or more layers as subbase as necessary according to lines, grades and cross-sections shown on the drawings or as directed by the Engineer. Materials: The material to be used for the work shall be crushed aggregate and it shall be free from organic or other deleterious constituents and conform to Grading I as given in the below Table for coarse-graded granular subbase materials.

5.3

TABLE: GRADING FOR COARSE GRADED GRANULAR SUB-BASE MATERIALS IS Sieve Designation 75.0 mm 53.0 mm 26.5 mm 9.50 mm 4.75 mm 2.36 mm 0.425 mm 0.075 mm CBR Value (Minimum) <10 30 <10 25 <10 20 10-30 15-35 25-45 55-75 Per cent by weight passing the IS Sieve Grading I 100 Grading II 100 50-80 100 Grading III -

5.4

Physical requirements: The material shall have a 10 per cent fines value of 50 kN or more (for sample in soaked condition) when tested in compliance with BS: 812 (Part III). The water absorption value of the coarse aggregate shall be determined as per IS: 2386 (Part 3); if this value is greater than 2 per cent, the soundness test shall be carried out on the material delivered to site as per IS: 383. For Grading II and III materials, the CBR shall be determined at the density and moisture content likely to be developed in equilibrium conditions which be taken as being the density relating to a uniform air voids content of 5 percent. Note: The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS: 2720 (Part 5) shall have liquid limit and plasticity index not more than 25 and 6 percent respectively. Construction Operations Preparation of subgrade: Immediately prior to the laying of sub-base, the subgrade already finished shall be prepared by removing all vegetation and other extraneous matter, lightly sprinkled with water if necessary and rolled with two passes of 80100 kN smooth wheeled roller.

5.5 5.5.1

5.5.2

Spreading and compacting: The sub-base material shall be spread on the prepared subgrade with the help of a motor grader of adequate capacity, its blade having hydraulic controls suitable for initial adjustment and for maintaining the required slope and grade during the operation or other means as approved by the Engineer. The sub-base material shall be mixed mechanically by the mix-in-place method. The equipment used for mix-in-place construction shall be a rotavator or similar approved equipment capable of mixing the material to the desired degree. If so desired by the Engineer, trial runs with the equipment shall be carried out to establish its suitability for the work. Moisture content of the loose material shall be checked in accordance with IS: 2720 (Part 2) and suitably by sprinkling additional water from a truck mounted or trailer mounted water tank and suitable for applying water uniformly and at controlled quantities to variable widths of surface or other means approved by the Engineer so that, at the time of compaction, it is from 1 percent above to 2 percent below the optimum moisture content corresponding to IS: 2720 (Part 8). While adding water, due allowance shall be made for evaporation losses. After water has been added, the material shall be processed by mechanical or other approved means like disc harrows, rotavators until the layer is uniformly wet. Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For a compacted single layer upto 225 mm the compaction shall be done with the help of a vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad foot-drum or heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum tyre pressure of 0.7 MN/m or equivalent capacity roller capable of achieving the required compaction. Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for portions having unidirectional crossfall and super elevation and shall commence at the edges and progress towards the centre for portions having cross fall on both sides. Each pass of the roller shall uniformly overlap not less than one third of the track made in the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and any high spots or depressions, which become apparent, corrected by removing or adding fresh material. The speed of the roller shall not exceed 5 km per hour. Rolling shall be continued till the density achieved is at least 98 percent of the maximum dry density for the material determined as per IS: 2720 (Part 8). The surface of any layer of material on completion of compaction shall be well closed, free from movement under compaction equipment and from compaction planes, ridges, cracks or loose material. All loose, segregated or otherwise defective areas shall be made good to the full thickness of layer and re-compacted.

5.5.3

Surface Finish and Quality Control of Work Control on the quality of materials and surface finishing shall be as per direction of Engineer. D.6.0 WET MIX MACADAM BASE

This work shall consist of laying and compacting clean, crushed, graded aggregate and granular material, premixed with water, to a dense mass on a prepared sub-base as the case may be in accordance with the requirements of these Specifications. The material shall be laid in one or more layers as necessary to lines, grades and cross-sections shown on the approved drawings or as direction by the Engineer. The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75 mm. 6.1 6.1.1 Materials Aggregates Physical requirements: Coarse aggregates shall be crushed stone. If crushed gravel is used, not less than 90 percent by weight of the gravel pieces retained on 4.75 mm sieve shall have at least two fractured faces. The aggregates shall conform to the physical requirements as given below table. TABLE: PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WET MIX MACADAM FOR BASE COURSES

Test * Los Angeles abrasion value or * Aggregate Impact value Combined Flakiness and Elongation indices (Total)

Test Method IS : 2386 (Part-4) IS : 2386 (Part-4) or IS : 5640 IS : 2386 (Part-1)

Requirements 40 per cent (Max.) 30 per cent (Max.) 30 per cent (Max.)**

* Aggregate may satisfy requirements of either of the two tests. ** To determine this combined proportion, the flaky stone from a representative sample should first be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal. Elongation index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up.

If the water absorption value of the coarse aggregate is greater than 2 per cent, the soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part- 5). 6.1.2 Grading requirements: The aggregates shall conform to the grading given in Table below.

TABLE: GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX MACADAM IS Sieve Designation Per cent by weight passing the IS sieve 100 95-100 60-80 40-60 25-40 15-30 8-22 0-8

53.00 mm 45.00 mm 26.50 mm 22.40 mm 11.20 mm 4.75 mm 2.36 mm 600.00 micron 75.00 micron

Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6. The final gradation approved within these limits shall be well graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa. 6.2 6.2.1 Construction Operations Preparation of base: The surface of the sub-base to receive the wet mix macadam course shall be prepared to the specified lines and crossfall (camber) and made free of dust and other extraneous material. Any ruts or soft yielding places shall be corrected in an approved manner and rolled until firm surface is obtained if necessary by sprinkling water. Any sub-base surface irregularities, where predominant, shall be made good by providing appropriate type of profile corrective course (levelling course). Provision of lateral confinement of aggregates: While constructing wet mix macadam, arrangement shall be made for the lateral confinement of wet mix. This shall be done by laying materials in adjoining shoulders along with that of wet mix macadam layer.

6.2.2

6.2.3

Preparation of mix: Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity having provision for controlled addition of water and forced/positive mixing arrangement like pugmill or pan type mixer of concrete batching plant. Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size. While adding water, due allowance should be made for evaporation losses. However, at the time of compaction, water in the wet mix should not vary from the optimum value by more than agreed limits. The mixed material should be uniformly wet and no segregation should be permitted. Spreading of mix: Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the prepared subgrade/sub-base/base in required quantities. In no case should these be dumped in heaps directly on the area where these are to be laid nor shall their hauling over a partly completed stretch be permitted. The mix may be spread either by a paver finisher or motor grader. For portions where mechanical means cannot be used, manual means as approved by the Engineer shall be used. The motor grader shall be capable of spreading the material uniformly all over the surface. Its blade shall have hydraulic control suitable for initial adjustments and maintaining the same so as to achieve the specified slope and grade. The paver finisher shall be self-propelled, having the following features: (i) Loading hoppers and suitable distribution mechanism (ii) The screed shall have tamping and vibrating arrangement for initial compaction to the layer as it is spread without rutting or otherwise marring the surface profile. (iii) The paver shall be equipped with necessary control mechanism so as to ensure that the finished surface is free from surface blemishes. The surface of the aggregate shall be carefully checked with templates and all high or low spots remedied by removing or adding aggregate as may be required. The layer may be tested by depth blocks during construction. No segregation of larger and fine particles should be allowed. The aggregates as spread should be of uniform gradation with no pockets of fine materials.

