Vol V-Technical Specifications-Pkg 14

Consultancy Services for preparation of Feasibility Study and
Detailed Project Report for Access Controlled Nagpur-Mumbai

Super Communication Expressway Package V
Construction Package 14
DETAILED PROJECT REPORT
VOLUME- V – Technical Specifications

Project: Preparation of Feasibility Study and Detailed Project Report of Access Controlled Nagpur-Mumbai Super
Communication Expressway, Package V
Construction Package 14 - Draft Detailed Project Report March 2018
VOLUME - V
Technical Specifications
Construction Package 14 - Detailed Project Report June 2018
Contents
Part A - TECHNICAL SPECIFICATIONS -Roads
1. GENERAL REQUIREMENTS ............................................................................................... 3
2. Clause 201 CLEARING AND GRUBBING ........................................................................... 3
3. Clause 202 DISMANTLING CULVERTS, BRIDGES AND OTHER STRUCTURES/PAVEMENTS
6
4. Clause 301 EXCAVATION FOR ROADWAY AND DRAINS .................................................. 8
5. Clause 302 BLASTING OPERATIONS............................................................................... 13
6. Clause 303 PRESPLITTING ROCK EXCAVATION SLOPES ................................................. 16
7. Clause 304 EXCAVATION FOR STRUCTURES .................................................................. 18
8. Clause 305 EMBANKMENT CONSTRUCTION ................................................................. 20
9. Clause 306 SOIL EROSION AND SEDIMENTATION CONTROL ........................................ 32
10. Clause 307 TURFING WITH SODS .................................................................................. 34
11. Clause 308 SEEDING AND MULCHING ........................................................................... 37
12. Clause310 PREPARATION AND SURFACE TREATMENT OF FORMATION ...................... 44
13. Clause 311 WORKS TO BE KEPT FREE OF WATER .......................................................... 44
14. Clause 312 WATER COURSES AT CULVERTS .................................................................. 44
15. Clause 313 ROCKFILL EMBANKMENT ............................................................................ 45
16. CLAUSE 401 GRANULAR SUB-BASE................................................................................ 46
17. Clause 406 WET MIX MACADAM SUB-BASE/BASE COURSE ......................................... 48
18. Clause 408 SHOULDERS, ISLANDS AND MEDIAN .......................................................... 50
19. Clause 507 BITUMINOUS CONCRETE ............................................................................ 59
20. Clause 801 TRAFFIC SIGNS ............................................................................................. 60
21. Clause 803 ROAD MARKINGS ........................................................................................ 63
22. Clause 805 Distance Indicator Posts .............................................................................. 65
23. Clause 806 ROAD DELINEATORS .................................................................................... 66
25. Clause 810 STRUCTURAL STEEL RAILING ....................................................................... 68
26. Clause 811 CRASH BARRIER ........................................................................................... 68
27. Clause 812 ROAD TRAFFIC SIGNALS .............................................................................. 69
28. Clause 813 TRAFFIC CONTROL AND SAFETY DEVICES IN CONSTRUCTION ZONE .......... 69
29. Clause 816 ADVANCED TRAFFIC MANAGEMENT SYSTEMS (ATMS).............................. 70
30. Clause 1502 MATERIALS ................................................................................................ 72
STRUCTURAL CONCRETE .......................................................................................................... 73
Part B : TECHNICAL SPECIFICATIONS – Structures

1. General .......................................................................................................................... 74
2. MATERIALS FOR STRUCTURES ....................................................................................... 79
Part C : TECHNICAL SPECIFICATIONS – Tunnel

1.0 General .......................................................................................................................... 81
2.0 Scope of the Work ......................................................................................................... 82
3.0 Special Features of the Work ........................................................................................ 83
4.0 Underground Excavation ............................................................................................... 83
5.0 Shot Concreting ............................................................................................................. 87
6.0 Supplying and Installing Rock bolts ; ............................................................................. 93
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7.0 Permanent Steel Supports ............................................................................................. 94

8.0 RCC Lagging with Concrete Back Packing ...................................................................... 96
9.0 Lining of Tunnel ............................................................................................................. 97
10.0 Drilling about 40 mm. dia., Probe Holes and Grout Holes....................................... 100
11.0 Pressure Grouting of Rock Mass / Strata ................................................................. 100
12.0 Providing and Installing Embedment in Position ..................................................... 101
14.0 Backfilling and Compacting Selected Fill Material behind Concrete Portal Walls and
Cut & Cover Portions : ........................................................................................................... 102
15.0 Providing and Fixing M.S. Reinforcement for Concrete Works ............................... 102
16.0 Providing and Installing Galvanized Iron Pipe Hand Railing for Walkways etc. ...... 102
17.0 Providing and Installing Fire Fighting Water Line etc. ............................................. 103
18.0 Construction of In-situ Kerbs, Crash Barriers, Side Drains and Pre-cast Concrete
Slabs for Drain-cover/ Walkway : .......................................................................................... 103
19.0 Treatment of Seepage Water : ................................................................................ 104
20.0 Installation of Spray Applied Waterproofing Membrane : (Delete) ........................ 105
21.0 Pipe Roofing : ........................................................................................................... 105
22.0 Rod fore poling:........................................................................................................ 105
23.0 Prevention & Mitigation of Tunneling hazards ........................................................ 106
24.0 Lighting (Required during execution of the work) ................................................... 107
25.0 Ventilation (Required during execution of the work).............................................. 107
26.0 Dewatering ............................................................................................................... 107
27.0 Submittals (Delete) .................................................................................................. 107
28.0 HEA Panels :- ............................................................................................................ 107
Annexure A - Indian Railway Standard Specification for Fabrication and Erection of Steel Girder
Bridges and Locomotive Turn-Tables
Page 2
PART A - TECHNICAL SPECIFICATIONS -Roads
PREAMBLE
1.1 The technical specifications contained herein shall be read in conjunction with the
other Bidding Documents shall consist of the various items as generally described in
the Tender Documents as well as in the Bill of Quantities furnished in the Tender
Document.
1.2 The Specification issued by Research Designs and Standards Organisation (RDSO),
Lucknow; “Indian Railway Standard Specification for Fabrication and Erection of Steel
Girder Bridges and Locomotive Turn-Tables”, SERIAL NO. B1-2001 has also been
referred. The specifications referred in RDSO standards are attached as Annexure A.
1. GENERAL REQUIREMENTS
2.1 The technical specifications in accordance with which the entire work described
hereinafter shall be constructed and completed by the contractor shall comprise of
the following:
2.2 Part – I: General Technical Specifications

The general technical specifications shall be the “SPECIFICATIONS FOR ROAD AND
BRIDGE WORKS (FIFTH REVISION, reprint of April 2013)” incorporating “Upgraded
Section 500 and its related aspects in Sections 900 and 3000”, as corrected in the
original issued by the Ministry of Surface Transport (Roads Wing), Government of
India and the Ministry of Road Transport and Highways (formerly the Ministry of
Surface Transport) respectively, and published by the Indian Roads Congress.
2.3 Additional Details to MORT&H Specification
2. Clause 201 CLEARING AND GRUBBING
Clause 201.1 Scope

This work shall consist of cuffing, removing and disposing of all materials such as trees, bushes,
shrubs, stumps, roots, grass, weeds, rubbish, top organic soil, etc. to an average depth of 150 mm in
thickness, which in the opinion of the Engineer are unsuitable for incorporation in the works, from
the area of road land containing road embankment, drains, cross-drainage structures and such other
areas as may be specified on the drawings or by the Engineer. It shall include necessary excavation,
backfilling of pits resulting from uprooting of trees and stumps to required compaction, handling,
salvaging, and disposal of cleared materials with all leads and lifts. Clearing and grubbing shall be
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performed in advance of earthwork operations and in accordance with the requirements of these
Specifications.
Roadside trees, shrubs, any other plants, pole lines, fences, signs, monuments, buildings,
pipelines, sewers and all highway facilities within or adjacent to the highway which are not to be
disturbed shall be protected from injury or damage. The Contractor shall provide and install at his
own cost, suitable safeguards approved by the Engineer for this purpose.
During clearing and grubbing, the Contractor shall take all adequate precautions against soil
erosion, water pollution, etc., and where required, undertake additional works to that effect vide
Clause 306. Before start of operations, the Contractor shall submit to the Engineer for approval,
his work plan including the procedure to be followed for disposal of waste materials, etc., and the
schedules for carrying out temporary and permanent erosion control works as stipulated in
Clause 306.3.
Clause 201.4 Disposal of Materials

All materials arising from clearing and grubbing operations shall be taken over and shall be disposed
of by the Contractor at suitable disposal sites with all leads and lifts. The disposal shall be in
accordance with local, State and Central regulations.
Clause 201.5 Measurements for Payment

Clearing and grubbing for road embankment, drains and cross-drainage structures shall be
measured on area basis in terms of hectares. Cutting of trees upto 300 mm in girth and removal
of their stumps, including removal of stumps upto 300 mm in girth left over after trees have been
cut by any other agency, and trimming of branches of trees extending above the roadway and
backfilling to the required compaction shall be considered incidental to the clearing and grubbing
operations. Clearing and grubbing of borrow areas shall be deemed to be a part of works
preparatory to embankment construction and shall be deemed to have been included in the rates
quoted for the embankment construction item and no separate payment shall be made for the
same.
Ground levels shall be taken prior to and after clearing and grubbing. Levels taken prior to clearing and
grubbing shall be the base level and will be accordingly used for assessing the depth of clearing and
grubbing and computation of quantity of any unsuitable material which is required to be removed. The
levels taken subsequent to clearing and grubbing shall be the base level for computation of earthwork
for embankment.
Cutting of trees, excluding removal of stumps and roots of trees of girth above 300 mm shall be
measured in terms of number according to the girth sizes given below: -
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i) Above 300 mm to 600 mm

ii) Above 600 mm to 900 mm
iii) Above 900 mm to 1800 mm
iv) Above 1800 mm
Removal of stumps and roots including backfilling with suitable material to required compaction
shall be a separate item and shall be measured in terms of number according to the sizes given
below: -
i) Above 300 mm to 600 mm
ii) Above 600 mm to 900 mm
iii) Above 900 mm to 1800 mm
iv) Above 1800 mm
For the purpose of cutting of trees and removal of roots and stumps, the girth shall be measured
at a height of 1 m above ground or at the top of the stump if the height of the stump is less than
one metre from the ground.
Clause 201.6 Rates
Clause 201.6.1
The Contract unit rates for the various items of clearing and grubbing shall be payment in full for
carrying out the required operations including full compensation for all labour, materials, tools,
equipment and incidentals necessary to complete the work. These will also include removal of
stumps of trees less than 300 mm girth excavation and back-filling to required density, where
necessary, and handling, giving credit towards salvage value disposing of the cleared materials
with all lifts and leads. Clearing and grubbing done in excess of 150 mm by the Contractor shall be
made good by the Contractor at his own cost as per Clause 301.3.3 to the satisfaction of the
Engineer prior to taking up earthwork. Where clearing and grubbing is to be done to a level
beyond 150 mm, due to site considerations, as directed by the Engineer, the extra quantity shall
be measured and paid separately.
Clause 201.6.2 The Contract unit rate for cutting trees of girth above 300 mm shall include
handling, giving credit towards salvage value disposing of the cleared materials with all lifts and
leads.
Clause 201.6.3 The Contract unit rate for removal of stumps and roots of trees girth above
300 mm shall include excavation and backfilling with suitable material to required compaction,
handling, giving credit towards salvage value disposing of the cleared materials with all lifts and
leads.
Clause 201.6.4 The Contract unit rate is deemed to include credit towards value of usable
materials, salvage value of unusable materials and off-set price of cut trees and stumps belonging
to the Forest Department. The off-set price of cut trees and stumps belonging to the Forest
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Department shall be deducted from the amount due to the Contractor and deposited with the
State Forest Department. In case the cut trees and stumps are required to be deposited with the
Forest Department the Contractor shall do so and no deduction towards the off-set price shall be
effected. The offset price shall be as per guidelines / estimates of the State Forest Department.
Clause 201.6.5 Where a Contract does not include separate items of clearing and
grubbing, the same shall be considered incidental to the earthwork items and the Contract unit
prices for the same shall be considered as including clearing and grubbing operations.
3. Clause 202 DISMANTLING CULVERTS, BRIDGES AND OTHER

STRUCTURES/PAVEMENTS
Clause 202.1 Scope
This work shall consist of dismantling and removing existing culverts, bridges, pavements kerbs
and other structures like guard-rails, fences, utility services, manholes, catch basins, inlets, etc.,
from the right of way which in the opinion of the Engineer interfere with the construction of road
or are not suitable to remain in place, disposing of the surplus/unsuitable materials and
backfilling to after the required compaction as directed by the Engineer.
Existing culverts, bridges, pavements and other structures which are within the highway and
which are designated for removal, shall be removed upto the limit and extent specified in the
drawings or as indicated by the Engineer.
Dismantling and removal operations shall be carried out with such equipment and in such a
manner as to leave undisturbed, adjacent pavement, structures and any other work to be left in
place.
All operations necessary for the removal of any existing structure which might endanger new
construction shall be completed prior to the start of new work.
Clause 202.2 Dismantling Culverts and Bridges
The structures shall .be dismantled carefully and the resulting materials so removed as not to
cause any damage to the part of the structure to be retained and any other properties or
structures nearby.
Unless otherwise specified, the superstructure portion of culverts/bridges shall be entirely

removed and other parts removed up to at least 600 mm below the sub-grade, slope face or
original ground level whichever is the lowest or as necessary depending upon the interference
they cause to the new construction. Removal of overlying or adjacent material, if required in
connection with the dismantling of the structures, shall be incidental to this item.
Where existing culverts/bridges are to be extended or otherwise incorporated in the new work,
only such part or parts of the existing structure shall be removed as are necessary and directed
by the Engineer to provide a proper connection with the new work. The connecting edges shall
Page 6
be cut, chipped and trimmed to the required lines and grades without weakening or damaging
any part of the structure to be retained. Due care should be taken to ensure that reinforcing bars
which are to be left in place so as to project into the new work as dowels or ties are not injured
during removal of concrete.
Pipe culverts shall be carefully removed in such a manner as to avoid damage to the pipes.
Steel structures shall, unless otherwise provided, be carefully dismantled in such a manner as to
avoid damage to members thereof. if specified in the drawings or directed by the Engineer that
the structure is to be removed in a condition suitable for re-erection, all members shall be match-
marked by the Contractor with white lead paint before dismantling; end pins, nuts, loose plates,
etc. shall be similarly marked to indicate their proper location; all pins, pin holes and machined
surfaces shall be painted with a mixture of white lead and tallow and all locl, parts shall be
securely wired to adjacent members or packed in boxes.
Timber structures shall be removed in such a manner as to avoid damage to such timber or
lumber having salvage value as is designated by the Engineer.
Clause 202.3 Dismantling Pavements and Other Structures
In removing pavements, kerbs, gutters, and other structures like guard-rails, fences, manholes,
catch basins, inlets, etc., where portions of the existing construction are to be left in the finished
work, the same shall be removed to an existing joint or cut and chiOped to a true line with a face
perpendicular to the surface of the existing structure. Sufficient removal shall be made to provide
for proper grades and connections with the new work as directed by the Engineer.
All concrete pavements, base courses in carriageway and shoulders etc., designated for removal
shall be broken to pieces whose volume shall not exceed 0.02 cu.m and used with the approval of
the Engineer or disposed of.
Clause 202A Back-filling
Holes and depressions caused by dismantling operations shall be backfilled with excavated or
other approved materials and compacted to required density as directed by the Engineer.
Clause 202.5 Disposal of Materials
All surplus materials shall be taken over by the Contractor which may either be re-used with the
approval of the Engineer or disposed of with all leads and lifts.
The work of dismantling shall be paid for in units indicated below by taking measurements before
and after, as applicable:
i) Dismantling brick/stone masonry/ cu.m

concrete (plain and reinforced)
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ii) Dismantling flexible and cement cu.m

concrete pavement
iii) Dismantling steel structures tonne
iv) Dismantling timber structures cu.m
v) Dismantling pipes, guard rails, kerbs, linear(m)

gutters and fencing
vi) Utility services No.
Clause 202.7 Rates
The Contract unit rates for the various items of dismantling shall be paid in full for carrying out
the required operations including full compensation for all labour, materials, tools, equipment,
safeguards and incidentals necessary to complete the work. The rates will include excavation and
backfilling to the required compaction and for handling, giving credit towards salvage value
disposing of dismantled materials with all lifts and leads
4. Clause 301 EXCAVATION FOR ROADWAY AND DRAINS