6.2.4

6.2.5

Compaction: After the mix has been laid to the required thickness, grade and crossfall/ camber the same shall be uniformly compacted, to the full depth with suitable roller. If the thickness of single compacted layer does not exceed

100 mm, smooth wheel roller of 80 to 100 kN weight may be used. For a compacted single layer upto 200 mm, the compaction shall be done with the help of vibratory roller of minimum static weight of 80 to 100 kN or equivalent capacity roller. The speed of the roller shall not exceed 5 km/h. In portions having unidirectional cross fall/super elevation, rolling shall commence from the lower edge and progress gradually towards the upper edge. Thereafter, roller should progress parallel to the centre line of the road, uniformly over-lapping each preceding track by at least one third width until the entire surface has been rolled. Alternate trips of the roller shall be terminated in stops at least 1 m away from any preceding stop. In portions in camber, rolling should begin at the edge with the roller running forward and backward until the edges have been firmly compacted. The roller shall then progress gradually towards the centre parallel to the centre line of the road uniformly overlapping each of the preceding track by at least onethird width until the entire surface has been rolled. Any displacement occurring as a result of reversing of the direction of a roller or from any other cause shall be corrected at once as specified and/or removed and made good. Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be thoroughly compacted with mechanical tampers or a plate compactor. Skin patching of an area without scarifying the surface to permit proper bonding of the added material shall not be permitted. Rolling should not be done when the subgrade is soft or yielding or when it causes a wave-like motion in the sub-base/base course or subgrade. If irregularities develop during rolling which exceed 12 mm when tested with a 3 metre straight edge, the surface should be loosened and premixed material added or removed as required before rolling again so as to achieve a uniform surface conforming to the desired grade and crossfall. In no case should the use of unmixed material be permitted to make up the depressions. Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry density for the material as determined by the method outlined in IS: 2720 (Part-8). After completion, the surface of any finished layer shall be well-closed, free from movement under compaction equipment or any compaction planes, ridges, cracks and loose material. All loose, segregated or otherwise defective areas shall be made good to the full thickness of the layer and recompacted. 6.3 Setting and drying: After final compaction of wet mix macadam course, the road shall be allowed to dry for 24 hours.

6.4

Opening to Traffic Preferably no vehicular traffic of any kind should be allowed on the finished wet mix macadam surface till it has dried and the wearing course laid. Surface Finish and Quality Control of Work Control on the quality of materials and surface finishing shall be as per direction of the Engineer. D.7.0 Prime Coat Over Granular Base

6.5

This work shall consist of application of single coat of low viscosity liquid bituminous material to an absorbent granular surface preparatory to any superimposed bituminous treatment or construction. D.7.1 Materials The choice of a bituminous primer shall depend upon the porosity characteristics of the surface to be primed as classified in IRC: 16. These are: (i) Surfaces of low porosity; such as wet mix macadam and water bound macadam, (ii) Surfaces of medium porosity; such as cement stabilized soil base, (iii) Surfaces of high porosity; such as a gravel base. The different ranges of viscosity requirements for the primers to be used for the different types of surfaces to be primed as classified are given in Table.

VISCOSITY REQUIREMENT AND QUANTITY OF BITUMINOUS PRIMER Type of surface Kinematic Viscosity of Primer at 60o C (Centistokes) 30-60 70-140 250-500 Quantity per 10 sq. m (Kg) 6 to 9 9 to 12 12 to 15

Low porosity Medium porosity High porosity

The bituminous primer shall be Medium Curing Cutback (MC) produced by fluxing, in an approved manner, bitumen of 80/100 penetration grade with kerosene. The cutback shall be free from water and shall not show any signs of separation prior to use. Slow setting Cationic emulsion as per IS: 8887 may also be used, but the particular grade to be used for the work shall be got approved by the Engineer.

Sampling and testing of bituminous primer shall be as per IS: 217; IS: 454 and IS: 8887. D.7.2 Weather and Seasonal Limitations The bituminous primer shall not be applied on a wet surface or during dust storm or when the weather is foggy, rainy or windy. The prime coat for surface treatment should not be applied when the temperature in the shade is less than 10C. D.7.3 Construction D.7.3.1Equipment: The primer distributor shall be pneumatic tyred self-propelled pressure distributor equipped for spraying the material uniformly at the specified rates and temperatures. Spraying by manual methods may be allowed for small areas at the discretion of the Engineer. Power broom and/or blowers may be supplemented by hand brooms as directed by the Engineer. D.7.3.2Preparation of road surface: The surface to be primed shall be swept clean, free from dust and shall be dry. It shall be shaped to the specified grades and section. It shall also be free from ruts, any other irregularities and segregated materials. Minor depressions and potholes may be ignored until the surface is primed, after which they shall be patched with a suitable premix material prior to the surface treatment. D.7.3.3Application of bituminous primer: The bituminous primer shall be sprayed/distributed uniformly over the prepared dry surface using self propelled sprayer equipped with self-heating arrangement, suitable pump, adequate capacity compressor and spraying bar with nozzles having constant volume or pressure system capable of supplying primer at specified rates and temperatures so as to provide a uniformly unbroken spread of primer. If the surface to be primed is so dry or dusty as to cause freckling of bituminous material, it shall be lightly and uniformly sprinkled with water immediately prior to priming; however, the bituminous material shall not be applied till such time as no surface water is visible. The primer shall be applied at the rate as specified in above Table. Temperature of application of a primer need only be high enough to permit the primer to be effectively sprayed through the jets of the spray bar and to cover the granular base surface uniformly in the desired quantity. The desirable range of temperatures at the time application of MC-30, MC-70 and MC-250 grades shall be 30 to 55C; 50 to 80C and 75 to 100C respectively. For a bituminous emulsion primer, the range of spraying temperature may be 20 to 60C. Following the application of bituminous material, the surface shall be allowed to cure for at least 24 hours or for any other period so as to allow penetration into the base course and aeration of volatiles from the primer material. If it is not absorbed within 24 hours after application, sand shall be spread over the

surface to blot the excess primer. Care shall be taken to prevent over-priming; any pools of excess primer left on any part of the surface shall be swept out over the adjacent surface before spreading sand. The primer coat shall be applied only on the topmost water bound macadam or any granular layer, over which the bituminous base course/wearing course, is to be laid. D.7.4 Curing of primer and opening to traffic: It shall always be ensured that while opening to any kind of traffic, the primed surface is fully cured and is not sticky to avoid being picked up by traffic. Normally, the primed surface shall be allowed to cure for not less than 24 hours and during this period no traffic of any kind shall be permitted. D.7.5 Laying of bituminous course over primed surface: Bituminous base course or wearing course shall be laid over the primed water bound macadam, wet mix macadam or any other granular base course, in the usual manner as per relevant Specification for the same including the requirement of tack coat as per Clause 6.04.03. D.7.6 Quality Control of Work Control on the quality of materials and work shall be as per directions of the Engineer. D.8.0 DENSE BITUMINOUS MACADAM This work shall consist of construction in a single course of 50 to 100 mm thick base/binder course to the following Specifications on a previously prepared base. D.8.1 Materials D.8.1.1Bitumen: The bitumen shall be paving bitumen of Grade VG-10, VG-20, VG- 30, VG-40 as per Indian Standard Specifications for Paving Bitumen IS: 73 -2006. D.8.1.2Coarse aggregates: The coarse aggregates shall consist of crushed stone, crushed gravel/shingle or other stones. They shall be clean, strong, durable, of fairly cubical shape and free from disintegrated pieces, organic or other deleterious matter and adherent coating. The aggregates shall preferably be hydrophobic and of low porosity. If hydrophilic aggregates are to be used, the bitumen shall be treated with anti stripping agents of approved quality in suitable doses. The aggregates shall satisfy the physical requirements as given below table. TABLE: PHYSICAL REQUIREMENTS OF AGGREGATES FOR DENSE BITUMINOUS MACADAM

S.No 1 2 3 4 5

Test Los Angeles Abrasion Value * Aggregate Impact value * Flakiness and Elongation** Indices (Total) Coating and Stripping of Bitumen Aggregate Mixtures Soundness (i) Loss with Sodium Sulphate (ii) Loss of Magnesium Sulphate Water absorption