Clause 301.1 Scope
The work shall consist of excavation, removal and satisfactory disposal of all materials necessary
for the construction of roadway, road shoulders, side drains and waterways in accordance with
requirements of these Specifications and the lines, grades and cross-sections shown in the
drawings or as indicated by the Engineer. It shall include the hauling and stacking of or hauling to
sites of embankment and sub grade construction, suitable cut materials as required, as also the
disposal of unsuitable cut materials in specified manner, trimming and finishing of the road to
specified dimensions or as directed by the Engineer.
Clause 301.3.3 Excavation – General

All excavations shall be carried out in conformity with the directions laid here-in-under and in a
manner approved by the Engineer. The work shall be so done that the suitable materials available
from excavation are satisfactorily utilized as deemed fit or as approved by the Engineer. While
planning or executing excavations, the Contractor shall take all adequate precautions against soil
erosion, water pollution etc. as per Clause 306, and take appropriate drainage measures to keep
the site free of water in accordance with Clause 311.
The excavations shall conform to the lines, grades, side slopes and levels shown on the drawings
or as directed by the Engineer. The Contractor shall not excavate outside the limits of excavation.
Subject to the permitted tolerances, any excess depth/width excavated beyond the specified
levels/dimensions on the drawings shall be made good at the cost of the Contractor with suitable
Page 8
material of characteristics similar to that removed and compacted to the requirements of Clause
305.
All debris and loose material on the slopes of cuttings shall be removed. No backfilling shall be
allowed to obtain required slopes excepting that when boulders or soft materials are
encountered in cut slopes, these shall be excavated to approved depth on instructions of the
Engineer and the resulting cavities filled with suitable material and thoroughly compacted in an
appropriate manner.
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.
Clause 301.3.4 Methods, Tools and Equipment
Only such methods, tools and equipment as approved by the Engineer shall be adopted/ used in
the work. If so desired by the Engineer, the Contractor shall demonstrate the efficacy of the type
of equipment to be used before the commencement of work
Clause 301.3.6 Marsh Excavation
The excavation of soil from marshes/swamps shall be carried out as per the programme
approved by the Engineer.
Excavation of marshes shall begin at one end and proceed in one direction across the entire
marsh immediately ahead of backfilling with materials like boulders, sand moorum, bricks bats,
dismantled concrete as approved by the Engineer. The method and sequence of excavating and
backfilling shall be such as to ensure, to the extent practicable, the complete removal or
displacement of all muck from within the lateral limits indicated on the drawings or as staked by
the Engineer.
Clause 301.3.8 Excavation for Surface/Sub-Surface Drains
Where the Contract provides for construction of surface/sub-surface drains, the same shall be
done as per Clause 309. Excavation for these drains shall be carried out in proper sequence with
other works as approved by the Engineer.
Clause 301.3.9 Slides
If slips, slides, over-breaks or subsidence occur in cuttings during the process of construction,
they shall be removed at the cost of the Contractor as ordered by the Engineer. Adequate
precautions shall be taken to ensure that during construction, the slopes are not rendered
unstable or give rise to recurrent slides after construction. If finished slopes slide into the
roadway subsequently, such slides shall be removed and paid for at the Contract rate for the
Page 9
class of excavation involved, provided the slides are not due to any negligence on the part of the
Contractor. The classification of the debris material from the slips, slides etc. shall conform to its
condition at the time of removal and payment made accordingly regardless of its condition
earlier.
Clause 301.3.10 Dewatering
If water is met with in the excavations due to springs, seepage, rain or other causes, it shall be
removed by suitable diversions, pumping or bailing out and the excavation kept dry whenever so
required or directed by the Engineer. Care shall be taken to discharge the drained water into
suitable outlets as not to cause damage to the works, crops or any other property. Due to any
negligence on the part of the Contractor, if any such damage is caused, it shall be the sole
responsibility of the Contractor to repair/restore to the original condition at his own cost or
compensate for the damage.
Clause 301.3.11 Use and Disposal of excavated materials
All the excavated materials shall either be reused with the approval of the Engineer or disposed off
with all leads and lifts as directed by the Engineer.
All the excavated materials shall be the property of the Employer. Suitable material obtained from
the excavation of the roadway, shoulders, verges, drains, cross drainage works, etc. shall be used
for:
i) filling for roadway embankments.
ii) filling existing pits in the right of way as directed by the Engineer, including levelling and
spreading, with all lifts and lead.
iii) for landscaping of the road as directed by the Engineer, including levelling and spreading,
with all lifts and lead.
Unsuitable and surplus material, which, in the opinion of the Engineer cannot be used in the works,
shall be removed from site by the Contractor and disposed off at the approved location in
accordance with all statutory requirements as approved by the Engineer” with all leads and lifts.
Clause 301.3.12 Backfilling

Backfilling of masonry/concrete hume pipe or drain excavation shall be done with approved material
with all leads and lifts after concrete/masonry/hume pipe is fully set and carried out in such a way as
not to cause undue thrust on any part of the structure and/or not to cause differential settlement. All
space between the drain walls and the side of the excavation shall be backfilled to the original surface
making due allowance for settlement, in layers (exceeding 150 mm compacted thickness to the
required density, using suitable compaction equipment such as trench compactor, mechanical
tamper, rammer or plate compactor a directed by the Engineer.
Clause 301A Plying of Construction Traffic
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Construction traffic shall not use the cut formation and finished subgrade without the pric
permission of the Engineer. Any damage arising out of such use shall be made good by the
Contractor at his own cost.
Clause 301.6 Preparation of Cut Formation
The cut formation, which serves as a sub-grade, shall be prepared to receive the sub-base/ base
course as directed by the Engineer.
Where the material in the subgrade has a density less than specified in MoRT&H Table 300-1, the
same shall be loosened to a depth of 500 mm and compacted in layers in accordance with the
requirements of Clause 305 adding fresh material, if any required, to maintain the formation level
as shown on the drawings. Any unsuitable material encountered in the subgrade level shall be
removed as directed by the Engineer, replaced with suitable material and compacted in
accordance with Clause 305.
In rocky formations, the surface irregularities shall be corrected and the levels brought up to the
specified elevation with granular base material as directed by the Engineer, laid and compacted
in accordance with the respective Specifications for these materials. The unsuitable material shall
be disposed of in accordance with Clause 301.3.11. After satisfying.
the density requirements, the cut formation shall be prepared to receive the sub-base/base
course in accordance with Clauses 310 and 311.
Clause 301.7 Finishing Operations
Finishing operations shall include the work of properly shaping and dressing all excavated
surfaces.
When completed, no point on the slopes shall vary from the designated slopes by more than 150
mm measured at right angles to the slope, except where excavation is in rock (ordinary or hard)
where no point shall vary more than 300 mm from the designated slope. In no case shall any
portion of the slope encroach on the roadway.
The finished cut formation shall satisfy the surface tolerances described in Clause 902.
Where directed, the topsoil removed and conserved (Clauses 301.3.2 and 305.3,3) shall be
spread over cut slopes, shoulders and other disturbed areas. Slopes may be roughened and
moistened slightly, prior to the application of topsoil, in order to provide satisfactory bond. The
depth of topsoil shall be sufficient to sustain plant growth, the usual thickness being from 75 mm
to 100 mm.
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Excavation for roadway shall be measured by taking cross sections at suitable intervals in the
original position before the work starts and after its completion and computing the volumes in
cu. m. by the method of average end areas for each class of material encountered. Where it is
not feasible to compute volumes by this method because of erratic location of isolated deposits,
the volumes shall be computed by other accepted methods.
At the option of the Engineer, the Contractor shall leave depth indicators during excavations of
such shape and size and in such position as directed so as to indicate the original ground level as
accurately as possible. The Contractor shall see that these remain intact till the final
measurements are taken.
For rock excavation, the overburden shall be removed first so that necessary cross-sections could
be taken for measurement. Where cross sectional measurements could not be taken due to
irregular configuration or where the rock is admixed with other classes of materials, the volumes
shall be computed on the basis of stacks of excavated rubble after making 35 per cent deduction
therefrom. When volumes are calculated in this manner for excavated material other than rock,
deduction made will be to the extent of 16 per cent of stacked volumes.
Works involved in the preparation of cut formation shall be measured in units indicated below:
1 . Loosening and recompacting the loosened material at subgrade ....cu.m
2 . Loosening and removal of unsuitable material and replacing with suitable ...cu.m
material and compacting to required density
3 . Preparing rocky subgrade ...sq.m
4 . Stripping including storing and reapplication of topsoil ...cu.m
Clause 301.9 Rates

Clause 301.9.1 The Contract unit rates for the items of roadway and drain excavation shall
be payment in full for carrying out the operations required for the individual items including full
compensation for:
i) setting out;
ii) transporting the excavated materials for use or disposal with all leads and lifts by giving
suitable credit towards the cost of re-usable material and salvage value of unusable
material;
iii) trimming bottoms and slopes of excavation;
iv) dewatering;
v) keeping the work free of water as per Clause 311;
vi) arranging disposal sites; and
vii) all labour, materials, tools, equipment., safety measures, testing and incidentals
necessary to complete the work to Specifications.
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Where presplitting of rock is prescribed it shall be governed by Clause 303.5.
Clause 301.9.2 The contract unit rate for loosening and recompacting at subgrade level
shall include full compensation for loosening to the specified depth, removing the loosened soil
outside the roadway excavation, rolling the surface below, breaking the clods, spreading the
excavated soil in layers, watering where necessary and compacting to the requirements.
Clause 301.9.3 Clauses 301.9.1 and 305.8 shall apply as regards Contract unit rate for item
of removal of unsuitable material and replacement with suitable material respectively.
Clause 301.9.4 The Contract unit rate for item of preparing rocky sub-grade as per Clause
301.6 shall be full compensation for providing, laying and compacting granular base material for
correcting surface irregularities including all materials, labour and incidentals necessary to
complete the work and all leads and lifts.
Clause 301.9.5 The Contract unit rate for the items of stripping and of reapplication of
topsoil shall include full compensation for all the necessary operations including all lifts and leads.
5. Clause 302 BLASTING OPERATIONS
302.1 General
Blasting shall be carried out in a manner that completes the excavation_ to the lines indicated in
drawings, with the least disturbance to adjacent material. It shall be done only with the written
permission of the Engineer. All the statutory laws, regulations, rules, etc., pertaining to the
acquisition, transportation, storage, handling and use of explosives shall be strictly followed by
the contractor.
The Contractor may adopt any method or methods of blasting consistent with the safety and job
requirements. Prior to starting any phase of the operation, the Contractor shall provide
information describing pertinent blasting procedures, dimensions and notes.
The magazine for the storage of explosives shall be built to the designs and specifications of the
Explosives Department concerned and located at the approved site. The storage places shall be
clearly marked "DANGER-EXPLOSIVES". The Contractor shall be liable for property damage, injury
or death resulting from the use of explosives. All permits shall be obtained by the Contractor. No
unauthorized person shall be admitted into the magazine which, when not in use, shall be kept
securely locked. No matches or inflammable material shall be allowed in the magazine. The
magazine shall have an effective lightning conductor. The following shall be hung in the lobby of
the magazine:
a) A copy of the relevant rules regarding safe storage both in English

and in the language with which the workers concerned are
familiar,
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b) A statement of up-to-date stock in the magazine,
c) A certificate showing the last date of testing of the lightning

conductor, and
d) A notice that smoking is strictly prohibited.
All explosives shall be stored in a secure manner in compliance with all laws and ordinances, and
all such storage places shall be marked. Where no local laws or ordinances apply, storage shall be
provided to the satisfaction of the Engineer and in general not closer than 300 m from the road
or from any building or camping area or place of human occupancy. In addition to these, the
Contractor shall also observe the following instructions and any further additional instructions
which may be given by the Engineer and shall be responsible for damage to property and any
accident which may occur to workmen or public on account of any operations connected with the
storage, handling or use of explosives and blasting. The Engineer shall frequently check the
Contractor's compliance with these precautions.
Clause 302.2 Materials, Tools and Equipment
All the materials, tools and equipment used for blasting operations shall be of approved type. The
Engineer may specify the type of explosives to be allowed in special cases. The fuse to be used in
wet locations shall be sufficiently water-resistant as to be unaffected when immersed in water
for 30 minutes. The rate of burning of the fuse shall be uniform and definitely known to permit
such a length being cut as will permit sufficient time to the firer to reach safely before explosion
takes place. Detonators shall be capable of giving effective blasting of the explosives. The blasting
powder, explosives, detonators, fuses, etc., shall be fresh and not damaged due to dampness,
moisture or any other cause. They shall be inspected before use and damaged articles shall be
discarded totally and removed from the site immediately.
Clause 302.3 Personnel
The blasting operation shall remain in the charge of competent and experienced supervisor and
workmen who are thoroughly acquainted with the details of handling explosives and blasting
operations.
Clause 302.4 Blasting Operations
The blasting shall be carried out during the pre-determined hours of the day preferably during
the mid-day luncheon hour or at the close of the work as ordered in writing by the Engineer. The
hours shall be made known to the people in the vicinity.
The Contractor shall notify each public utility company having structures in proximity to the site
of the work of his intention to use explosives. Such notice shall be given sufficiently in advance to
enable the companies to take such steps as they may deem necessary to protect their property
from injury. In advance of any blasting work within 50 m of any railway track or structures, the
Contractor shall notify the concerned Railway Authority of the location, date, time and
approximate duration of such blasting operation.
Page 14
Red danger flags shall be displayed prominently in all directions during the blasting operations.
The flags shall be planted 200 m from the blasting site in all directions. People, except those who
actually light the fuse, shall be prohibited from entering this area and all persons including
workmen shall be kept away from the flagged area, and all persons including workmen shall be
removed from the flagged area at least 10 minutes before the firing. A warning siren shall be
sounded for the above purpose.
Only controlled blasting shall be resorted to along with the safeguard above at locations where
built-up area, huts and structures in use lie within 200 m. Similarly excavation of hard rock
without blasting is mandatory where people live within 20 m of blast site.
The charge holes shall be drilled to required depths and at suitable places. Blasting should be as
light as possible consistent with thorough breakage of the material necessary for economic
loading and hauling. Any method of blasting which leads to overshooting shall be discontinued.
When blasting is done with powder, the fuse cut to the required length shall be inserted into the
hole and the powder dropped shall be gently tamped with copper roads with rounded ends. The
explosive powder shall then be covered with tamping material which shall be tamped lightly but
firmly.
When blasting is done with dynamite and other high explosives, dynamite cartridges shall be
prepared by inserting the square cut end of a fuse into the detonator and finishing it with nippers
at the open end, the detonator gently pushed into the primer leaving 1/3rd of the copper tube
exposed outside. The paper of the cartridge shall then be closed up and securely bound with wire
or twine. The primer shall be housed into the explosive. Boreholes shall be cleared of all debris
and explosives inserted. The space of about 200 mm above the charge shall then be gently filled
with dry clay, pressed home and the rest of the tamping formed of any convenient material
gently packed with a wooden rammer.
At a time not more than 10 such charges will be prepared and fired. The man in charge shall blow
a siren in a recognized manner for cautioning the people. All the people shall then be required to
move to safe distances. The charges shall be lighted by the man-in-charge only. The man-in-
charge shall count the number of explosions. He shall satisfy himself that all the charges have
been exploded before allowing the workmen to go back to the work site.
After blasting operation, the Contractor shall compact the loose residual material below
subgrade and replace the material removed below subgrade with suitable material.
Clause 302.5 Misfire
In case of misfire, the following procedure shall be observed:
i) Sufficient time shall be allowed to account for the delayed blast. The man-in-charge shall
inspect all the charges and determine the missed charge.
If it is the blasting powder charge, it shall be completely flooded with water. A new hole
shall be drilled at about 450 mm from the old hole and fired. This should blast the old
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charge. In case, it does not blast the old charge, the procedure shall be repeated till the
old charge is blasted.
ii) In case of charges of gelignite, dynamite, etc., the man-in-charge shall gently remove the
tamping and the primer with the detonator. A fresh detonator and primer shall then be
used to blast the charge. Alternatively, the hole may be cleared of 300 mm of tamping and
the direction ther ascertained by placing a stick in the hole. Another hole may then bE
drilled 150 mm away and parallel to it. This hole shall then be charges and fired when the
misfired hole should explode at the same time. ThE man-in-charge shall at once report to
the Contractor's office and the Engineer all cases of misfire, the cause of the same and
what steps were taken in connection there with.
If a misfire has been found to be due to defective detonator or dynamite, the whole quantity in
the box from which defective article was taken must be sent to the authority directed by the
Engineer for inspection to ascertain whether all the remaining materials in the box are also
defective.
Clause 302.6 Account
A careful and day to day account of the explosive shall be maintained by the Contractor in an
approved register and manner which shall be open to inspection by the Engineer at all times.
6. Clause 303 PRESPLITTING ROCK EXCAVATION SLOPES
Clause 303.1 General
Presplitting is defined as the establishment of a specified excavation slope in rock by the

controlled use of explosives and blasting accessories in properly aligned and spaced drill holes.
The presplitting technique shall be used for forming rock excavation slopes at locations shown on
the drawings or as otherwise decided by the Engineer.
Clause 303.2 Construction Operations
Prior to starting drilling operations for presplitting, the Contractor shall furnish the Engineer a
plan outlining the position of all drill holes, depth of drilling, type of explosives to be used,
loading pattern and sequence of firing. The drilling and blasting plan is for record purposes only
and will not absolve the Contractor of his responsibility for using proper drilling and blasting
procedures. Controlled blasting shall begin with a short test section of a length approved by the
Engineer. The test section shall be presplit, production drilled and blasted and sufficient material
excavated whereby the Engineer can determine if the Contractor's method have produced an
acceptable slope.
All overburden soil and weathered rock along the top of the excavation for a distance of about 5
to 15 m beyond the drilling limits, or to the end of the excavation, as decided by the Engineer
shall be removed before drilling the presplittlng holes. Particular care and attention shall be
directed to the beginning and end of excavations to ensure complete removal of overburden soil
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and weathered rock and to expose fresh rock to an elevation equal to the bottom of the adjacent
lift of the presplitting holes being drilled.
Slope holes for presplitting shall be drilled along the line of the planned slope within the specified
tolerances. The drill holes shall not be less than 60 mm nor more than 75 mm in diameter.
Drilling operations shall be controlled by the use of proper equipment and technique to ensure
that no hole shall deviate from the plane of the planned slope by more than 300 mm nor shall
any hole deviate from being parallel to an adjacent hole by more than two-third of the planned
horizontal spacing between holes.
The length of presplit holes for any individual lift shall not exceed 9 m.
The spacing of presplit holes shall not exceed 900 mm on centres and shall be adjusted to result
in a uniform shear face between holes.
Auxiliary drill holes along the presplit line, not loaded or stemmed, may be ordered by the
Engineer. Except for spacing, auxiliary drill holes shall conform to the provisions for presplit holes.
The line of production holes shall be placed inside the presplit lines in such a manner as to avoid
damage to the presplit face.
If necessary, to reduce shatter and overbreak of the presplit surface, the first line of the
production holes shall be drilled parallel to the slope line at the top of the cut and at each bench
level thereafter.
Any blasting technique, which results in damage to the presplit surface, shall be immediately
discontinued.
No portion of any production holes shall be drilled within 2.5 m of a presplit plane except as
approved by the Engineer. The bottom of the production holes shall not be lower than the
bottom of the presplit holes.
A maximum offset of 600 mm will be permitted for a construction working bench at the bottom
of each lift for use in drilling the next lower presplitting pattern. The drilling operations shall be
adjusted to compensate for drift of previous levels and for the offset at the start of new levels to
maintain the specified slope plane.
The maximum diameter of explosives used in presplit holes shall not be greater than one-half the
diameter of the presplit hole.
Only standard cartridge explosives prepared and packaged by explosive manufacturing firms shall
be used in presplit holes. These shall be fired as recommended by the manufacturer. Ammonium
nitrate composition blasting agents will not be permitted in presplitting operations.
Stemming may be required to achieve a satisfactory presplit face. Stemming material shall be dry
free-running material all of which passes 11.2 mm sieve and 90 percent of which is retained on
2.80 mm sieve. Stemmed presplit holes shall be completely filled to the collar.
All charges in each presplitting pattern shall be detonated simultaneously.
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Clause 303.3 Tolerances
The presplit face shall not deviate more than 300 mm from the plane passing through adjacent
drill holes, except where the character of the rock is such that, as determined by the Engineer,
irregularities are unavoidable. When completed, the average plane of the slopes shall conform to
the slopes indicated on the plans and no point on the completed slopes shall vary from the
designated slopes by more than 300 mm. These tolerances shall be measured perpendicular to
the plane of the slope. In no case shall any portion of the slope encroach on the side drains.
As long as equally satisfactory presplit slopes are obtained, then either the slope face may be
presplit before drilling for production blasting or presplitting the slope face and production
blasting may be done at the same time, provided that the presplitting drill holes are fired with
zero delay and the production holes are delayed starting at the row of holes farthest from the
slope and progressing in steps to the row of holes nearest the presplit lines, which row shall be
delayed at least 50 milliseconds. In either case the presplitting holes shall extend either to the
end of the excavation or for a distance of not less than 15 m beyond the limits of the production
holes to be detonated.
The area of presplitting to be paid for, will be measured as square metres of acceptable presplit
slope surface.
Clause 303.5 Rates
The Contract unit rate for presplitting work shall be payment in full for carrying out the required
operations for obtaining acceptable presplit slope surfaces. The quantity of rock excavated
through the production/presplit holes shall be paid for as per Clause 301.9.1.
7. Clause 304 EXCAVATION FOR STRUCTURES

Clause 304.1 Scope
Excavation for structures shall consist of the removal of material for the construction of
foundation for bridges, culverts, retaining walls, headwalls, cutoff walls, pipe culverts and other
similar structures, in accordance with the requirements of these Specifications and the lines and
dimensions shown on the drawings or as indicated by the Engineer. The work shall include
construction of the necessary cofferdams and cribs and their subsequent removal; all necessary
sheeting, shoring, bracing, draining and pumping; the removal of all logs, stumps, grubs and other
deleterious matter and obstructions, necessary for placing the foundations; trimming bottoms of
excavations; backfilling and clearing up the site and the disposal of all surplus material.
Clause 304.3.4 Preparation of Foundation
The bottom of the foundation shall be leveled both longitudinally and transversely or stepped as
directed by the Engineer. Before footing is laid, the surface shall be slightly watered and rammed
in the event of excavation having been made deeper than that shown on the drawings or as
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otherwise ordered by the Engineer, the extra depth shall be made up with concrete or masonry
of the foundation at the cost of the Contractor as per Clause 210.4.1. Ordinary filling shall not be
used for the purpose to bring the foundation to the design level as shown in drawing.
When rock or other hard strata is encountered it shall be freed of all soft and loose material,
cleaned and cut to a firm surface either level and stepped as directed by the Engineer. All seams
shall be cleaned out and filled with cement mortar or grout to the satisfaction of the Engineer. In
the case of excavation in rock, annular space around footing shall be filled with lean concrete (M-
15) upto the top level of rock.
If the depth of fill required is more than 1.5 m above the top of the footing, filling upto 1.5m
above top of footing shall be done with lean concrete (M-15) followed by boulders grouted with
cement.
When foundation piles are used, the excavation of each pit shall be substantially completed
before beginning pile-driving operations therein. After pile driving operations in a given pit are
completed, all loose and displaced materials therein shall be removed to the elevation of the
bottom of the footings.
Clause 304.3.6 Public Safety

Near towns, villages and all frequented places, trenches and foundation pits shall be securely
fenced, provided with proper caution signs and marked with red lights at night to avoid
accidents. The Contractor shall take adequate protective measures to see that the excavation
operations do not affect or damage adjoining structures. For safety precautions, guidance may be
taken from IS:3764.
Clause 304.3.7 Backfilling

Backfilling shall be done with approved material after concrete or masonry is fully set and carried out
in such a way as not to cause undue thrust on any part of the structure. All space between foundation
masonry or concrete and the sides of excavation shall be refilled to the original surface in layers not
exceeding 150 mm compacted thicknesses. The compaction shall be done with the help of suitable
equipment such as trench compactor, mechanical tamper, rammer, plate vibrator etc., after
necessary watering, so as to achieve the maximum dry density.
Clause 304.5.1 The Contract unit rate for the items of excavation for structures shall be
payment in full for carrying out the required operations including full compensation for:
i) setting out;
ii) transporting the excavated materials for use or disposal with all leads and lifts;
iii) construction of necessary cofferdams, cribs/sheeting, shoring and bracing and
their subsequent removal;
Page 19
iv) removal of all logs, stumps, grubs and other deleterious matter and obstructions,
for placing the foundations including trimming of bottoms of excavations;
v) foundation sealing, dewatering including pumping when no separate provision
for it is made in-the Contract;
vi) backfilling, clearing up the site and disposal of all surplus material with all leads
and lifts or as otherwise specified; and
vii) all labour, materials, tools, equipment, safety measures, diversion of traffic and
incidentals necessary to complete the work to Specifications.
Clause 304.5.2 Rates

The Contract unit rate for preparation of rock foundation shall be full compensation for cutting,
trimming and cleaning the foundation surface and filling/sealing of all seams with cement grout
or mortar including all materials, labour and incidentals required for completing the work.
8. Clause 305 EMBANKMENT CONSTRUCTION
Clause 305.1.1 Description
These Specifications shall apply to the construction of embankments including subgrades,

earthen shoulders and miscellaneous backfills with approved material obtained from roadway
and drain excavation, borrow pits or other sources. All embankments, subgrades, earthen
shoulders and miscellaneous backfills shall be constructed in accordance with the requirements
of these Specifications and in conformity with the lines, grades, and cross-sections shown on the
drawings or as directed by the Engineer.
Clause 305.2 Materials and General Requirements
Clause 305.2.1 Physical requirements
Clause 305.2.1.1. The materials used in embankments, subgrades, earthen shoulders and
miscellaneous backfills shall be soil, moorum, gravel, a mixture of these or any other material
approved by the Engineer. Such materials shall be free of logs, stumps, roots, rubbish or any
other ingredient likely to deteriorate or affect the stability of the embankment/subgrade.
The following types of material shall be considered unsuitable for embankment:

a) Materials from swamps, marshes and bogs;
b) Peat, log, stump and perishable material; any soil that classifies as OL, 01,
OH or Pt in accordance with IS:1498;
c) Materials susceptible to spontaneous combustion;
d) Materials in a frozen condition;
e) Clay having liquid limit exceeding 50 and plasticity index exceeding 25; and
f) Materials with salts resulting in leaching in the embankment.
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Clause 305.2.1.3Any fill material with a soluble sulphate content exceeding 1.9 grams of sulphate (expressed as
SO3) per litre when tested in accordance with BS:1377, Part 3, but using a 2:1 water-soil ratio shall not be deposited within
500 mm distance(or any other distance described in the Contract), of permanent works constructed out of concrete,
cement bound materials or other cementitious material.
Materials with a total sulphate content (expressed as SO3) exceeding 0.5 percent by mass, when tested in
accordance with BS:1377, Part 3 shall not be deposited within 500 mm, or other distances described in the
Contract, of metallic items forming part of the Permanent Works.
Clause 305.2.1.4 The size of the coarse material in the mixture of earth shall ordinarily not exceed 75
mm when placed in the embankment and 50 mm when placed in the sub-grade. However, the Engineer may at his
discretion permit the use of material coarser than this also if he is satisfied that the same will not present any difficulty as
regards the placement of fill material and its compaction to the requirements of these Specifications. The maximum
particle size in such cases, however, shall not be more than two-thirds of the compacted layer thickness.
Clause 305.2.1.5 ordinarily, only the materials satisfying the density requirements given in Table 300-1
shall be employed for the construction of the embankment and the sub-grade.
Table 300-1: DENSITY REQUIREMENTS OF EMBANKMENT AND SUBGRADE MATERIALS.