Test Method IS: 2386 (Part-4) IS: 2386 (Part-4) IS: 2386 (Part-1) AASHTO T 182 IS: 2386 (Part-5) 5 cycles 5 cycles IS: 2386 (Part-3)

Requirement 40 per cent Max 30 per cent Max 30 per cent Max Minimum retained coating 95 per cent 12 per cent Max 18 per cent Max

2 per cent Max

* Aggregates may satisfy requirements of either of the two tests. ** To determine this combined proportion, the flaky stone from a representative sample should first be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal. Elongation index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up. If crushed gravel/shingle is used, not less than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The portion of the total aggregate passing 4.75mm sieve shall have a sand equivalent value of not less than 50 when tested in accordance with the requirement of IS: 2720 (Part-37). The plasticity index of the fraction passing the 425 micron sieve shall not exceed 4. D.8.1.3Fine aggregates: Fine aggregates shall be the fraction passing 2.36 mm sieve and retained on 75 micron sieve, consisting of crusher-run screening, gravel, sand or a mixture of both. These shall be clean, hard, durable, uncoated, dry and free from any injurious, soft or flaky pieces and organic or other deleterious substances. D.8.1.4Filler: Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement as approved by the Engineer. The filler shall be graded within the following limits: IS Sieve 600 Micron 300 Micron 75 Micron Per cent passing by weight 100 95 100 85 100

The filler shall be free from organic impurities and have a Plasticity Index not greater than 4. The Plasticity Index requirement shall not apply if filler is cement or lime. When the coarse aggregate is gravel, 2 per cent by mass of total aggregate of portland cement or hydrated lime shall be added and the percentage of fine aggregate reduced accordingly. Cement or hydrated lime is not required when the gravel is limestone. D.8.1.5Aggregate gradation: The combined coarse and fine aggregates and filler (when used) shall produce a mixture to conform to the grading set forth in Table below. Table: AGGREGATE GRADATION FOR DENSE BITUMINOUS MACADAM Sieve Designation 37.5 mm 26.5 mm 13.2 mm 4.75 mm 2.36 mm 300 micron 75 micron Percentage passing the sieve by weight 100 90-100 56-80 29-59 19-45 5-17 1-7

The aggregate mix, as used in work, shall not vary from the low limit on one sieve to the high limit on the adjacent sieve but shall be well graded. D.8.2 Mix Design D.8.2.1Requirement of mix: Apart from conformity with grading and quality requirements of individual ingredients, the mix shall meet the requirements set out in Table below. Table: REQUIREMENTS OF DENSE BITUMINOUS MACADAM MIX S. No Description Requirements 1 Marshall stability (ASTM Designation-D-1559) 820 kg (1800 lb) determined on Marshall specimens compacted by 75 minimum compaction blows on each end 2 Marshall flow (mm) 2-4 3 Per cent Air voids 3-5 4 Minimum voids in mineral aggregates (VMA) 10 percent-12per cent 5 Per cent voids in mineral aggregates filled 65-75 by bitumen (VFB) 6 Binder content percent by weight of total mix Not less than 4.0%

D.8.2.3Binder content: The binder content shall be so fixed as to achieve the requirements of the mix set out in the above Table. Marshall method for arriving at the binder content shall be adopted, replacing the aggregates retained on 26.5 mm sieve by the aggregates passing 26.5 mm sieve and retained on 22.4 mm sieve. D.8.2.4Job mix formula: The Contractor shall intimate to the Engineer in writing, atleast 20 days before the start of the work, the job mix formula proposed to be used by him for the work and shall give the following details: i) Source and location of all materials; ii) Proportions of all materials expressed as follows where each is applicable; (a) Binder, as percentage by weight of total mix; (b) Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of total aggregate including mineral filler. iii) A single definite percentage passing each sieve for the mixed aggregate; iv) The results of tests enumerated in above Table as obtained by the Contractor; v) Test results of physical characteristics of aggregates to be used; vi) Mixing temperature and compacting temperature. While working out the job mix formula, the Contractor shall ensure that it is based on a correct and truly representative sample of the materials that will actually be used in the work and that the mix and its different ingredients satisfy the physical and strength requirements of these Specifications. Approval of the job mix formula shall be based on independent testing by the Engineer for which samples of all ingredients of the mix shall be furnished by the Contractor as required by the former. The approved job mix formula shall remain effective unless and until modified by the Engineer. Should a change in the source of materials be proposed, a new job mix formula shall be established and got approved from the Engineer before actually using the materials. D.8.2.5Permissible variation from job mix formula: It shall be the responsibility of the Contractor to produce a uniform mix conforming to the approved job mix formula subject to the permissible variations of the individual percentages of the various ingredients in the actual mix from the job mix formula to be used within the limits as specified in below Table.

TABLE: PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA S. No. 1 2 3 4 5 6 7 8 Description of Ingredients Permissible variation by weight of total mixin per cent Aggregate passing 13.2 mm sieve and larger sieves 8 Aggregate passing 11.2 mm sieve and 5.6 mm sieve 7 Aggregate passing 2.80 mm sieve and 1.40 mm sieve 6 Aggregate passing 710 micron sieve and 355 micron 5 sieve Aggregate passing 180 micron sieve 4 Aggregate passing 90 micron sieve 2 Binder 0.3 Mixing temperature 10C

D.8.3 Construction Operations D.8.3.1Weather and seasonal limitations: The work of laying shall not be taken up during rainy or foggy weather or when the base course is damp or wet, or during dust storm or when the atmospheric temperature in shade is 10C or less. D.8.3.2Preparation of base: The base on which Dense Bituminous Macadam is to be laid shall be prepared, shaped and conditioned to the specified lines, grades and cross sections as indicated in the drawings or as directed by the Engineer. The surface shall be thoroughly swept clean free from dust and foreign matter using mechanical broom and dust removed or blown off by compressed air. In portions where mechanical means cannot reach, other approved method shall be used. A priming coat where needed, shall be applied as per direction of the Engineer. D.8.3.3Tack coat The surface on which the tack coat is to be applied shall be cleaned of dust and any extraneous material before the application of the binder, by using a mechanical broom or any other approved equipment/method as specified by the Engineer. Binder may be heated to the temperature appropriate to the grade of cutback used and approved by the Engineer and sprayed on the base at the rate specified in below Table. The normal range of spraying temperature for a bituminous emulsion shall be 20 C - 60 C and for a cutback 50C 80C if RC-70/MC-70 grade is used. It shall be the responsibility of the Contractor to carefully handle the inflammable bituminous cutback material so as to safeguard against any fire mishap. The binder shall be applied uniformly with the aid of either self-propelled or towed bitumen pressure sprayer with self heating arrangement and spraying bar with nozzles having constant volume or pressure system, capable of spraying bitumen at specified rates and

temperature so as to provide a uniformly unbroken spread of bitumen. Work should be planned so that no more than the necessary tack coat for the days operation is placed on the surface. After application and prior to succeeding construction allow the tack coat to cure, without being disturbed, until the water/cutter has completely evaporated, as determined by the Engineer. TABLE: RATE OF APPLICATION OF TACK COAT Sl.No Type Surface Quantity of liquid Bituminous material in kg per 10 sq. m. area 2.0 to 2.5 2.5 to 3.0 2.5 to 3.0

i) ii) iii) iv)

Normal bituminous surfaces Dry and hungry bituminous surfaces Granular surfaces treated with primer Non bituminous surfaces a) Granular base (not primed) b) Cement concrete pavement

3.5 to 4.0 3.0 to 3.5

Note: There is no need to apply a tack coat on a freshly laid bituminous course if the subsequent bituminous course is overlaid the same day without opening it to traffic. D.8.4 Preparation of mix: Dense Bituminous macadam mix shall be prepared in a hot mix plant of adequate capacity and capable of yielding a mix of proper and uniform quality with thoroughly coated aggregates. Hot mix plant shall be of suitable capacity preferably of batch mix type. Total system for crushing of stone aggregates and feeding of aggregate fractions in required proportions to achieve the desired mix, deployed by the Contractor must be capable of meeting the overall Specification requirements under stringent quality control. The plant shall have the following essential features: D.8.5 General (a) The plant shall have coordinated set of essential units capable of producing uniform mix as per the job mix formula. (b) Cold aggregate feed system with minimum 4 bins having belt conveyor arrangement for initial proportioning of aggregates from each bin in the required quantities. In order to have free flow of fines from the bin, it is advisable to have vibrator fitted on bin to intermittently shake it.