Maximum laboratory dry unit weight
S. Type of Work
when tested as per 1S:2720 (Part 8)
No.
Embankments up to 3 m height, not subjected to Not less than 15.2 kN/cu.m

1.
extensive flooding
Not less than 16 kN/ cu.m
Embankments exceeding 3 m height or embankments of
2.
any height subject to long periods of inundation
Not less than 17.5 kN/cu.m

3. Subgrade and earthen shoulders/verges/ backfill
Clause 305.2.1.6 The material to be used in subgrade shall conform to the design CBR value at
the specified dry density and moisture content of the test specimen. In case the available materials
fails to meet the requirement of CBR, use of stabilization methods in accordance with Clauses 403
and 404 or by any stabilization method approved by the Engineer or by the IRC Accreditation
Committee shall be followed.
Clause 305.2.1.7 The material to be used in high embankment construction shall satisfy the
specified requirements of strength parameters.
Clause 305.2.2 General Requirements
Clause 305.2.2.1 The materials for embankment shall be obtained from approved sources
with preference given to acceptable materials becoming available from nearby roadway
excavation under the same Contract.
Page 21
The work shall be so planned and executed that the best available materials are saved for the
subgrade and the embankment portion just below the subgrade.
Clause 305.2.2.2 Borrow materials
The arrangement for the source of supply of the material for embankment and sub-grade and compliance with
the guidelines, and environmental requirements, in respect of excavation and borrow areas as stipulated, from
time to time by the Ministry of Environment and Forests, Government of India and the local bodies, as
applicable shall be the sole responsibility of the Contractor.
Borrow pits along the road shall be discouraged. If permitted by the Engineer, these shall not be dug
continuously. Ridges of not less than 8 in width should be left at intervals not exceeding 300 m. Small drains
shall be cut through the ridges to facilitate drainage. The depth of the pits shall be so regulated that their
bottom does not cut an imaginary line having a slope of 1 vertical to 4 horizontal projected from the edge of
the final section of the bank, the maximum depth in any case being limited to 1.5 m. Also, no pit shall be dug
within the offset width of a minimum of 10 m.
Haulage of material to embankments or other areas of fill shall proceed only when sufficient spreading and
compaction plant is operating at the place of deposition.
Where the excavation reveals a combination of acceptable and unacceptable materials, the Contractor shall,
unless otherwise agreed by the Engineer, carry out the excavation in such a manner that the acceptable
materials are excavated separately for use in the permanent works without contamination by the unacceptable
materials. The acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the stability of excavation or fills by the methods
of stockpiling materials, use of plants or siting of temporary buildings or structures.
Clause 305.2.2.3 Fly-Ash

Use of fly-ash shall conform to the Ministry of Environment and Forest guidelines. Where fly-
ash is used the embankment construction shall conform to the physical and chemical
properties and requirements of IRC: SP: 38-2001, "Guidelines for Use of Flyash in Road
Construction". The term fly-ash shall cover all types of coal ash such as pond ash, bottom ash
or mound ash.
Embankment constructed out of fly ash shall be properly designed to ensure stability and protection
against erosion in accordance with IRC guidelines. A suitable thick cover may preferably be provided
at intervening layers of pond ash for this purpose. A thick soil cover shall bind the edge of the
embankment to protect it against erosion. Minimum thickness of such soil cover shall be 500 mm.
Clause 305.2.2.4 Compaction Requirements
The Contractor shall obtain representative samples from each of the identified borrow areas and
have these tested at the site laboratory following a testing programme approved by the Engineer. It
shall be ensured that the subgrade material when compacted to the density requirements as in Table
300-2 shall yield the specified design CBR value of the sub-grade.
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Table 300-2: Compaction requirements for embankment and subgrade

Relative compaction as perscentage of
Sl. No. Type of Work / Material maximum laboratory dry density as per IS:2720
(Part 8)
1. Subgrade and earthen shoulders Not less than 97%
2. Embankment Not less than 95%
Expansive clays
a) Subgrade and 500 mm portion just Not Allowed
3.
below the subgrade
b) Remaining portion of embankment 90-95%
The contractor shall atleast 7 working days before commencement of compaction submit the
following to the Engineer for approval:
i) The Values of maximum dry density and optimum moisture content obtained in
accordance with IS:2720 (Part 8) for each fill material he intends to use.
A the graphs showing values of dry density against moisture content from which each
of the values in (i) above of maximum dry density and optimum moisture content were
determined.
ii) The dry density - moisture content- CBR relationship for each of the fill materials he
intends to use in the subgrade'.
Once the above information has been approved by the Engineer, it shall form the basis for
compaction.
Clause 305.3.1 Setting Out
After the site has been cleared to Clause 201, the work shall be set out to Clause 301.3.1 The limits of
embankment/sub-grade shall be marked by fixing batter pegs on both sides at regular intervals as guides
before commencing the earthwork. The embankment/sub-grade shall be built sufficiently wider than the
design dimension so that surplus material may be trimmed, ensuring that the remaining material is to the
desired density and in position specified and conforms to the specified side slopes.
Clause 305.3.2 Dewatering
If the foundation of the embankment is in an area with stagnant water, and in the opinion of the Engineer
it is feasible to remove it, the same shall be removed by bailing out or pumping, as directed by the
Engineer and the area of the embankment foundation shall be kept dry. Care shall be taken to discharge
the drained water so as not to cause damage to the works, crops or any other property. Due to any
negligence on the part of the Contractor, if any such damage is caused, it shall be the sole responsibility of
the Contractor to repair/restore it to original condition or compensate for the damage at his own cost.
If the embankment is to be constructed under water, Clause 305.4.6 shall apply.
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Clause 305.3.3 Stripping and Storing Topsoil
When so directed by the Engineer, the topsoil from all areas of cutting and from all areas to be covered by
embankment foundation shall be stripped to specified depths not exceeding 150 mm and stored in
stockpiles of height not exceeding 2 m for covering embankment slopes, cut slopes and other disturbed
areas where re-vegetation is desired. Topsoil shall not be unnecessarily subjected to traffic either before
stripping or when in a stockpile. Stockpiles shall not be surcharged or otherwise loaded and multiple
handling shall be kept to a minimum
Clause 305.3.4 Compacting ground supporting embankment/subgrade

Where necessary, the original ground shall be levelled, mixed with water and then compacted by
rolling to facilitate placement of 1st layer embankment and its compaction in accordance with the
requirement as given in table 300.2.
In case where the difference between the subgrade level (top of the subgrade on which
pavement rests) and ground level is less than 0.5 m and the ground does not have 97 percent
relative compaction with respect to the dry density as given in Table 300-2, the ground shall be
loosened upto a level 0.5 m below the subgrade level, watered and compacted in layers in
accordance with Clauses 305.3.5 and 305.6 to not less than 97 per cent of dry density as given in
Table 300-2.
Where necessary to facilitate compaction of the subgrade to 97% relative compaction as stated
above, a further depth of maximum of 0.20m thickness shall be loosened, watered and
compacted in accordance with Clause 305.3.5 and 305.3.6 to not less than 95% of maximum dry
density, determined in accordance with IS:2720(Part 8)."
Where so directed by the Engineer, any unsuitable material occurring in the embankment
foundation shall be removed and replaced by approved materials laid in layers to the required
degree of compaction.
Embankment or subgrade work shall not proceed until the foundations for
embankment/subgrade have been inspected by the Engineer for satisfactory condition and
approved.
Any foundation treatment specified for embankments especially high embankments, resting on
suspect foundations as revealed by borehole logs shall be carried out in a manner and to the
depth as desired by the Engineer. Where the ground on which an embankment is to be built has
any of the material types (a) to (f) in Clause 305.2.1, at least 500 mm of such material must be
removed and replaced by acceptable fill material before embankment construction commences.
Clause 305.3.5 Spreading Material in Layers and Bringing to Appropriate Moisture

Content
Clause 305.3.5.1 The embankment and sub-grade material shall be spread in layers of uniform
thickness in the entire width with a motor grader. The compacted thickness of each layer shall
not be more than 250 mm when vibratory roller/vibratory soil compactor is used and not more
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than 200 mm when 80-100 kN static roller is used. The motor grader blade shall have hydraulic
control suitable for initial adjustment and maintain the same so as to achieve the specific slope
and grade. Successive layers shall not be placed until the layer under construction has been
thoroughly compacted to the specified requirements as in Table 300-2 and got approved by the
Engineer. Each compacted layer shall be finished parallel to the final cross-section of the
embankment.
Clause 305.3.5.2 Moisture content of the material shall be checked at the site of placement
prior to commencement of compaction; if found to be out of agreed limits, the same shall be
made good. Where water is required to be added in such constructions, water shall be sprinkled
from a water tanker fitted with sprinkler capable of applying water uniformly with a controllable
rate of flow to variable widths of surface but without any flooding. The water shall be added
uniformly and thoroughly mixed in soil by blading, using disc harrow until a uniform moisture
content is obtained throughout the depth of the layer.
If the material delivered to the roadbed is too wet, it shall be dried, by aeration and exposure to
the sun, till the moisture content is acceptable for compaction. Should circumstances arise,
where owing to wet weather, the moisture content cannot be reduced to the required amount
by the above procedure, compaction work shall be suspended.
Moisture content of each layer of soil shall be checked in accordance with IS:2720 (Part 2), and
unless otherwise mentioned, shall be so adjusted, making due allowance for evaporation losses,
that at the time of compaction it is in the range of 1 percent above to 2 percent below the
optimum moisture content determined in accordance with IS:2720 (Part 8) as the case may be.
Expansive clays shall, however, be compacted at moisture content corresponding to the specified
dry density, but on the wet side of the optimum moisture content obtained from the laboratory
compaction curve.
After adding the required amount of water, the soil shall be processed by means of graders,
harrows, rotary mixers or as otherwise approved by the Engineer until the layer is uniformly wet.
Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when being
placed in the embankment and a maximum size of 50 mm when being placed in the sub-grade.
Clause 305.3.5.3 Embankment and other areas of fill shall, unless otherwise required in the
Contract or permitted by the Engineer, be constructed evenly over their full width and their
fullest possible extent and the Contractor shall control and direct construction plant and other
construction vehicles. Damage by construction plant and other vehicular traffic shall be made
good by the Contractor with material having the same characteristics and strength of the
material before it was damaged.
Embankments and unsupported fills shall not be constructed with steeper side slopes or to
greater widths than those shown in the drawings, except to permit adequate compaction at the
Page 25
edges before trimming back, or to obtain the final profile following any settlement of the fill and
the underlying material,
Whenever fill is to be deposited against the face of a natural slope, or sloping earthworks face
including embankments, cuttings, other fills and excavations steeper than 1 vertical to 4
horizontal, such faces shall be benched as per Clause 305.4.1 immediately before placing the
subsequent fill.
All permanent faces of side slopes of embankments and other areas of fill shall, subsequent to
any trimming operations, be reworked and sealed to the satisfaction of the Engineer by tracking a
tracked vehicle, considered suitable by the Engineer, on the slope or any other method approved
by the Engineer.
Clause 305.3.6 Compaction
Only the compaction equipment approved by the Engineer shall be employed to compact the
different material types encountered during construction. Static three-wheeled roller, self-
Propelled single drum vibratory roller, tandem vibratory roller, pneumatic tyre roller, pad foot
roller, etc., of suitable size and capacity as approved by the Engineer shall be used for the
different types and grades of materials required to be compacted either individually or in suitable
combinations.
The compaction shall be done with the help of self-propelled single drum vibratory roller or pad
foot vibratory roller of 80 to 100 kN static weight or heavy pneumatic tyre roller capable of
achieving required compactions. The Contractor shall demonstrate the efficacy of the equipment
he intends to use by carrying out compaction trials. The procedure to be adopted for these site
trials shall first be submitted to the Engineer for approval.
Earthmoving plant shall not be accepted as compaction equipment nor shall the use of a lighter
category of plant to provide any preliminary compaction to assist the use of heavier plant be
taken into account.
Each layer of the material shall be thoroughly compacted to the densities specified in Table 300-
2. Subsequent layers shall be placed only after the finished layer has been tested according to
Clause 903.2.2 and accepted by the Engineer. The Engineer may permit measurement of field dry
density by a nuclear moisture/density gauge used in accordance with agreed procedure and the
gauge is calibrated to provide results identical to that obtained from tests in accordance with IS:
2720 (Part 28). A record of the same shall be maintained by the Contractor.
When density measurements reveal any soft areas in the embankment/subgrade/earthen
shoulders, further compaction shall be carried out as directed by the Engineer. If in spite of that
the specified compaction is not achieved, the material in the soft areas shall be removed and
replaced by approved material, compacted to the density requirements and satisfaction of the
Engineer.
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Clause 305.3.7 Drainage

The surface of the embankment/subgrade at all times during construction shall be maintained at
such a cross fall (not flatter than that required for effective drainage of an earthen surface) as will
shed water and prevent ponding.
Clause 305.3.8 Repairing of Damages Caused by Rain/Spillage of Water
The soil in the affected portion shall be removed in such areas as directed by the Engineer before
next layer is laid and refilled in layers and compacted using appropriate mechanical means such
as small vibratory roller, plate compactor or power rammer to achieve the required density in
accordance with Clause 305.3.6. If the cut is not sufficiently wide for use of required mechanical
means for compaction, the same shall be widened suitably to permit their use for proper
compaction. Tests shall be carried out as directed by the Engineer to ascertain the density
requirements of the repaired area. The work of repairing the damages including widening of the
cut, if any, shall be carried out by the Contractor at his own cost, including the arranging of
machinery/equipment for the purpose.
Clause 305.3.9 Finishing Operations
Finishing operations shall include the work of shaping and dressing the shoulders/verge/ roadbed
and side slopes to conform to the alignment, levels, cross-sections and dimensions shown on the
drawings or as directed by the Engineer subject to the surface tolerance described in Clause 902.
Both the upper and lower ends of the side slopes shall be rounded off to improve appearance
and to merge the embankment with the adjacent terrain.
The topsoil, removed and conserved earlier (Clauses 301.3.2 and 305.3.3) shall be spread over
the fill slopes as per directions of the Engineer to facilitate the growth of vegetation. Slopes shall
be roughened and moistened slightly prior to the application of the topsoil in order to provide
satisfactory bond. The depth of the topsoil shall be sufficient to sustain plant growth, the usual
thickness being from 75 mm to 150 mm.
Where directed, the slopes shall be turfed with sods in accordance with Clause 307. If seeding
and mulching of slopes is prescribed, this shall be done to the requirements of Clause 308.
When earthwork operations have been substantially completed, the road area shall be cleared of
all debris, and ugly scars in the construction area responsible for objectionable appearance
eliminated.
Clause 305.4 Construction of Embankment and Sub-grade under Special Conditions
Clause 305.4.1 Earthwork for Widening Existing Road Embankment
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When an existing embankment and/or sub-grade is to be widened and its slopes are steeper than
1 vertical on 4 horizontal, continuous horizontal benches, each at least 300 mm wide, shall be cut
into the old slope for ensuring adequate bond with the fresh embankment/subgrade material to
be added. The material obtained from cutting of benches could be utilized in the widening of the
embankrnent/subgrade. However, when the existing slope against which the fresh material is to
be placed is flatter than 1 vertical on 4 horizontal, the slope surface may only be ploughed or
scarified instead of resorting to benching.
Where the width of the widened portions is insufficient to permit the use of conventional rollers,
compaction shall be carried out with the help of light weight vibratory roller, double drum walk
behind roller, vibratory plate compactor or vibratory tamper or any other appropriate equipment
approved by the Engineer. End dumping of material from trucks for widening operations shall be
avoided except in difficult circumstances when the extra width is too narrow to permit the
movement of any other types of hauling equipment.
Clause 305.4.2 Earthwork for Embankment and Sub-Grade to be Placed Against Sloping
Ground
Where an embankment/subgrade is to be placed against sloping ground, the latter shall be

appropriately benched or ploughed/scarified as required in Clause 305.4.1 before placing the
embankment/sub-grade material. Extra earthwork involved in benching or due to ploughing
scarifying etc. shall be considered incidental to the work.
For wet conditions, benches with slightly inward fall and subsoil drains at the lowest point shall
be provided as per the drawings, before the fill is placed against sloping ground.
Where the Contract requires construction of transverse subsurface drain at the cut-fill interface,
work on the same shall be carried out to Clause 309 in proper sequence with the embankment
and sub-grade work as approved by the Engineer.
Clause 305.4.5 Construction of Embankment over Ground Incapable of Supporting

Construction Equipment
Where embankment is to be constructed across ground which will not support the weight of
repeated heavy loads of construction equipment, the first layer of the fill may be constructed by
placing successive loads of material in a uniformly distributed layer of a minimum thickness
required to support the construction equipment as permitted by the Engineer. The Contractor, if
so desired by him, may also use suitable geosynthetic material to increase the bearing capacity of
the foundation. This exception to normal procedure will not be permitted where, in the opinion
of the Engineer, the embankments could be constructed in the approved manner over such
ground by the use of lighter or modified equipment after proper ditching and drainage have been
provided. Where this exception is permitted, the selection of the material and the construction
procedure to obtain an acceptable layer shall be the responsibility of the Contractor. The cost of
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providing suitable traffic conditions for construction equipment over any area of the Contract will
be the responsibility of the Contractor and no extra payment will be made to him. The remainder
of the embankment shall be constructed as specified in Clause 305.3.
Clause 305.4.6 Embankment Construction under Water and Waterlogged Areas
Clause 305.4.6.1 Embankment Construction under Water
Where filling or backfilling is to be placed under water, only acceptable granular material or rock
shall be used unless otherwise approved by the Engineer. Acceptable granular material shall be of
GW, SW, GP, SP as per IS:1498 and consist of graded, hard durable particles with maximum
particle size not exceeding 75 mm. The material should be non-plastic having uniformity
coefficient of not less than 10. The material placed in open water shall be deposited by end
tipping without compaction.
Clause 305.4.6.2 Embankment Construction in Waterlogged and Marshy Areas
The work shall be done as per IRC: 34.
Clause 305.4.7 Earthwork for High Embankment
The material for high embankment construction shall conform to Clause 305.2.1.7. In the case of
high embankments (more than 6 m), the Contractor shall normally use fly ash in conformity with
Clause 305.2.1.1 or the material from the approved borrow area.
Where provided, stage construction of embankment and controlled rates of filling shall be carried
out in accordance with the Contract including installation of instruments and its monitoring.
Where required, the Contractor shall surcharge embankments or other areas of fill with approved
material for the periods specified in the Contract. If settlement of surcharged fill results the
Contractor shall bring the resultant level up to formation level with acceptable material for use in
fill.
Clause 305.4.8 Settlement Period
Where settlement period is specified in the Contract, the embankment shall remain in place for
the required settlement period before excavating for abutment, wing wall, retaining wall,
footings, etc., or driving foundation piles. The duration of the required settlement period at each
location shall be as provided for in the Contract or as directed by the Engineer.
Clause 305.5 Plying of Traffic
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Construction and other vehicular traffic shall not use the prepared surface of the embankment
and/or sub-grade without the prior permission of the Engineer. Any damage arising out of such
use shall, however, be made good by the Contractor at his own cost as directed by the Engineer.
Clause 305.6 Surface Finish and Quality Control of Work
The surface finish of construction of sub-grade shall conform to the requirements of Clause 902.
Control on the quality of materials and works shall be exercised in accordance with Clause 903.
Clause 305.7 Sub-grade Strength
Clause 305.7.1 It shall be ensured prior to actual execution that the material to be used in
the sub-grade satisfies the requirements of design CBR.
Clause 305.7.2 Sub-grade shall be compacted and finished to the design strength
consistent with other physical requirements. The actual laboratory CBR values of constructed
sub-grade shall be determined on remoulded samples, compacted to the field density at the field
moisture content and tested for soaked/unsoaked condition as specified in the Contract.
Clause 305.8.1 Earth embankment/sub-grade construction shall be measured separately

by taking cross sections at intervals given in Sub-Section 113.3 after completion of clearing and
grubbing and after completion of embankment/sub-grade. The volume of earthwork shall be
computed in cubic metres by the method of average end areas.
Clause 305.8.2 The measurement of fill material from borrow areas shall be the difference
between the net quantities of compacted fill and the net quantities of suitable material brought
from roadway and drainage excavation. For this purpose, it shall be assumed that one cu.m of
suitable material brought to site from road and drainage excavation forms one cu.m of
compacted fill and all bulking or shrinkage shall be ignored.
Clause 305.8.3 The embankment constructed with fly ash will be measured in cu.m,
separately for the fly ash portions and for the soil cover and intervening layers of soil, unless
otherwise specified in the Contract.
Clause 305.8.4 Construction of embankment under water shall be measured in cu.m.
Clause 305.8.5 Construction of high embankment with specified material and in specified
manner shall be measured in cu.m.
Clause 305.8.6 Stripping including storing and reapplication of top soil shall be measured
in cu.m.
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Clause 305.8.7 Work involving loosening and recompacting of ground supporting

embankment/sub-grade shall be measured in cu.m.
Clause 305.8.8 Removal of unsuitable material at embankment/sub-grade foundation and

replacement with suitable material shall be measured in cu.m.
Clause 305.8.9 Scarifying existing granular/bituminous road surface shall be measured in square
metres.
Clause 305.8.10 Dismantling and removal of existing cement concrete pavement shall be
measured vide Clause 202.6.
Clause 305.3.11 Filter medium and backfill material behind abutments, wing walls and
other retaining structures shall be measured as finished work in position in cu.m.
Clause 305.9 Rates
Clause 305.9.1 The Contract unit rates for the items of embankment and subgrade construction
shall be payment in full for carrying out the required operations including full compensation for:
(i) Cost of arrangement of land as a source of supply of material of required quantity
for construction unless provided otherwise in the Contract;
(ii) Setting out;
(iii) Compacting ground supporting embankment/subgrade except where removal and
replacement of unsuitable material or loosening and recompacting is involved;
(iv) Scarifying or cutting continuous horizontal benches 300 mm wide on side slopes of
existing embankment and subgrade as applicable;
(v) Cost of watering or dying of material including removal of top soil in borrow areas
and/or embankment and subgrade during construction as required;
(vi) Spreading in layers, bringing to appropriate moisture content and compacting to
Specification requirements;
(vii) Shaping and dressing top and slopes of the embankment and subgrade including
rounding of corners;
(viii) Restricted working at sites of structures;
(ix) Working on narrow width of embankment and subgrade;
(x) Excavation in all soils from borrow pits/designated borrow areas including clearing
and grubbing and transporting the material to embankment and subgrade site with
all lifts and leads unless otherwise provided for in the Contract;
(xi) All labour, materials, tools, equipment and incidentals necessary to complete the
work to the Specifications;
(xii) Dewatering; and
(xiii) Keeping the embankment/completed formation free of water as per Clause 311.
(xiv) Transporting unsuitable excavated material for disposal with all leads and lifts.
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Clause 305.9.2 Clause 301.9.5 shall apply as regards Contract unit rates for items of stripping
and storing top soil including reapplication of topsoil.
Clause 305.9.3 Clause 301.9.2 shall apply as regards Contract unit rate for the item of
loosening and recompacting the embankment/sub-grade foundation.
Clause 305.9.4 Clauses 309.1.1 and 305.8 shall apply as regards Contract rates for items of
removal of unsuitable material and replacement with suitable material, respectively.
Clause 305.9.5 The Contract unit rate for scarifying existing granular/bituminous road surface
shall be payment in full for carrying out the required operations including full compensation for all
labour, materials, tools, equipment and incidentals, necessary to complete the work. This will also
comprise of handling, giving credit towards salvage value and disposal of the dismantled materials
with all leads and lifts or as otherwise specified.
Clause 305.9.6 Clause 202.7 shall apply as regards Contract unit rate for dismantling and
removal of existing cement concrete pavement.
Clause 305.9.7 The Contract unit rate for providing and laying filter material shall be payment
in full for carrying out the required operations including all materials, labour, tools, equipment and
incidentals to complete the work to Specifications.
Clause 305.9.8 The Contract unit rate for providing and compacting backfill material behind
abutments and retaining walls shall be payment in full for carrying out the required operations
including all materials, labour, tools, equipment and incidentals to complete the work to
Specifications.
Clause 305.9.9 Clause 305.4.6 shall apply as regards Contract unit rate for construction of
embankment under water.
Clause 305.9.10 Clause 305.4.7 shall apply as regards Contract unit rate for construction of
high embankment. It shall include cost of instrumentation, its monitoring and settlement period,
where specified in the Contract or directed by the Engineer.
9. Clause 306 SOIL EROSION AND SEDIMENTATION CONTROL
Clause 306.1 Description
This work shall consist of measures as shown on drawings or as directed by the Engineer to control
soil erosion, sedimentation and water pollution, through use of berms, dikes, sediment basins, fibre
mats, mulches, grasses, slope drains, and other devices.
Clause 306.2 Materials
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All materials shall meet commercial grade standards and shall be approved by the Engineer before
being used in the work
Prior to the start of the relevant construction, the Contractor shall submit to the Engineer for
approval his schedules for carrying out temporary and permanent erosion/sedimentation control
works as are applicable for the items of clearing and grubbing, roadway and drainage excavation,
embankment/sub-grade construction, bridges and other structures across water courses, pavement
courses and shoulders. He shall also submit for approval his proposed method of
erosion/sedimentation control on service road and borrow pits and his plan for disposal of waste
materials. Work shall not be started until the erosion/sedimentation control schedules and methods
of operations for the applicable construction have been approved by the Engineer.
The surface area of erodible earth material exposed by clearing and grubbing, excavation, borrow
and fill operations shall be limited to the extent practicable. The Contractor shall provide immediate
permanent or temporary erosion, slope protection and sedimentation control measures to prevent
soil erosion and sedimentation that will adversely affect construction operations, damage adjacent
properties, or cause contamination of nearby streams or other water courses, lakes, reservoirs etc.
Such work may involve the construction of temporary berms, dikes, sediment basins, slope drains
and use of temporary mulches, fabrics, mats seeding, or other control devices or methods as
necessary to control erosion and sedimentation. Cut and fill slopes shall be seeded and turfed as
shown on the drawings.
The Contractor shall be required to incorporate all permanent erosion and sedimentation control
features into the project at the earliest practicable time as outlined in his accepted schedule to
minimize the need for temporary erosion and sedimentation control measures.
Temporary erosion/sedimentation and pollution control measures shall be used to control. the
phenomenon of erosion, sedimentation and pollution that may develop during normal construction
practices, but may neither be foreseen during design stage nor associated with permanent control
features on the Project.
Where erosion or sedimentation is likely to be a problem, clearing and grubbing operations should
be so scheduled and performed that grading operations and permanent erosion or sedimentation
control features can follow immediately thereafter if the project conditions permit; otherwise
temporary erosion or sedimentation control measures may be required.
Between successive construction stages. Under no conditions shall a large. Surface of erodible earth
material be exposed at one time by clearing and grubbing or excavation without prior approval of
the Engineer.
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The Engineer may limit the area of excavation, borrow and embankment operations in progress,
commensurate with the Contractor's capability and progress in keeping the finish grading, mulching,
seeding and other such permanent erosion, sedimentation and pollution control measures, in
accordance with the accepted schedule. Should seasonal limitations make such coordination
unrealistic, temporary erosion/sedimentation control measures shall be taken immediately to the
extent feasible and justified.
In the event temporary erosion, sedimentation and pollution control measures become necessary
due to the Contractor's negligence, carelessness or failure to install permanent controls as a part of
the work as scheduled or ordered by the Engineer, these shall be carried out at the Contractor's own
cost. Temporary erosion, sedimentation and pollution control work required, which is not attributed
to the Contractor's negligence, carelessness or failure to install permanent controls, will be
performed as ordered by the Engineer.
Temporary erosion, sedimentation and pollution control may include construction work outside the
right-of-way where such work is necessary as a result of road construction such as borrow pit
operations, service roads and equipment storage sites.
The temporary erosion, sedimentation and pollution control features installed by the Contractor
shall be acceptably maintained by him till these are needed, unless otherwise agreed by the
Engineer.
Clause 306.4 Measurement for Payment
The soil erosion, sedimentation and pollution control works shall be measured in terms of units
specified in the Bill of Quantities for the respective items.
Clause 306.5 Rates
The Contract unit rate for different items of soil erosion, sedimentation and pollution control works
shall be payment in full for carrying out all required operations including full compensation for all
labour, materials, tools, equipment and incidentals to complete the works to the Specifications.
10. Clause 307 TURFING WITH SODS
Clause 307.1 Scope
This work shall consist of furnishing and laying of the live sod of perennial turf forming grass on
Section 300 Earthwork, Erosion Control and Drainage embankment slopes, verges (earthen
shoulders) or other locations shown on the drawings or as directed by the Engineer. Unless
otherwise specified, the work shall be taken up as soon as possible following construction of the
embankment, provided the season is favorable for establishment of the sod.
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The sod shall consist of dense, well-rooted growth of permanent and desirable grasses, indigenous
to the locality where it is to be used, and shall be practically free from weeds or other undesirable
matter. At the time the sod is cut, the grass on the sod shall have a length of approximately 50 mm
and the sod shall have been freed of debris.
Thickness of the sod shall be as uniform as possible, with some 50-80 mm or so of soil covering the
grass roots depending on the nature of the sod, so that practically all the-dense root system of the
grasses is retained in the sod strip. The sods shall be cut in rectangular strips of uniform width, not
less than about 250 mm x 300 mm in size but not so large that it is inconvenient to handle and
transport these without damage. During wet weather, the sod shall be allowed to dry sufficiently to
prevent tearing during handling and during dry weather shall be watered before lifting to ensure its
vitality and prevent the dropping of the soil in handling.
Clause 307.3.1 Preparation of the Earth Bed
The area to be sodded shall have been previously constructed to the required slope and cross-
section. Soil on the area shall be loosened, freed of all stones larger than 50 mm size, sticks, stumps
and any undesirable foreign matter, and brought to a reasonably fine granular texture to a depth of
not less than 25 mm for receiving the sod.
Where required, topsoil shall be spread over the slopes. Prior to placing the topsoil, the slopes shall
be scarified to a depth which, after settlement, will provide the required nominal depth shown on
the drawings. Spreading shall not be done when the ground is excessively wet.
Following soil preparation and top soiling, where required, fertilizer and ground limestone when
specified shall be spread uniformly at the rate indicated on the drawings. After spreading, the
materials shall be incorporated in the soil by using disc harrow or other means to the depths shown
on the drawings.
Clause 307.3.2 Placing the Sods
The prepared sod bed shall be moistened to the loosened depth, if not already sufficiently moist,
and the sod shall be placed thereon within approximately 24 hours after the same had been cut.
Each sod strip shall be laid edge to edge and such that the joints caused by abutting ends are
staggered. Every strip, after it is snugly placed against the strips already in position, shall be lightly
tamped with suitable wooden or metal tampers so as to eliminate air pockets and to press it into the
underlying soil.
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On side slopes steeper than 2 (horizontal) to 1 (vertical), the laying of sods shall be started from
bottom upwards. At points where water may flow over a sodded area, the upper edges of the sod
strips shall be turned into the soil below the adjacent area and a layer of earth placed over this
followed by its thorough compaction.
Clause 307.3.3 Staking the Sods
Where the side slope is 2 (horizontal) to 1 (vertical) or steeper and the distance along the slope is
more than 2 m, the sods shall be staked with pegs or nails spaced approximately 500 to 1000 mm
along the longitudinal axis of the sods strips. Stakes shall be driven approximately plumb through
the sods to be almost flush with them.
Clause 307.3.4 Top Dressing
After the sods have been laid in position, the surface shall be cleaned of loose sod, excess soil and
other foreign material. Thereafter, a thin layer of topsoil shall be scattered over the surface of top
dressing and the area thoroughly moistened by sprinkling with water.
Clause 307.3.5 Watering and Maintenance
The sods shall be watered by the Contractor for a period of at least four weeks after laying. Watering
shall be so done as to avoid erosion and prevent damage to sodded areas by wheels of water tanks.
The Contractor shall erect necessary warning signs and barriers, repair or replace sodded areas
failing to show uniform growth of grass or damaged by his operations and shall otherwise maintain
the sod at his cost until final acceptance.
Turfing with sods shall be measured as finished work in square metres.
Clause 307.5 Rate
The Contract unit rate for turfing with sods shall mean paying in full for carrying out all the required
operations explained above including compensation for
i) furnishing all the materials to be incorporated in the Works with all leads and lifts; and all
labour, tools, equipment and incidentals to complete the work in accordance with these
Specifications.
The Contract unit rate for application of topsoil shall be as per Clause 301.9.5.
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11. Clause 308 SEEDING AND MULCHING
Clause 308.1 Scope
This shall consist of preparing slopes, placing topsoil, furnishing all seeds, commercial or organic
fertilizers and mulching materials, providing jute netting, coir netting, or polymer netting and placing
and incorporating the same on embankment slopes or other locations designated by the Engineer or
shown in the Contract documents.
Clause 308.2.1 Seeds
The seeds shall be of approved quality and type suitable for the soil on which these are to be
applied, and shall give acceptable purity and germination to requirements set down by the Engineer.
Fertilizers shall consist of standard commercial materials and conform to the grade specified.
Organic manure shall be fully putrified organic matter such as cow dung.
Mulching materials shall consist of straw, hay, wood shavings, or sawdust and shall be delivered in
dry condition suitable for placing with a mulch blower. They shall be reasonably free of weed seed
and such foreign materials as may detract from their effectiveness as a mulch or be injurious to the
plant growth.
Clause 308.2.2 Topsoil
Topsoil shall not be obtained from an area known to have noxious weeds growing in it. If treated
with herbicide or sterilents, it shall be got tested by appropriate agricultural authority to determine
the residual in the soil. Topsoil shall not contain less than 2 percent and more than 12 percent
organic matter.
Clause 308.2.3 Bituminous Emulsion
A suitable grade of bituminous emulsion used as a tie down for mulch shall be as described in the
Contract document or as desired by the Engineer. Emulsified bitumen shall not contain any solvent
or diluting agent toxic to plant life.
Clause 308.2.4 Netting
Jute netting shall be undyed jute yarn woven into a uniform open weave with approximate 25 mm
square openings.
Geonetting shall be made of uniformly extruded rectangular mesh having mesh opening of 20 mm x
20 mm. The colour may be black or green. It shall weigh not less than 3.8 kg per 1000 sqm.
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Clause 308.2.5 A layer of biodegradable mulching material sandwiched between two layers of
polymer netting or non-woven coconut fibre coir netting can also be used.
Clause 308.3 Seeding Operations
Clause 308.3.1 Seed-Bed Preparation
The area to be seeded shall be brought to the required slope and cross-section by filling, reshaping
eroded areas and refinishing slopes, medians etc. Topsoil shall be evenly spread over the specified
areas to the depth shown on the drawings, unless otherwise approved by the Engineer. The seed-
bed preparation shall consist of eliminating all live plants by suitable means using agricultural
implements. All stones 150 mm and larger shall be removed. The soil shall be excavated on the
contour to a depth of 100 mm. All clods larger than 25 mm in diameter shall be crushed and packed.
Where necessary, water shall then be applied. All topsoil shall be compacted unless otherwise
specified or approved by the Engineer. Compaction shall be by slope compactor, cleated tractor or
similar equipment approved by the Engineer. Equipment shall be so designed and constructed as to
produce a uniform rough textured surface ready for seeding and mulching and which will bond the
topsoil to the underlying material. The entire area shall be covered by a minimum of 4 passes of the
roller or approved equipment.
Clause 308.3.2 Fertilizer Application
Fertilizer to the required quantities shall be spread and thoroughly incorporated into the soil surface
as a part of the seed-bed preparation.
Clause 308.3.3 Planting of Seeds
All seeds shall be planted uniformly at the approved rate. Immediately after sowing, the area shall
be raked, dragged or otherwise treated so as to cover the seeds to a depth of 6 mm.
The operation of seed sowing shall not be performed when the ground is muddy or when the soil or
weather conditions would otherwise prevent proper soil preparation and subsequent operations.
Clause 308.3.4 Soil Moisture and Watering Requirements
Soil moisture shall exist throughout the zone from 25 mm to at least 125 mm below the surface
at the time of planting.
Watering of the seeded areas shall be carried out as determined by the Engineer.
Clause 308.4 Mulching, Applying Bituminous Emulsion and Jute Netting/Geonetting/ Netting of
Coir
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Within 24 hours of seeding, mulching material mixed with organic manure shall be placed so as to
form a continuous, unbroken cover of approximate uniform thickness of 25 mm using an acceptable
mechanical blower. Mulching material shall be held in place and made resistant to being blown
away by suitable means approved by the Engineer. When called for in the Contract documents,
mulch material shall be anchored in place with bituminous emulsion applied at the rate of 2300
litres per hectare. Any mulch disturbed or displaced following application shall be removed,
reseeded and remulched as specified. Jute netting/geonetting or netting of coir shall be unrolled and
placed parallel to the flow of water immediately following the bringing, to finished grade, the area
specified on the drawings or the placing of seed and fertilizer. Where more than one strip is required
to cover the given areas, they shall overlap a minimum of 100 mm. Jute netting/Geonetting /coir
netting shall be held in place by approved wire staples, pins, spikes or wooden stakes driven
vertically into the soil.
Clause 308.5 Maintenance
The Contractor shall maintain all seeded and mulched areas until final acceptance. Maintenance
shall include protection of traffic by approved warning signs or barricades and repairing any areas
damaged following the seeding and mulching operations. If mulched areas become damaged, the
area shall be reshaped and then seeded and mulched again as originaly specified.
Clause 308.6 Measurements of Payment
Seeding and mulching shall be measured as finished work in square metres.
Clause 308.7 Rate
The Contract unit rate for seeding and mulching shall be payment in full for carrying out all the
required operations including full compensation for all materials, labour, tools and incidentals.
Clause 309 Surface / Sub surface drain