(c) Belt conveyers below each bin should have variable speed drive motors. There should be electronic load sensor on the main conveyer for measuring the flow of aggregates. (d) Dryer unit with burner capable of heating the aggregate to the required temperature without any visible unburnt fuel or carbon residue on the aggregate and reducing the moisture content of the aggregate to the specified minimum. (e) The plant shall be fitted with suitable type of thermometric instruments at appropriate places so as to indicate or record/register the temperature of heated aggregate, bitumen and mix. (f) Bitumen supply unit capable of heating, measuring/metering and spraying of bitumen at specified temperature with automatic synchronisation of bitumen and aggregate feed in the required proportion. (g) A filler system suitable to receive bagged or bulk supply of filler material and its incorporation to the mix in the correct quantity wherever required. (h) A suitable built-in dust control system for the dryer to contain/recycle permissible fines into the mix. It should be capable of preventing the exhaust of fine dust into atmosphere for environmental control wherever so specified by the Engineer. (i) The plant should have centralised control panel/cabin capable of presetting, controlling/synchronising all operations starting from feeding of cold aggregates to the discharge of the hot mix to ensure proper quality of mix. It should have indicators for any malfunctioning in the operation. (j) Every hot mix plant should be equipped with siren or horn so that the operator may use the same before starting the plant every time in the interest of safety of staff. The temperature of binder at the time of mixing shall be in the range of 150 C to 163 C and that of the aggregate in the range of 155 oC-163oC provided that the difference in temperature between the binder and aggregate at no time exceeds 14 C. Mixing shall be thorough to ensure that a homogeneous mixture is obtained in which all particles of the aggregates are coated uniformly, and the discharge temperature of mix shall be between 130 C to 160 C. The mixture shall be transported from the mixing plant to the point of use in suitable tipper vehicles. The vehicles employed for transport shall be clean and be covered in transit if so directed by the Engineer. Any tipper causing excessive segregation of materials by its spring suspension or other contributing factors or that which shows undue delay shall be removed from the work unit such conditions are corrected. D.8.6 Spreading: The mix transported from the hot mix plant to the site shall be spread by means of a self-propelled paver with suitable screeds capable of spreading, tamping and finishing the mix to specified grade, lines and crosssection. However, in restricted locations and in narrow widths where the available equipment cannot be operated in the opinion of the Engineer, he may permit

manual laying of the mix. Similarly for smaller jobs, mechanical paver may be used with the approval of the Engineer. The temperature of mix at the time of laying shall be in the range of 120 -160 C. Mixes with a temperature of less than 120 C shall not be put into paver spreader. Longitudinal joints and edges shall be constructed true to the delineating lines parallel to the centre line of the road. Longitudinal and transverse joints shall be offset by at least 250 mm from those in the lower courses and the joint on the top most layer shall not be allowed to fall within the wheel path. All transverse joints shall be cut vertically to the full thickness of the previously laid mix with asphalt cutter and the surface painted with hot bitumen before placing fresh material. Longitudinal joints shall be preferably hot joints. Cold longitudinal joints shall be properly heated with joint heater to attain a suitable temperature of about 80 C laying of adjacent material. D.8.7 Rolling: After spreading the mix by paver, it shall be thoroughly compacted by rolling with a set of rollers moving at a speed not more than 5 km/h, immediately following close to the paver. Generally the initial or breakdown rolling shall be done with 80-100 kN static weight smooth-wheeled roller. The intermediate rolling shall be done with 80-100 kN static weight vibratory roller or with a pneumatic tyred roller of 150-250 kN weight having a tyre pressure of at least 0.7 MPa. The finish rolling shall be done with 60-80 kN weight smooth wheeled tandem roller. All the compaction operations, i.e., breakdown rolling and intermediate rolling can be accomplished by using vibratory tandem roller of 80-100 kN static weight. During initial breakdown rolling and finish rolling, no vibratory compaction shall be resorted to. The exact pattern of rolling shall be established after trial compaction as approved by the Engineer. Any displacement occurring as a result of reversing of the direction of a roller or from any other cause shall be corrected at once as specified and/or removed and made good. The rollers shall not be permitted to stand on pavement which has not been fully compacted and where temperature is still more than 70C. Necessary precautions shall be taken to prevent dropping of oil, grease, petrol or other foreign matter on the pavement either when the rollers are operating or standing. The wheels of roller shall be kept moist to prevent the mix from adhering to them. But in no case shall fuel/lubricating oil be used for this purpose nor excessive water poured on the wheels. Rolling shall commence longitudinally from edges and proceed towards the centre, except that on superelevated and unidirectional cambered portions, it shall progress from the lower to upper edge parallel to the centre line of the pavement. The roller shall proceed on the fresh material with rear or fixed wheel leading so as to minimise the pushing of the mix and each pass of the roller shall overlap the preceding one by half the width of the rear wheel. Rolling shall be continued till the density achieved is at least 98 per cent of that of laboratory Marshall specimen (compacted as defined in Table

requirements of Dense Bituminous Macadam mix) and all roller marks are eliminated. Skin patching of an area that has been rolled will not be permitted. Rolling operations shall be completed in all respects before the temperature of the mix falls below 100C. D.8.8 Opening to Traffic Traffic may be allowed after completion of the final rolling when the mix has cooled down to the surrounding temperature. The Dense Bituminous Macadam shall be provided with an appropriate wearing course as early as possible prior to regular opening to normal traffic and/or impending rain. D.8.9 Surface Finish and Quality Control of Work Control on the quality of materials & surface finishing shall be as per direction of the Engineer. D.9.0 BITUMINOUS CONCRETE This work shall consist of constructing in a single layer, bituminous concrete (asphaltic concrete) of thickness 25-100 mm on previously prepared bituminous course to the requirements of these Specifications. D.9.1 Materials D.9.1.1 Bitumen: The bitumen shall be paving bitumen of Grade VG-10, VG-20, VG- 30, VG-40 as per Indian Standard Specifications for Paving Bitumen IS: 73 - 2006. D.9.1.2Coarse aggregates: The coarse aggregates shall consist of crushed stone, crushed gravel/shingle or other stones. They shall be clean, strong, durable, of fairly cubical shape and free from disintegrated pieces, organic or other deleterious matter and adherent coating. The aggregates shall preferably be hydrophobic and of low porosity. If hydrophilic aggregates are to be used, the bitumen shall be treated with antistripping agents of approved quality in suitable doses. The aggregates shall satisfy the physical requirements as indicated in clause xxxxx. If crushed gravel/shingle is used, not less than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The portion of the total aggregate passing 4.75mm sieve shall have a sand equivalent value of not less than 50 when tested in accordance with the requirement of IS: 2720 (Part-37). The plasticity index of the fraction passing the 425 micron sieve shall not exceed 4.

D.9.1.3Fine aggregates: Fine aggregates shall be the fraction passing 2.36 mm sieve and retained on 75 micron sieve, consisting of crusher-run screening, gravel, sand or a mixture of both. These shall be clean, hard, durable, uncoated, dry and free from any injurious, soft or flaky pieces and organic or other deleterious substances. D.9.1.4Filler: Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement as approved by the Engineer. The filler shall be graded within the following limits: IS Sieve 600 Micron 300 Micron 75 Micron Per cent passing by weight 100 95 100 85 100

The filler shall be free from organic impurities and have a Plasticity Index not greater than 4. The Plasticity Index requirement shall not apply if filler is cement or lime. When the coarse aggregate is gravel, 2 per cent by mass of total aggregate of portland cement or hydrated lime shall be added and the percentage of fine aggregate reduced accordingly. Cement or hydrated lime is not required when the gravel is limestone.