Clause 309.1 Scope
This work shall consist of constructing surface and /or sub-surface drains in accordance with the
requirements of these Specifications and to the lines, grades dimensions and other particulars
shown on the drawings or as directed by the Engineer. Schedule of work shall be so arranged that
the drains are completed in proper sequence with road works to ensure that no excavation of the
completed road works is necessary subsequently or any damage is caused to these works due to
lack of drainage.
Clause 309.2 Surface Drains

Surface drains shall be excavated to the specified lines, grades, levels and dimensions to the
requirements of Clause 301. The excavated material shall be removed from the area adjoining
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the drains and if found suitable, utilised in embankment /subgrade construction. All unsuitable
material shall be disposed of as directed.
The excavated bed and sides of the drains shall be dressed to bring these in close conformity with
the specified dimensions, levels and slopes.
Where so indicated, drains shall be lined or dressed to bring these in close conformity with the
specified dimensions, levels and slopes.
All works on drain construction shall be planned and executed in proper sequence with other
works as approved by the Engineer, with a view to ensuring adequate drainage for the area and
minimising erosion/sedimentation.
Clause 309.3 Sub-Surface Drains

Clause 309.3.1 Scope
Sub-surface drains shall be of close-jointed perforated pipes, open-jointed unperforated pipes,
surrounded by granular material laid in a trench or aggregate drains to drain the pavement
courses. Sub-surface drains designed using Geosynthetics and approved by the Engineer can also
be used.
Clause 309.3.2 Materials
Clause 309.3.2.1 Pipe
Perforated pipes for the drains may be metal/asbestos cement/cement concrete/Poly Vinyl
Chloride (PVC)/Poly Propylene (PP)/Poly Ethylene (PE) and unperforated pipes of metal vitrified
clay/cement concrete/asbestos cement PVC/PP/PE. The type, size and grade of the pipe to be
used shall be as specified in the Contract. In no case, however, shall the internal diameter of the
pipe be less than 100 mm. Holes for perforated pipes shall be on one half of the circumference
only and conform to the spacing indicated on the drawings. Size of the holes shall not ordinarily
be greater than half of D85 size of the material surrounding the pipe, subject to being minimum 3
mm and maximum 6 mm. D85 stands for the size of the sieve that allows 85 percent of the
material to pass through it.
Clause 309.3.2.2 Backfill Material

Backfill material shall consist of sound, tough, hard, durable particles of free draining sand-gravel
material or crushed stone and shall be free of organic material, clay balls or other deleterious
matter. Unless the Contract specifies any particular gradings for the backfill material or requires
these to be designed on inverted filter criteria for filtration and permeability to the approval of
the Engineer, the backfill material shall be provided on th'e following lines:
i) Where the soil met with in the trench is of fine grained type (e.g., silt,
clay or a mixture thereof), the backfill material shall conform to Class I grading set out in-Table 300-
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3;
ii) Where the soil met with in the trench is of coarse silt to medium sand or
sandy type, the backfill material shall correspond to Class II grading of Table 300-3; and
iii) Where soil met with in the trench is gravelly sand, the backfill material shall
correspond to Class Ill grading of Table 300-3.
Geosynthetics for use with subsurface drain shall conform to the requirements as per Section
700.
Clause 309.3.3 Trench Excavation
Trench for sub-surface drain shall be excavated to the specified lines, grades and dimensions shown in
the drawings provided that width of trench at pipe level shall not be less than 450 mm. The excavation
shall begin at the outlet end of the drain and proceed towards the upper end. Where unsuitable material
is met with at the trench bed, the same shall be removed to such depth as directed by the Engineer and
backfilled with approved material which shall be thoroughly compacted to the specified degree.
Clause 309.3.4 Laying of Pipe and Backfilling

Laying of pipe in the trench shall be started at the outlet end and proceed towards the upper
end, true to the lines and grades specified
Table 300-3: Grading Requirements for Filter Material Percent Passing by Weight
Sieve Designation Class I Class II Class Ill

53mm - - 100
45 mm - - 97-100
26.5 mm - 100 -
22.4 mm - 95-100 58-100
11.2 mm 100 48-100 20-60
5.6 mm 92-100 28-54 4-32
2.8 mm 83-100 20-35 0-10
1.4 mm 59-96 - 0-5
710 micron 35-80 6-18 -
355 micron 14-40 2-9 -
180 micron 3-15 - -
90 micron 0-5 0-4 0-3
Before placing the pipe, backfill material of the required grading(s) shall be laid for full width of the trench
bed and compacted to a minimum thickness of 150 mm or as shown on the drawings. The thickness of
the backfill material on the sides of the pipe shall be as shown on the drawings subject to a minimum of
150 mm. The pipe shall then be embedded firmly on the bed.
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Perforated pipes, unless otherwise specified, shall be placed with their perforations down to
minimize clogging. The pipe sections shall be joined securely with appropriate coupling fittings or
bands.
Non-perforated pipes shall be laid with joints as close as possible with the open joints wrapped with
suitable pervious material (like suitable Geosynthetics of not less than 150 mm width) to permit entry of
water but prevent fines entering the pipes. In the case of non-perforated pipes with bell end, the bell shall
face upgrade.
Upgrade end sections of the pipe installation shall be tightly closed by means of concrete plugs or plugs
fabricated from the same material as the pipe and securely held in place to prevent entry of soil materials.
After the pipe installation has been completed and approved, backfill material of the required grading (s)
(see Clause 309.3.2.2) shall be placed over the pipe to the required level in horizontal layers not exceeding
150 mm in thickness and thoroughly compacted. The minimum thickness of material above the top of the
pipe shall be 300 mm.
Unless otherwise provided, sub-surface drains not located below the road pavement shall be
sealed at the top by means of 150 mm thick layer of compacted clay so as to prevent percolation
of surface water.
Clause 309.3.5 Use of Geosynthetics in Laying of Pipe and Backfilling
After excavating the trench for subsurface drain, the filter fabric shalt be placed, the pipe installed and
the trench backfilled with permeable material according to dimensions and details shown on the
drawings. Surfaces to receive filter fabric prior to placing shall be free of loose or extraneous material
and sharp objects that may damage the filter fabric during installation. Adjacent rolls of the fabric shall
be overlapped a minimum of 450 mm. The preceding roll shall overlap the following roll in the direction
the material is being spread.
Damage to the fabric resulting from Contractor's vehicles, equipment or operations shall be
replaced or repaired by the Contractor at his Cost.
Clause 309.3.6 Drain Outlet
The outlet for a sub-surface drain shall not be under water or plugged with debris but should be a
free outlet discharging into a stream, culvert or open ditch. The bottom of the pipe shall be kept
above high water level in the ditch and the end protected with a grate or screen. For a length of
500 mm from the outlet end, the trench for pipe shall not be provided with granular material but
backfilled with excavated soil and thoroughly compacted so as to stop water directly percolating
from the backfill material around the pipe. The pipe in this section shall not have any
perforations.
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Clause 309.3.7 Aggregate Drains
Aggregate drains shall be placed within the verge/shoulders after completion of the pavement. Depth,
thickness and spacing of the aggregate drains shall be as shown on the drawings.
Trenches for aggregate drains shall be excavated to a minimum width of 300 mm and to the depth
shown on the drawings or ordered by the Engineer. The bottom of the trench shall be sloped to drain
and shall be free from loose particles of soil. The trench shall be excavated so as to expose clearly the
granular pavement courses to be drained.
Aggregate for the drains shall be durable gravel, stone or slag and shall be free from vegetable matter and
other deleterious substances. The grading requirements are given in Table 300-4. Grading to be adopted
shall be indicated in the drawings.
Table 300-4: Grading Requirements for Aggregate Drains

Percent Passing by Weight
Sieve Designation Type A Type B
63 mm - 100
37.5 mm 100 85-100
19 mm - 0 -25
- 45 — 100 0 -5
3.35 mm
9.5 mm 25 — 80 -
600 micron 8 — 45 -
150 micron 0 — 10 -
75 micron 0—5 -

Measurement for surface and sub-surface drains shall be per running metre length of the drain.
Clause 309.5 Rates
The Contract unit rates for surface and sub-surface drains shall be payment in full for all items
such as excavation, dressing the sides and bottom; providing lining, turfing, pitching, masonry,
concrete and plastering; providing, laying and jointing pipes including wrapping with geosynthetic
fabric; providing, laying and compacting backfill around the pipe, granular bedding; providing,
fixing and painting of cover etc. including full compensation for all materials, labour, tools,
equipment and other incidentals to complete the work as shown on drawings with all leads and
lifts including removal of unsuitable material. Provision of inlets, gratings, sumps, outlet pipes,
bedding, disbursers etc. wherever required shall be incidental to construction of drain.
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12. Clause310 PREPARATION AND SURFACE TREATMENT OF FORMATION
Preparation and surface treatment of the formation shall be carried out only after completion of
any specified sub-grade drainage and unless otherwise agreed by the Engineer, immediately prior
to laying the sub-base or the road base where no sub-base is required. The sequence of
operations shall be as follows:
a) Full formation, after reinstatement of any soft areas to the required Specifications shall be
well cleaned and freed of all mud and slurry.
b) The surface shall be compacted to the required density by a smooth wheeled roller of 80
to 100 kN weight after spraying requisite amount of water, if required.
c) the formation shall be finished to the requirements of Clause
The entire work of surface treatment of formation shall be deemed as incidental to the work of
sub-base/base course to be provided for the same
13. Clause 311 WORKS TO BE KEPT FREE OF WATER
Clause 311.1 The Contractor shall arrange for the rapid dispersal of water
collected/accumulated on the earthwork or completed formation during construction or on the
existing roadway or which enters the earthwork or any other item of work from any source, and
where practicable, the water shall be discharged in to the permanent outfall of the drainage
system. The arrangements shall be made in respect of all earthworks including excavation for
pipe trenches, foundations or cuttings.
Clause 311.2 The Contractor shall provide, where necessary, temporary water courses, ditches,
drains, pumping or other means for maintaining the earthwork free from water. Such provisions
shall include carrying out the work of forming the cut sections and embankments in such manner
that their surfaces have at all times a sufficient minimum cross fall and where practicable, a
sufficient longitudinal gradient to enable them to shed water and prevent ponding.
The works involved in keeping the earthwork or any other item of works free of water shall be
deemed as incidental to the respective item of work and as such no separate payment shall be
made for the same.
14. Clause 312 WATER COURSES AT CULVERTS
312.1 Excavation carried out in the diversion, enlargement, deepening or straightening water courses at
culverts, where necessary, shall include the operations such as clearing, grubbing, removal of vegetation,
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trimming of slopes, grading of beds, disposal of excavated materials, pumping, timbering etc. necessary
for dealing with the flow of water.
312.2 The beds and sloping sides of water courses shall, where shown on the drawings, be protected
against the action of water by rubble paving to form a flat or curved surface as indicated. The protection
shall consist of large smooth faced stones or of blocks of precast concrete. Stones for rubble paving shall
be roughly dressed square. No stone shall be less than 225 mm in depth nor less than 0.02 cu.m in volume
and no rounded boulders shall be used. After completion of construction of culverts, temporary diversion
of water course, if any, shall be closed and water course restored for flow through the culvert as per the
direction of the Engineer.
312.3 Measurements for Payment
The work for water courses at culverts as stated above shall be measured in terms of units
specified in the Bill of Quantities for respective items. The temporary diversion of channel to
facilitate construction of culverts, its closure and restoration to original water course shall be
considered incidental to the work of construction of culverts and no extra payment shall be made for the
same.
312.4 Rates
The Contract unit rates for different items of water courses at culverts shall be payment in full for carrying
out all required operations including full compensation for all cost of materials, labour, tools, equipment
and other incidentals to complete the work to the Specifications.
15. Clause 313 ROCKFILL EMBANKMENT
313.1 Scope
The work covers embankment constructed with pieces of rock and shall be in accordance with the lines,
grades and cross-sections as shown in drawings or as directed by the Engineer.
There shall be a minimum of 500 mm thick earthen cushion over the rockfill. The construction of earth fill/
subgrade does not form part of scope of this work.
313.2 Materials
The size of rock pieces used in rockfill embankments shall be such that they can be deposited in layers so
as to suit the conditions evaluated in the field compaction trials or as directed by the Engineer. The rockfill
shall consist of hard, durable and inert material, preferably maximum size not exceeding 300 mm and
percent finer than 125 mm not exceeding10 percent.
Argillaceous rocks (clay, shales etc,), unburnt colliery stock and chalk shall not be used in rockfill.
The rock fragments and blinding material required for filling the voids shall also satisfy the above
requirements.
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Clause 313.3 Spreading and Compaction
The material shall be tipped, spread and levelled in layers extending to the full width of embankment by a
suitable dozer. Fragments of rock shall then be spread on the top of layer to the required extent and layer
compacted by minimum of 5 passes of vibratory roller having static weight 8-10. tonnes. The compacted
thickness of each layer shall not exceed 500 mm. After compaction of each layer, the surface voids shall be
filled with broken fragments. Next layer, where required, shall be placed in the same manner, above the
earlier compacted layer. The top layer of rockfill, on which normal earth fill will rest shall be thoroughly
blinded with suitable granular material to seal its surface.
313.4 Measurements for Payment
Measurement shall be made by taking cross-sections at intervals in the original position before the work
starts and after its completion and computing the volume in cu.m by the method of average end areas.
313.5 Rate
The Contract unit rate shall be paid in full for carrying out all the above operations including cost of
rockfili, broken fragments and blinding material and shall provide full compensation for all items as per
clause 305.8.
16. CLAUSE 401 GRANULAR SUB-BASE
Clause 401.2.1 The material to be used for the work shall be natural sand, crushed gravel,
crushed stone, crushed slag, or combination thereof depending upon the grading required. Use
of materials like brick metal, Kankar and crushed concrete shall be permitted in the lower sub-
base. The material shall be free from organic or other deleterious constituents and shall conform
to the gradings given in Table 400-1 and physical requirements given in Table 400-2. Gradings Ill
and IV shall preferably be used in lower sub-base. Gradings V and VI shall be used as a sub-base-
cum-drainage layer. The grading to be adopted for a project shall be as specified in the Contract.
Where the sub-base is laid in two layers as upper sub-base and lower sub-base, the thickness of
each layer shall not be less than 150 mm.
TABLE 400-1. GRADING FOR GRANULAR SUB-BASE MATERIALS

IS Sieve Percent by Weight Passing the IS Sieve
Designation Grading I Grading II Grading III Grading IV Grading V Grading VI
_75.0 mm 100 - - - 100 -
53.0 mm 80-100 100 100 100 80-100 100
26.5 mm 55—90 70-100 55-75 50-80 55-90 75-100
9.50 mm 35-65 50-80 — — 35-65 55-75
4.75 mm 25 — 55 40-65 10-30 15-35 25-50 30-55
2.36 mm 20- 40 30-50 — — 10-20 10-25
0.85 mm — — — — 2-10 —
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0.425 mm 10-15 10- 15 — — 0-5 0-8

0.075 mm <5 <5 <5 <5 — 0-3
Table 400-2: Physical Requirements for Materials for Granular Sub -base
IS:2386 (Part 4)
Aggregate Impact Value (AIV) 40 maximum
or IS:5640
Liquid Limit IS:2720 (Part 5) Maximum 25
Plasticity Index IS:2720 (Part 5) Maximum 6
CBR at 98% dry density Minimum 30 unless otherwise
IS:2720 (Part 5)
(at 18:2720-Part 8) specified in the Contract
Clause 401.3 Construction operation

Clause 401.3.2 Spreading and Compacting
The sub-base material of the grading specified in the Contract and water shall be mixed
mechanically by a suitable mixer equipped with provision for controlled addition of water and
mechanical mixing. So as to ensure homogenous and uniform mix. The required water content
shall be determined in accordance with IS:2720 (Part 8). The mix 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.
Moisture content of the mix shall be checked in accordance with IS:2720 (Part 2) and suitably adjusted so that,
at the time of compaction, it is from 1 to 2 percent below the optimum moisture content.
Immediately after spreading the mix, rolling shall be done by an approved roller. 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 200 mm the compaction shall be done with the help of a vibratory roller of
minimum 80 to 100 kN static weight 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 or
on super-elevation. For carriageway having crossfall on both sides, rolling shall commence at the edges and
progress towards the crown.
Each pass of the roller shall uniformly overlap not less than one-third of the track made in the
proceeding pass. During rolling, the grade and cross-fall shall be checked and any high spots or
depressions, which become apparent, corrected by removing or adding fresh material. The
speed of the roller shall not exceed 5 km per hour.
Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry
density for the material determined as per IS:2720 (Part 8). The surface of any layer of material
on completion of compaction shall be well closed, free from movement under compaction
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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.
17. Clause 406 WET MIX MACADAM SUB-BASE/BASE COURSE

Clause 406.2.1.1 Physical requirements
Coarse aggregates shall be crushed stone. If crushed gravel/shingle is used, not less than 90 per
cent by weight of the gravel/shingle pieces retained on 4.75mm sieve shall have at least two
fractured faces. The aggregates shall conform to the physical requirements set forth in Table 400-
12.
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).
TABLE 400-12. PHYSICAL REQUIREMENTS OF AGGREGATES FOR WET MIX MACADAM FOR SUB-
BASE/BASE COURSES
Test Test Method Requirements
1. * Los Angeles IS:2386 (Part-4) 40 per cent (Max.)

Abrasion value
Or
* Aggregate IS:2386 (Part-4) 30 per cent (Max.)
Impact value Or IS:5640
2. Combined Flakiness IS:2386 (Part-1) 30 per cent (Max)**
and Elongation
indices (Total)
** 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.
Clause 406.3.3 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 pug mill 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
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agreed limits. The mixed material should be uniformly wet and no segregation should be
permitted.
Clause 406.3.4 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 shall be spread by paver finisher. The paver finisher shall be self-propelled of adequate
capacity with following features:
i) Loading hoppers and suitable distribution system, so as to provide a
smooth uninterrupted material flow for different layer thicknesses from the tipper to
the screed.
ii) Hydraulically operated telescopic screed for paving width upto to
8.5 m and fixed screed beyond this. The screed shall have tamping and vibrating
arrangement for initial compaction of the layer.
iii) Automatic levelling control system with electronic sensing device to maintain
mat thickness and cross slope of mat during laying procedure.
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 large and fine particles should be allowed.
The aggregates as spread should be of uniform gradation with no pockets of line materials.
Clause 406.3.5 Compaction

After the mix has been laid to the required thickness in layers the compaction shall be done with
the help of vibratory roller of minimum 80-100 KN static weight. Each layer should be compacted
at 98% MDD before laying the subsequent layer. The compaction shall be tested and verified by
field density test apparatus.
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
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towards the centre parallel to the centre line of the road uniformly overlapping each of the
preceding track by at least one-third width until the entire surface has been rolled.
Any displacement occurring as a result of reversing of the direction of a roller or from any other
cause shall be corrected at once as specified and/or removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be
thoroughly compacted with mechanical tampers or a plate compactor. Skin patching of an area
without scarifying the surface to permit proper bonding of the added material shall not be
permitted.
Rolling should not be done when the subgrade is soft or yielding or when it causes a wave-like
motion in the sub-base/base course or subgrade. If irregularities develop during rolling which
exceed 12 mm when tested with a 3 metre straight edge, the surface should be loosened and
premixed material added or removed as required before rolling again so as to achieve a uniform
surface conforming to the desired grade and crossfall. In no case should the use of unmixed
material be permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry
density for the material as determined by the method outlined in IS: 2720 (Part-8).
After completion, the surface of any finished layer shall be well-closed, free from movement
under compaction equipment or any compaction planes, ridges, cracks and loose material. All
loose, segregated or otherwise defective areas shall be made good to the full thickness of the
layer and re-compacted.
18. Clause 408 SHOULDERS, ISLANDS AND MEDIAN

Should read as “SHOULDERS”
Clause 408.1. Scope
The work shall consist of constructing shoulders (hard/paved/earthen) on either side of the
pavement, median in the road dividing the carriageway into separate lanes and islands for
channelising the traffic at junctions in accordance with the requirements of these Specifications
and in conformity with the lines, grade and cross-sections shown on the drawings or ad directed
by the Engineer.

Shoulders on either side of the road may be of selected earth/granular material/paved
conforming to the requirements of Clause 305/401 and the median may be of selected earth
conforming to the requirements of Clause 305.
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Median/Traffic islands shall be raised and kerbed at the perimeter and the enclosed area filled
with earth and suitably covered with grass turf/shrubs as per Clause 307 and/or paved as per
Clause 409.3.4 or 409.3.5.
Paved shoulders shall consist of sub-base, base and surfacing courses, as shown in the drawings
for the same shall conform to relevant Specifications of the corresponding items. When paved or
hard shoulders are not provided, the pavement shall be provided with brick/stone block edgings
as shown in the drawings. The bricks shall conform to Clause 1003 of these Specifications. Stone
blocks shall conform to Clause 1004 of these Specifications and shall be of size 225 mm x 110 mm
x 75 mm.
Clause 408.3 Size of Shoulders/Median/Islands

Shoulders (earthen/hard/paved)/median/traffic islands dimensions shall be as shown on the
drawings or as directed by the Engineer.
Shoulders: The sequence of operations shall be such that the construction of paved shoulder is
done in layer each matching the thickness of adjoining pavement layer. Only after a layer of
pavement and corresponding layers in paved and earth shoulder portion have been laid and
compacted, the construction of next layer of pavement and shoulder shall be taken up.
Where the materials in adjacent layers are different, these shall be laid together and the
pavement layer shall be compacted first. The corresponding layer in paved shoulder portion shall
be compacted thereafter, which shall be followed by compaction of earth shoulder layer. The
adjacent layers having same material shall be laid and compacted together.
In all cases where paved shoulders have to be provided alongside of existing carriageway, the
existing shoulders shall be excavated in full width and to the required depth as per Clause
301.3.7. Under no circumstances, box cutting shall be done for construction of shoulders.
Compaction requirement of earthen shoulder shall be as per Table 300-2. In the case of
bituminous courses, work on shoulder (earthen/hard/paved), shall start only after the pavement
course has been laid and compacted.
During all stages of shoulder (earthen/hard/paved) construction, the required cross fall shall be
maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material shall be placed directly on
the shoulder. Any spilled material dragged on to the pavement surface shall be immediately
removed, without damage to the pavement, and the areas so affected thoroughly cleaned.
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Clause 408.4.2. Median and Islands

Median and Islands shall be constructed in a manner similar to shoulder upto the road level.
Thereafter the median and islands, if raised, shall be raised at least 300 mm by using kerb stones
of approved material and dimensions and suitably finished and pained and directed by the
Engineer. If not raised, the median and islands shall be differentiated from the
shoulder/pavement as the case may be, as directed by the Engineer. The confined area of the
median and islands shall be filled with local earth or granular material or any other approved
material and compacted by plate compactor/power rammer. The confined areas after filling with
earth shall be turfed with grass or planted with shrubs and in case of granular fill it can be
finished with tiles/slabs as directed by the Engineer.