D.9.2 Aggregate gradation: The combined coarse and fine aggregates and filler (when used) shall produce a mixture to conform to the grading set forth in Table below. Table: AGGREGATE GRADATION FOR BITUMINOUS CONCRETE

Sieve Designation 26.5 mm 19 mm 9.5 mm 4.75 mm 2.36mm 300 micron 75 micron

Percentage passing the sieve by weight 100 90-100 56-80 35-65 23-49 5-19 2-8

The aggregate mix, as used in work, shall not vary from the low limit on one sieve to the high limit on the adjacent sieve but shall be well graded.

D.9.3 Mix Design D.9.3.1Requirement of mix: Apart from conformity with the grading and quality requirements of individual ingredients, the mix shall meet the requirements set forth in Table below.

TABLE: REQUIREMENTS OF BITUMINOUS CONCRETE MIX S. No 1 Description Marshall stability (ASTM Designation-D-1559) determined on Marshall specimens compacted by 75 compaction blows on each end Marshall flow (mm) Per cent voids in mix Minimum voids in mineral aggregates (VMA) Per cent voids in mineral aggregates filled by bitumen (VFB) Binder content percent by weight of total mix Water Sensitivity (ASTM D1075) Loss of stability on immersion in water at 60C Swell Test (Asphalt Instt. MS-2, No. 2) Requirements 820 kg (1800 lb) minimum 2-4 3-5 Min 11-13 percent 65-75 Min 4.5 percent Min 75 percent retained strength 1.5 percent max

2 3 4 5 6 7 8

D.9.3.2Binder content: The binder content shall be so fixed as to achieve the requirements of the mix set forth in above Table. Marshall method for arriving at the binder content shall be adopted. D.9.3.3Job mix formula: Clause 6.03.03 shall apply except that the requirement of Bituminous Concrete mix shall be as per above table. D.9.3.4Permissible variations from the job mix formula: The Contractor shall have the responsibility of ensuring proper proportioning of materials in accordance with the approved job mix formula and producing a uniform mix. The permissible variations of individual percentages of various ingredients in the actual mix from the job mix formula may be within the limits as specified in clause xxxxxxx. D.9.4 Construction Operations D.9.4.1Weather and seasonal limitations: The work of laying shall not be taken up during rainy or foggy weather or when the base course is damp or wet, or during dust storm or when the atmospheric temperature in shade is 10C or less. D.9.4.2Preparation of base:

The base on which bituminous concrete is to be laid shall be prepared, shaped and conditioned to the specified levels, grade and crossfall (camber) as per drawing. The surface shall be thoroughly swept clean free from dust and foreign matter using mechanical broom and dust removed by mechanical means or blown off by compressed air. In portions where mechanical means cannot reach, other approved method shall be used. D.9.4.3Tack coat: A tack coat complying with Clause 6.04.03 shall be applied over the base. D.9.4.4Preparation of mix: Clause 6.04.04 shall apply. D.9.4.5 Spreading: Clause 6.04.05 shall apply. D.9.4.6 Rolling: Clause 6.04.06 shall apply. D.9.5 Opening to Traffic Traffic may be allowed immediately after completion of the final rolling when the mix has cooled down to the surrounding temperature. D.9.6 Surface Finish and Quality Control of Work Control on the quality of materials and surface finishing shall be as per direction of the Engineer.

D.10.0

Forming embankment (Retaining side earth)

The work shall include preliminaries of clearing site, setting out and preparing the ground and there after forming embankment for the roads, paths etc. With approved material available from excavations under this contract (excavation paid separately under respective items) or elsewhere, spreading in layers, watering and compacting to the required density and lines, curves, grades, chambered cross section and dimensions shown in the plan or as directed by the Consultant. When the embankment is to be laid on hill sides or slopes, the existing slopes are to be ploughed deeply. If the cross slopes are steeper than 1 in 3, steps with reverse slope shall be cut into the slopes to give proper hold and seating to the bank as directed by the Consultant. The top 15cm of soil shall be scarified and watered if directed and compacted to the same density as specified for the embankment before any material is laid for the embankment work. Only the approved excavated earth shall be placed in the embankments in successive horizontal layers not exceeding 200mm, extending to the full width of the embankment including the slopes at the level of the particular layer and 30 cm, more on both sides to allow compaction of the full specified section. The extra loose stuff at the edges shall be trimmed later after completion of the bank work without extra cost leaving the correct section fully compacted. Keeping the width of the bank initially less and widening it later by dumping loose earth on the slopes shall not be permitted as the additional width and slopes will remain loose and uncompacted. Similar procedure to extend the embankment by dumping the material longitudinally shall also not be allowed. Each layer of the embankment shall be watered, levelled and compacted as specified here-in-after, before the succeeding layers are placed. The surface of the embankment shall at all times during construction, be maintained in such a manner so as to prevent ponding. Water to be used shall be free from all harmful elements which may cause efflorescence etc. and approved by the Consultant. If the material for embankment contains moisture less than the optimum moisture, water shall be added in the 100mm, layers of the embankment to bring moisture uniformly up to requirement. It the excavated material contain more than required moisture, it shall be allowed to dry until the moisture is reduced to required extent. If due to the wetness, the moisture content of the soil cannot be reduced to the appropriate amount by exposure, embankment work shall be suspended till suitable conditions prevail at no extra claim/compensation. When loose layer is levelled manually or mechanically and moistened or dried to a uniform moisture content suitable for maximum compaction, it

shall be compacted by 8 to 10 tonne power roller or sheep foot rollers or heavy hauling or dozing equipment to give the specified 95% of the proctor density, if on testing, the density is found to be less than 95% of the proctor density, the contractor shall do additional compaction necessary to get the specified density after adding water if required. If the density cannot be improved by such reasonable efforts, the work may be accepted as substandard work by the Consultant. If he thinks it is not harmful for the purpose and paid for at a reduce rate. Test shall be made to determine the maximum density of the material to be used by the proctor method before starting the work. Density test shall be carried out for the embankment work during the progress of the work. One set of three core samples for every 1000 sqm. area of each layer of embankment work shall be taken and tested. The average density shall not be less than 90% of the proctor density, obtained in the laboratory. Arrangement for obtaining the samples and transporting the same to laboratory, shall be made by the contractor his own cost. Embankment not accessible to rollers, such as those adjoining bridges, culverts and other works shall be carried out independently of the main embankments and shall have the layers placed in 150 mm to 200 mm height and each layer shall to moistened and thoroughly compacted with mechanical or manual tamper. Before placing the next layer, the surface of the under layer shall be moistened and scarified so as to provide a satisfactory bond with the next layer. The embankment shall be finished and dressed smooth and even, in conformity with the alignment levels and cross section, and dimensions shown on the drawing. On curves, section shall be provided with super elevation and increased width, is shown on the plans as directed by the Consultant. Joining of old and new embankment shall be done by stepping in an overall slope of about 1 to 5. The contractor shall be responsible for maintaining the embankment work in satisfactory conditions at his own cost till finally accepted including making good any damage. D.10.1 PREPERATION OF SUB GRADE: The surface of the formation for a width of subbase which shall be as per drg. shall first be cut to a depth equal to the combine depth of sub-base and surface courses below the proposed finished level (due allowance being made for consolidation). It shall then be cleaned of all foreign substances. Any ruts or soft yielding patches that appear due to improper drainage conditions, traffic hauling or from any other cause, shall be corrected and the sub-grade dressed off parallel to finished profile.

D.10.2

Consolidation: The sub grade shall be consolidated with a power road roller of 8 to 12 tonnes. The roller shall run over the sub grade till the soil is evenly and densely consolidated and behaves as an elastic mass (the roller shall pass a minimum of 5 runs on the sub grade). All undulations in the surface that develop due to rolling shall be made good with fresh material or quarry spoils as the case may be and the sub grade is rerolled. Surface Regularity: The finished surface shall be uniform and conform to the lines, grades and typical cross sections shown in the drawings. When tested with the template and straight edge, the variation shall be within the tolerances specified in the Table below:

D.10.3

D.10.4

Permissible tolerances of surface regularity Longitudinal profile Maximum permissible undulation when measured with a 3 metre straight edge Cross profile Maximum permissible variation from specified profile when measured with a camber-template

24 mm

15 mm

Where the surface irregularity of the sub-grade falls outside the specified tolerances, the contractor shall be liable to rectify these with fresh material or quarry spoils as the case may be, and the sub grade rerolled to the satisfaction of the Consultant.

SPECIFIC TECHNICAL REQUIREMENT The following are the general scope of work and the specific technical requirement for the fulfillment of the contract.

1. Remove 500 mm top surface slushy soil by excavation. 2. Driving casurina piles of 13 to 15 cm diameter at 750mm c/c spacing in both direction in the base for formation of approach road for a depth of 6m 3. Filling with selected earth for 500mm excavated portion and well consolidation 4. Filling the base portion with selected earth for 500 mm depth (in road portion ) and 1830 mm (in Parking portion ) above GL in layers of 300mm and well consolidation. 5. Filling gravel and selected earth each of layer 150mm above selected earth and well consolidation 6. Filling the gravel for 150mm over selected earth and consolidation. 7. Providing granular sub base (GSB) 250 mm over gravel layer. 8. Providing 250mm thick Wet Mix Mecadam over GSB. 9. Providing two layer of Dense Bituminous Mecadam of thick 150mm (each layer 75mm thickness) over WMM 10. The road top shall be provided with bituminous concrete 40mm thick finished to a level of +8.65m.

GENERAL REQUIREMENTS Testing: Daily test (not less than two specimen per day) shall be made by them on the bituminous mixture produced to ensure compliance with these specification and copy of the test results duly signed by the competent authority shall be submitted to the Engineer in charge. Tests shall include water absorption, stability, filler content etc. The contractor shall give all facilities at all items to the Engineer at site or his representative to inspect the work or testing done by him. Generally the frequency of site test shall be carried out as follows:A) Borrow material a) Sand content (IS: 2720-part IV) -- 1 to 2 tests per 8000 cum of soil b) Plasticity test (IS: 2720-part V) -- 1 to 2 tests per 8000 cum of soil c) Density test (IS: 2720-part VII) -- 1 to 2 tests per 8000 cum of soil d) Moisture content test (IS: 2720-part II)1 test per 250 cum of soil e) CBR test (IS: 2720-part XVI) -- 1test per 3000 cum of soil f) Compaction control (IS: 2720-part XXVIII) -- 1test per 1000 Sqm area

B) Water Bound Maccadam a) Aggregate impact value -- 1 test per 200 cbm of aggregate b) Grading -- 1 test per 100 cbm of aggregate c) Flakiness index -- 1 test per 200 cbm of aggregate d) Atterbergs limits -- 1 test per 25 cbm of binding material C) Prime coat/Seal coat a) binder temperature -- at close intervals b) Rate of spread -- Two tests per day D) Seal coat/Surface dressing a) Aggregate impact value -- 1 test/ 50 cbm of aggregate b) Flakiness index -- 1 test /50 cbm of aggregate c) Grading of aggregate -- 1 test /25 cbm of aggregate E) Bituminous concrete a) Aggregate impact value, Flakiness index -- 1 test / 50-100 cbm of aggregate b) Density of compacted layer -- 1 test / 500 Sq.m area. Testing Surface: The completed surface when ready for acceptance shall be thoroughly compacted, smooth, true to line, grade, camber and free from irregularities when tested by means of a straight edge of 3m long, laid on the finished surface parallel with the centre line of the road, the surface shall in no place vary more than 6mm from the working edge. The limiting valves of the defects shall be the following a) Deformation : 25mm in 3 m b) Cracks : 1500 mm in lengths and 3mm in width c) Disintegrated revealed patches: 2.00 sqm and/ or 12mm in depth.

IS / IRC CODES IRC: 37 Guidelines for design of flexible pavements IRC: 73 Geometric design of roads IS 73 Paving Bitumen IS 702 Industrial Bitumen IS 1201 Methods of testing tar and Bituminous materials

CODES AND STANDARDS All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of conflict between this specification and those (IS standards, codes etc.) referred to here-in, the former shall prevail. Some of the relevant Indian standards, Acts and Codes are referred to here below: IS: 383 1970 Specification for coarse and fine aggregates from natural sources for concrete. IS 2720 (Part- 2) 1973 Methods of test for soils-Determination of water content IS 2720 (Part4-4 ) 1985 Methods of test for soils-Grain size analysis IS 2720 (Part-5 ) 1985 Methods of test for soils-Determination of liquid limit & plastic limit IS 2720 (Part-6 ) 1972 Methods of test for soils-Determination of shrinkage factors IS 2720 (Part-7 ) 1980 Methods of test for soils-Determination of water content-Dry density relation using light compaction IS 2720 (Part-8 ) 1983 Methods of test for soils- Determination of water content-Dry density relation using heavy compaction IS 2720 (Part-14 ) 1983 Methods of test for soils-Determination of dry index(relative density) IS 2720 (Part-21 ) 1977 Methods of test for soils-Determination of total soluble solids IS 2720 (Part-23 ) 1976 Methods of test for soils-Determination of calcium carbonate IS 2720 (Part-24 ) 1976 Methods of test for soils-Determination of cat ion exchange capacity IS 2720 (Part-27 ) 1977 Methods of test for soils-Determination of total soluble sulphates IS 2720 (Part-29 ) 1975 Methods of test for soils-Determination of dry density of soil inplace by core cutter method IS: 3764 1992 Safety code for excavation work IS: 4081 1986 Safety code for blasting and related drilling operations IS: 4701 1982 Code of practice for earth work on canals IS: 9759 1981 Guide lines of dewatering during construction IS: 10379 1982 Code of practice for field control of moisture and compaction of soils for embankment and sub grade Indian Explosives Act 1940 as updated. 2.0 MATERIALS 2.01 Stone Aggregate For WBM construction stone metal grade I& II of hard granite or equivalent as approved by Engineer-in-Charge shall be used. River borne or weathered stone metal shall not be used for the work. The stone metal and aggregates shall not

be obtained from the rock which has been exposed to atmosphere for a long time. They shall be clean, hard, durable of fairly cubical shape and free from excess flat, elongated, soft & disintegrated particles, fracture, cleavage, dirt & other deleterious materials and organic impurities. The aggregates shall preferable be hydrophobic and low porosity. The aggregates shall satisfy the physical requirements as set forth in Table I.
Table I (Physical Requirement of Coarse Aggregate) Type of Construction Type of Construction Test Test Requirement Los Angeles Abrasion Value IS-2386 (Part-IV) or Aggregate Impact Value (Maximum) IS-5640*** 2. Base (Maximum) (Maximum) Flakiness Index **15% (Maximum) * Aggregates may satisfy requirements of either of the two tests. ** The requirements of flakiness index shall be enforced only in case of crushed / broken stone .. *** Aggregates like brick metal, kankar and laterite which get softened in presence of water, shall be tested for impact value under wet conditions in accordance with IS:5640. IS-5640*** IS-2386 (Part-I) Los Angeles Abrasion Value IS-2386 (Part-IV) or Aggregate Impact Value IS-2386 (Part-IV) 50% IS-2386 (Part-IV)

Sl. No.

Method

1. Sub-Base (Maximum)

60%

*50%

*40%

2.02

Sand / Stone Dust Sand/ Stone dust shall be clean, hard durable, uncoated, dry and free from injurious soft or flaky pieces and organic or deleterious substances. Quality of sand/ stone dust shall conform to IS: 383.

2.03

Supply and stacking of materials Stone metal, boulder, sand, stone dust etc. Ground where stacks are proposed to be made shall be cleared, leveled or dressed to a uniform slope and all lumps, depressions etc. shall be removed. The stacked material shall be free from vegetation and other undesirable material. All rejected materials shall be immediately removed from site.

Stone metal and boulder shall be stacked in convenient units of one metre top width, 2.2 m bottom width, 60 cm height and of length in multiples of 3 meter. Template of wood or steel shall be used for making the stack and shall always be kept at site for check measurements. Sand or stone dust shall be stacked in convenient units of one cum. The stack shall be made with wooden boxes open at both ends and of 2 m x 2 m x 0.25 m dimensions. These boxes shall always be kept at site for stacking and check measurements. The stacks shall be uniformly distributed along the road side and shall be numbered serially. The number plate shall be planted on each stack which shall remain in position until the stack is used in the work. Sample of materials shall be got approved from Engineer-in-Charge before the material in bulk is brought to the site.

2.03

Measurement for Payment Length, breadth and height shall be measured correct to a cm and volume shall be calculated in cum correct to two places of decimal. The volume of stacks shall be reduced by percentage as shown below on account of voids to arrive at the net quantity for payment. Earth In loose stacks such as cart loads, lorry etc. - 20% In consolidated fills - 10% In fills consolidated by heavy mechanical machinery but not under OMC In fills consolidated by heavy mechanical machinery at OMC Consolidated fills in confined situation such as under floors Sand/ Stone dust - Nil Moorum - Nil Stone metal 40 mm nominal size and above - 7.5% Coarse Aggregate below 40 mm nominal size - Nil Soling Stone / Boulder 100 mm nominal size and above Excavated Rock - 50%

i) ii) iii) iv) v) vi) vii) viii) ix) x) xii)

5% Nil Nil

15%

Unless otherwise directed, measurement shall not be taken until sufficient materials for use on the road (for a road length of minimum five hundred metre) have been colleted and stacked. Immediately after measurement the stack shall be marked by white wash or other means as directed by Engineer-in-Charge.

3.0 3.01

ROLLING: Rolling shall be done by 80 / 100 KN smooth wheeled power roller (3 wheel or tandem) or vibratory roller of 80 100 KN static weight. Rolling shall start as soon as possible after the materials have been spread, deploying a set of rollers as the rolling is to be completed in limited time frame. Rolling shall be done with care to avoid unduly roughening of the pavement surface. The roller shall move at a speed not more than 5 km / hour. Rolling of longitudinal joints shall be done immediately behind the paving operation. After this the rolling shall commence at the edges and progress towards the centre longitudinally, except that on super elevated and unidirectional cambered portions, where the rolling shall proceed from inner edge to the outer parallel to the centre line of the pavement. First the edge / edges shall be compacted with roller running forward and backward. The roller shall then move inward parallel to the centre line of the road, in successive passes uniformly lapping preceedings tracks by at least one-half width of WBM. When the roller has passed over the whole area once, any high spots or depressions which become apparent shall be corrected by removing or adding mix material. The rolling shall be continued till the entire surface has been rolled to 95% of the Proctors density, there is no crushing of aggregates and all roller marks have been eliminated. Roller shall not stand on newly laid material while there is a risk that surface will be deformed thereby.

3.02

Time Schedule for Rolling Operations The minimum duration for rolling shall be governed by the guidelines set forth in Table-3. However, Engineer-in-Charge shall have the full authority to increase the duration to an extent as he may deem necessary, to satisfy himself that the compaction must comply with the specifications. Table-3

Sl. No. Volume 1. 2. 3.

Items Preparation of Sub-grade 75 mm thick WBM with Stone Metal Grade II 150 mm thick WBM with Stone Metal Grade I

Duration 1 hour 1 hour 1 hour

Surface Area / 200 sqm 50 sqm 100 sqm

3.03

Rates The contract unit rate for the work shall be payment in full for carrying out the required operations including full compensation for

(i)

Making arrangements for traffic to Clause 112 of Specifications for Road & Bridge Works published by Ministry of Surface Transport except for initial treatment to verge, shoulders and construction of diversion. Preparation of base except for laying of profile corrective course but including filling of pot holes. Providing all materials to be incorporated in the work including the arrangements for stockyard, all royalties, octroi, fees, cess, rents where necessary and all leads and lifts. All labour, tools, equipment, power supply units and all machines incidental to complete the work to the specifications. Carrying out the work in part widths of the road, wherever directed. Carrying out all tests for quality control.

(ii)

(iii)

(iv)

(v) (vi)

SURFACE FINISH 4.01 4.02 CONTROL OF ALIGNMENT LEVEL & SURFACE REGULARITY General All works to be performed shall conform to the lines, grades, cross-sections and dimensions shown on the drawings or as directed by Engineer-in-Charge, subject to the permitted tolerances described hereinafter. 4.03 Horizontal Alignment Horizontal alignment shall be reckoned with respect to the entire line of the carriageway as shown on the drawings. The edges of the carriageway as constructed shall be correct within a tolerance of +/- 10 mm there from. The corresponding tolerance for edges of the roadway and lower layers of pavement shall be +/- 25 mm. 4.04 Surface Levels

The levels of the sub-grade and different pavement courses as constructed, shall not vary from those calculated with reference to the longitudinal and cross-profile of the road shown on the drawings or as directed by the Engineer-in-Charge beyond the tolerances mentioned in Table -4. Table-4 1. Sub-grade + 20 mm / - 25 mm 2. Sub-base a) Flexible Pavement + 10 mm / - 20 mm

Provided, however, that the negative tolerance for wearing course shall not be permitted in conjunction with positive tolerance for basic course, if the thickness of the former is thereby reduced by more than 6 mm for flexible pavement and 5 mm for concrete pavements. 4.05 Surface Regularity The longitudinal profile shall be checked with a 3 metre long straight-edge at the middle of each traffic lane along a line parallel to the centre line of the road. The maximum allowable difference between the road surface and underside of a 3 m straight-edge when placed parallel with, or at right angles to the centre line of the road at points decided by the Engineer-in-Charge shall be as under: For WBM Sub-base / Base Course 4.06 8 mm

Rectification / Reconstruction of Defective Macadam Where the surface regularity of sub-grade and the various pavement courses fall outside the specified tolerances, the contractor shall be liable to rectify these at their own cost in the manner described below and to the satisfaction of the Engineer-in-Charge.

4.07

Sub-Grade Where the surface is high, it shall be trimmed and suitably compacted. Where the surface is low, the deficiency shall be corrected by scarifying the lower layer and adding fresh material and re-compacting to the required density.

4.08

WBM (Sub-base / Base Course) Where the surface is either high or low, the course to its full thickness shall be scarified over the affected area, reshaped with added material or removed and replaced with fresh material and re-compacted to the required density. In no case shall depressions be filled up with screenings or binding material.

5.02

EARTH WORK IN EXCAVATION General All excavation shall be carried out in conformity with the lines, grades, side slopes and levels shown on the drawings or as directed by the Engineer-inCharge. The contractor shall not excavate outside the limits of excavation. After excavation, the sides of excavated area shall be trimmed and the area contoured to minimize erosion and ponding, allowing for natural drainage to take place.

Rock, when encountered in road excavation, shall be removed upto the formation level. Rocks and large boulders which are likely to cause differential settlement and also local drainage problems should be removed to the extent of 500 mm below the formation level in full formation width. 5.03 Slope in cutting and filling at hill side and valley side shall be as per direction of Engineer-In-Charge. Disposal of Excavated Materials All the excavated materials shall be the property of the Employer. The materials obtained from excavation shall be used for filling in the adjacent embankments as directed by the Engineer-in-Charge. All hard rocks, not intended for use shall be stacked neatly on specified land as directed by the Engineer-in-Charge. Unsuitable and surplus materials not intended for use shall be transported and disposed clear of the site as directed by the Engineer-in-Charge. EARTH WORK 5.01a EARTH WORK IN FILLING Earth work in filling in banks shall be done in layers, each layer not exceeding 20 cm in thickness and should be properly watered to maintain the optimum moisture content. Consolidation of every 3rd layer (alternate layer) and the topmost layer should be done with power roller of minimum 80-100 KN capacity and got approved by Engineer-in-Charge before compacting the next layer. Required quantity of earth should be obtained from borrow-pits, the sites of which should necessarily be approved by Engineer-in-Charge. No borrow-pits should be dug within 4.5 m of toe of the final section of the embankment. Necessary witness should be left for the purpose of measurement of quantity of earth excavated and used in embankment. Proper profiles of embankment shall be maintained. Requisite allowance in height varying from 25 50 mm as directed by Engineerin-Charge shall be left for settlement. Side slopes shall be maintained strictly as per drawings. 5.01b Earthwork in filling shall be measured in compacted volume of finished work in cubic metres.

5.04

6.0

PREPARATION OF SUB-GRADE The optimum moisture content should always be maintained by sprinkling requisite quantity of water in order to keep the sub-grade in established condition in accordance with the direction of Engineer-in-Charge. The sub-grade must not be allowed to become dry and break-up for want of cohesion. The final sectioning should be done to proper camber, gradient and super elevation with the help of template and strings. The rate of preparation and consolidation of sub-grade

includes earth work in cutting and filling upto 22.5 cm thickness, if necessary, in order to achieve the desired profile. The dressed surface should be properly consolidated by rolling with power road roller of minimum 80-100 KN capacity. 7.0 WATER BOUND MACADAM (SUB BASE / BASE COURSE) 7.01 SCOPE This work shall consist of clean, crushed aggregates mechanically interlocked by rolling and bonding together with screening, binding material where necessary and water laid on a properly prepared sub grade and finished in accordance with the requirements of these specifications and in close conformity with the lines, grades, cross sections and thickness as per approved plans or as directed by Engineer in-Charge. It is not desirable to lay Water Bound Macadam on an existing thin black topped surface without providing adequate drainage facility for water that would get accumulated at the interface of exiting bituminous surface and WBM. 7.02 MATERIALS 7.021 Coarse Aggregate Coarse Aggregates shall conform to the grading requirement as set forth in
Table 5

Table 5 Size of Aggregate Grade I (45 mm to 90 mm) IS Sieve Designation 100 mm 80 mm 63 mm 40 mm 20 mm 80 63 50 40 20 mm mm mm mm mm % by Weight Passing IS Sieve 100 65-85 25-60 0-15 0-05 100 90-100 35-70 0-15 0-05

Grade II (45 mm to 63 mm)

7.022 Stone Screenings Screening to fill voids in the coarse aggregates shall generally consist of the same material as the coarse aggregate. Screening shall conform to the grading requirements as set forth in Table 6. Table 6 Size of Screenings 13.2 mm IS Sieve Designation 13.2 mm 11.2 mm 5.6 mm 180 micron % by Weight Passing IS Sieve 100 95-100 15-35 0-10

7.023 Proportioning of Materials Approximate quantities of coarse aggregate and stone screenings required for Water Bound Macadam base / sub-base course shall be as mentioned in Table-7. Table - 7 (Quantity for 10 Sqm Area)
Classification Size / Range Compacted Thickness Net Quantity Stone Screening Grading For WBM SubClassification base / Base & Size Course (Net Quantity) Type-A 0.285 m 3 (13.2 mm) Type-A 0.135 m 3 (13.2 mm) Binding Material

Grade I Grade II

45 mm 90 mm 45 mm 63 mm

100 mm 75 mm

1.245 m 3 0.935 m 3

0.10 m 3 0.09 m 3

* Net quantity means the quantity of metal measured in stacks and reduced by 7.5%. 7.03 CONSTRUCTION OPERATIONS 7.031 Preparation of Base The surface of the sub grade / sub-base base to receive the Water Bound Macadam course shall be prepared to the specified lines grades & camber and made free of dust and other extraneous material. Any soft yielding places shall be corrected in an approved manner and rolled until firm surface is obtained if necessary by sprinkling water. Any sub -

base/base/surface irregularities, where predominant shall be made good by providing appropriate type of profile corrective course (leveling course)

7.032 Spreading Coarse Aggregates The coarse aggregate shall be spread uniformly and evenly upon the prepared sub-grade to proper profile by using templates placed across the road about 6m apart in such quantities that the thickness of each compacted layer is not more than 100mm for Grade-I and 75 mm for Grade-II. Wherever possible, approved mechanical devices such as aggregate spreader shall be used to spread the aggregates uniformly so as to minimize the need for manual rectification afterwards. The surface of the aggregates spread shall be carefully checked with templates and all high or low spots remedied by removing or adding aggregates as may be required. The surface shall be checked frequently with a straight-edge while spreading and rolling so as to ensure a finished surface as per approved drawings. The course aggregates shall not normally be spread more than 3 days in advance of the subsequent construction operations. 7.033 Rolling Immediately following the spreading of the coarse aggregates, rolling shall be started with three wheeled Power Roller of 80-100 KN capacity or Vibratory Rollers of 80-100 KN static weight. The type of roller to be used shall be approved by the Engineer-in-Charge based on trial run Rolling shall be discontinued when the aggregates are partially compacted with sufficient void space in them to permit the application of stone screenings. The rolled surface shall be checked transversely and longitudinally, with templates and any irregularities corrected by loosening the surface, adding or removing necessary amount of aggregates and re -rolling until the entire surface conforms to desired grade and camber. In no case sh all be use of screenings be permitted to make up depressions. Material which gets crushed excessively during compaction or becomes segregated shall be removed and replaced with suitable aggregates. 7.034 Application of Screenings After the coarse aggregate has been rolled completely, screenings to completely fill the interstices shall be applied gradually over the surface. These shall not be damp or wet at the time of application. Dry rolling shall be done while the screenings are being spread so that vib rations of the roller cause them to settle into the voids of the coarse aggregates. The

screenings shall not be dumped in piles but be spread uniformly in successive thin layers either by the spreading motions of hand shovels or by mechanical spreaders. The screenings shall be applied at a slope and uniform rate (in three or more applications) so as to ensure filling of all voids. This shall be accompanied by dry rolling and brooming with mechanical or hand brooms. P-12

7.035 Sprinkling of Water and Grouting After the screenings have been applied the surface shall be copiously sprinkled with water swept and rolled. Hand brooms shall be used to sweep the wet screenings into voids and to distribute them evenly. The sprinkling, sweeping and rolling operations shall be continued, with additional screenings applied as necessary until the coarse aggregate has been thoroughly keyed, well bonded and firmly set in its full depth and a grout has been formed of screenings. Care shall be taken to see that the base or sub-grade does not get damaged due to the addition of excessive quantity of water during construction. 7.036 Application of binder Material (Moorum / Stone Dust) After the application of stone screening in accordance with Clauses 8.034 and 8.035 the binding material where it is required to be used shall be applied successively in two or more thin layers at a slow and uniform rate. After each application, the surface shall be copiously sprinkled with water, the resulting slurry swept in with hand brooms or mechanical brooms to fill the voids properly and rolled during which water shall be applied to the wheels of the roller if necessary to wash down the binding material sticking to them. These operations shall continue until the resulting slurry after filling of voids forms a wave ahead of the wheels of the moving roller. 7.037 Setting and Drying After the final compaction of Water Bound Macadam course the pavement shall be allowed to dry overnight. Next morning hungry spots shall be filled with screenings or bending materials as directed, lightly sprinkled with water if necessary and rolled. No traffic shall be allowed on the road until the macadam has set. 7.038 Measurement for Payment

Water Bound Macadam shall be measured as finished work in cubic meters.