Shoulders (earthen/hard/paved), island and median construction shall be measured as finished
work in position as below:
(i) For excavation in cu. M.

(ii) For earth work/granular fill in cu. M.
(iii) For sub-base, base, surfacing courses in units as for respective items.
(iv) For kerb in running metres.
(v) Fur turfing and tile/slab finish in sq.m.
(vi) For brick/stone block edging in sq.m.
Clause 408.7 Rate

The Contract unit rate for shoulder (hard/paved/earthen with brick or stone block edging), island
and median construction shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 401.8 (i) to (v) as applicable. The
rate for brick/stone block edging shall include the cost of sand cushion.
Clause 501.3 MIXING

Pre-mixed bituminous materials 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. Appropriate mixing
temperatures are given in Table 500-2 of these Specifications. The difference in temperature
between the binder and aggregate shall at no time exceed 14°C. In order to ensure uniform quality of the
mix and better coating of aggregates, the hot mix plant shall be calibrated from time to time. The essential
features of the hot mix plants are given in Annex A of IRC:27.
Table 500-2: Mixing, Laying and Rolling Temperatures for Bituminous Mixes (Degree Celsius)
Page 52
Bitumen Bitumen Aggregate Mixed Laying *Rolling

Viscosity Temperature Temperature Material Temperature Temperature
Grade Temperature
VG-40 160-170 160-175 160-170 150 Min 100 Min

VG-30 150-165 150-170 150-165 140 Min 90 Min
VG-20 145-165 145-170 145-165 135 Min 85 Min
VG-10 140-160 140-165 140-160 130 Min 80 Min
*Rolling must be completed before the mat cools to these minimum temperatures.
If a continuous type mixing plant is used, the Contractor must demonstrate by laboratory analysis that
the cold feed combined grading is within the grading limits specified for that bituminous bound material.
In the case of a designed job mix, the bitumen and filler content shall be derived using this combined
grading.
Clause 501.5.3 Spreading

Bituminous materials shall be spread, levelled and tamped by an approved self-propelled paving
machine equipped with an electronic sensing device. The essential features of the paver finisher
shall conform to Annex A of IRC:27. As soon as possible after arrival at site, the materials shall be
supplied continuously to the paver and laid without delay. The rate of delivery of material to the
paver shall be regulated to enable the paver to operate continuously. The travel rate of the paver,
and its method of operations, shall be adjusted to ensure an even and uniform flow of bituminous
material across the screed, free from dragging, tearing and segregation of the material. In areas with
restricted space (such as confined space, foot ways, of irregular shape and varying thickness,
approaches to expansion joints, etc.) where paver cannot be used, the material shall be spread, raked
and levelled with suitable hand tools by trained staff.
The minimum thickness of material laid in each paver pass shall be in accordance with the
minimum values given in the relevant parts of these Specifications. When laying binder course
or wearing course approaching an expansion joint of a structure, machine laying shall stop 300
mm short of the joint. The remainder of the pavement up to the joint, and the corresponding
area beyond it, shall be laid by hand, and the joint or joint cavity shall be kept clear of surfacing
material.
Bituminous material, with a temperature greater than 145°C, shall not be laid or deposited on
bridge deck water-proofing systems, unless precautions against heat damage have been
Clause 501.6 Compaction

Bituminous materials shall be laid and compacted in layers, which enable the specified thickness,
surface level, regularity requirements and compaction to be achieved.
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Compaction of bituminous materials shall commence as soon as possible after laying. Compaction
shall be substantially completed before the temperature falls below the minimum rolling
temperatures stated in the relevant part of these Specifications. Rolling of the longitudinal joints shall
be done immediately behind the paving operation. After this, rolling shall commence at the edges and
progress towards the center longitudinally except that on super-elevated and unidirectional cambered
portions, it shall progress from the lower to the upper edge parallel to the center line of the pavement.
Rolling shall continue until all roller marks have been removed from the surface. All deficiencies in the
surface after laying shall be made good by the attendants behind the paver, before initial rolling is
commenced. The initial or breakdown rolling shall be done with 8-10 tonne static weight smooth-wheel
rollers. The intermediate rolling shall be done with 8-10 tonnes dead weight on vibratory roller
possibly by smooth wheeled rollers. The finish rolling shall be done with 6 to 8 tonnes smooth
wheeled tandem rollers. The Contractor shall demonstrate the efficiency of the equipment proposed to
be used by carrying compaction trials. The procedure for site trials shall be submitted to the Engineer for
approval. The finish rolling shall be done with 6 to 8 tonne smooth wheel tandem rollers. Rolling shall
continue until the specified compaction is achieved.
Where compaction is to be determined by density of cores, the requirements to prove the performance
of rollers shall apply in order to demonstrate that the specified density can be achieved. In such cases the
Contractor shall specify the plant, and the method by which he intends to achieve the specified level of
compaction and finish at temperatures above the minimum specified rolling temperature. Laying trials
shall then demonstrate the acceptability of the plant and method used.
Bituminous materials shall be rolled in a longitudinal direction, with the driven rolls nearest the paver.
The roller shall first compact material adjacent to joints and then work from the lower to the upper side
of the layer, overlapping on successive passes by at least one-third of the width of the rear roll or, in the
case of a pneumatic-tyred roller, at least the nominal width of 300 mm.
In portions with super-elevated and unidirectional camber, after the edge has been rolled, the
roller shall progress from the lower to the upper edge.
Rollers should move at a speed of not more than 5 km per hour. The roller shall not be permitted to stand on
pavement which has not been fully compacted, and necessary precautions shall be taken to prevent dropping
of oil, grease, petrol/ diesel or other foreign matter on the pavement either when the rollers are operating or
standing. The wheels of roller machine shall be in good working order, to prevent the mix from adhering to
the Wheels. Only sufficient moisture to prevent adhesion between the wheels of rollers and the mix should
be used. Surplus water shall not be allowed to stand on the partially compacted pavement. Rolling shall be
continued till the density achieved satisfies the requirements of Clause 903.4.2 and all roller marks
are eliminated.
Clause 502.2.3 Choice of Primer

Cutback for primer shall not be prepared at the site. Type and quantity of cutback bitumen for
various types of granular surface shall be as given in Table 500-4.
Table 500-4: Type and Quantity of Cutback Bitumen for Various Types of Granular Surface
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Rate of Spray
Type of Surface Type of Cutback
(kg/sq.m)
WMM/WBM MC 30 0.6-0.9
Stabilized soil bases/ Crusher Run Macadam MC 70 0.9-1.2
Clause 502.2.3 The correct quantity of primer shall be decided by the Engineer and shall
be such that it can be absorbed by the surface without causing run-off of excessive primer and to
achieve desired penetration of about 8-10 mm.
Clause 502.4.3 Application of Bituminous Primer

The viscosity and rate of application of primer shall be the medium viscosity @ 10 kg/10 sq.m.
The method for application of the primer will depend on the type of equipment to be used, size of
nozzles, pressure at the spray bar and speed of forward movement. The Contractor shall demonstrate
at a spraying trial, that the equipment and method to be used is capable of producing a uniform spray,
within the tolerances specified.
No heating or dilution of SS1 bitumen emulsion and shall be permitted at site. Temperature of
cutback bitumen shall be high enough to permit the primer to be sprayed effectively though the jets
of the spray and to cover the surface uniformly.
Clause 502.8 Rate

The contract unit rate for prime coat shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 401.7 (i) to (v) and applicable to the work
specified in these Specifications. Payment shall be made on the basis of provision of prime coat at an
application rate of 1 kg/1 sq.m including material, labour, machinery with all leads and lifts.
Clause 503.4.3 Application of Tack Coat

The rate of application of tack coat over primed surface shall be @ 3.0 kg/10 sq.mt. No dilution or
heating at site of RS1 bitumen emulsion shall be permitted. Paving bitumen if used for tack coat shall
be heated to appropriate temperature in bitumen boilers to achieve viscosity less than 2 poise. The
normal range of spraying temperature for a bituminous emulsion shall be 20°C to 70°C and for
cutback, 50°C to 80°C. The method of application of tack coat will depend on the type of equipment
to be used, size of nozzles, pressure at the spray bar, and speed or forward movement. The
Contractor shall demonstrate at a spraying trial, that the equipment and method to be used is
capable of producing a uniform spray, within the tolerances specified.
Table 500-5: Rate of Application of Tack Coat
Type of Surface Rate of Spray of Binder in Kg per sq. m
Bituminous surfaces 0.20 — 0.30
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Granular surfaces treated with primer 0.25 — 0.30

Cement concrete pavement 0.30 — 0.35
Clause 504.2.1 Bitumen

The bitumen shall be paving bitumen of penetration grade 60/70. The type and grade of bitumen to
be used depends upon the climatic conditions and the traffic.
Clause 504.2.2 Coarse Aggregates

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained
on 2.36 mm sieve. It shall be clean, hard, durable and cubical shape, free from dust and soft organic
and other deleterious substances. The aggregate shall satisfy the physical requirements specified in
Table 500-6. Where crushed gravel is proposed for use as aggregate, not less than 90 percent by
weight of the crushed material retained on 4.75 mm sieve shall have at least two fractured faces
resulting from crushing operation. Before approval of the source, the aggregates shall be tested for
stripping. Where the Contractor's selected sources of aggregates have poor affinity for bitumen, as a
condition for the approval of that source, the bitumen shall be treated with approved anti-stripping
agents, as per the manufacturer's recommendations, without additional payment.
Clause 504.2.3 Fine Aggregates

Fine aggregates shall consist of crushed or naturally occurring mineral material, or a combination of
two, passing 2.36 mm sieve and retained on 75micron sieve. It shall be clean, hard, durable, free
from dust and soft organic and other deleterious substances. Natural sand shall not be 'used in the
binder course.
Table 500-6: Physical Properties of Coarse Aggregate
Property Test Requirement Test method
Max. 5% passing
Cleanliness Grain size analysis IS:2386 Part I
0.075 micron
Particle shape Combined Flakiness and Elongation Indices Max. 35% IS:2386 Part I
Los Angeles Abrasion Value or Max. 40% IS:2386 Part IV

Strength
Aggregate Impact Value Max. 30% 15:2386 Part IV
5 cycles
Soundness (Sodium or Magnesium) IS:2386 Part, V
Durability Max. 12%
Sodium Sulphate Magnesium Sulphate IS:2386 Part V
Max. 18%
Water absorption Water absorption Max. 2% IS:2386 Part III

Min. Retained Coating
Stripping Coating and Stripping of Bitumen Aggregate IS:6241
95%
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Water sensitivity Retained Tensile strength* Min. 80% AASHTO 283

*If the minimum retained tensile strength falls below 80 percent, use of anti-stripping agent is
recommended to meet the minimum requirements.
Clause 504.3.4 Preparation & Transport of Mix.

Hot mix plant shall be batch type of minimum capacity of more than 120 tonne per hour. For
mixing Clause 501.3 shall apply. Bituminous materials shall be transported in clean insulated and
covered vehicles. An asphalt release agent, such as soap or lime water, may be applied to the
interior of the vehicle to prevent sticking and to facilitate discharge of the material.

Bituminous macadam shall be measured as finished work in cubic metres.
Clause 505 DENSE BITUMINOUS MACADAM

The Bitumen shall be paving bitumen of Penetration Grade 60/70 as per Indian Standard
Specifications for Paving Bitumen – IS:73.
Clause 505.2.2 Coarse Aggregates

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material
retained on 2.36 mm sieve. They shall be clean, hard, durable, of cubical shape, free from dust
and soft or friable matter, organic or other deleterious substances. Where the Contractor's
selected source of aggregates has poor affinity for bitumen, the Contractor shall produce test
results that with the use of anti-stripping agents, the stripping value is improved to satisfy the
specification requirements. The Engineer may approve such a source and as a condition for the
approval of that source, the bitumen shall be treated with an approved anti-stripping agent, as
per the manufacturer's recommendations, at the cost of the Contractor. The aggregates shall
satisfy the requirements specified in Table 500-8.
Table 500-B: Physical Properties of Coarse Aggregate

Property Test Specification Method of Test
Cleanliness Max 5% passing

Grain size analysis 1S:2386 Part 1
(dust) 0.075 mm sieve
Particle shape Combined Flakiness and Elongation Indices* Max 35% 1S:2386 Part I
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Los Angeles Abrasion Value or Max 35%

Strength IS:2386 Part IV
Aggregate Impact Value Max 27%
Soundness either:
Durability Sodium Sulphate or Max 12% IS:2386 Part V
Magnesium Sulphate Max 18%
Water
Water Absorption Max 2% IS:2386 Part Ill
Absorption
Coating and Stripping of Bitumen Aggregate Minimum retained
Stripping 1S:6241
Mix coating 95%
Water Sensitivity Retained Tensile Strength** Min. 80% AASHTO 283
* Aggregate should satisfy both the tests value of Los Angeles Abrasion Value and Aggregate Impact
Value
Clause 505.2.3 Fine Aggregates

Fine aggregates shall consist of crushed mineral material, passing the 2.36 mm sieve and retained on the
75micron sieve. These shall be clean, hard, durable, dry and free from dust, and soft or friable matter,
organic or other deleterious matter. Natural sand shall not be allowed in binder courses. However, natural
sand upto 50 percent of the fine aggregate may be allowed in base courses. The fine aggregate shall have a
sand equivalent value of not less than 50 when tested in accordance with the requirement of IS:2720 (Part
37). The plasticity index of the fraction passing the 0.425 mm sieve shall not exceed 4, when tested in
accordance with IS:2720 (Part 5).
Clause 507.3.3 Job Mix Formula

The Contractor shall submit to the Engineer for approval at least 21 days before the start the work, the job
mix formula proposed for use in the works, together with the following details:
i) Source and location of all materials;
ii) Proportions of all materials expressed as follows:
a. Binder type, and 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 individual grading of the individual aggregate fraction, and the proportion
of each in the combined grading;
v) The results of mix design such as maximum specific gravity of loose mix (Gmm),
compacted specimen densities, Marshall stability, flow, air voids, VMA, VFB and
related graphs and test results of AASHTO T 283 Moisture susceptibility test;
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vi) Where the mixer is a batch mixer, the individual weights of each type of
aggregate, and binder per batch;
vii) Test results of physical characteristics of aggregates to be used;
viii) Mixing temperature and compacting temperature.
While establishing the job mix formula, the Contractor shall ensure that it is based on a correct and truly
representative sample of the materials that will actually be used in the work and that the 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 Engineer.
Mix design shall be carried out in accordance with the modified Marshall method described in
Asphalt Institute Manual MS-2. The approved job mix formula shall remain effective unless and until a
revised Job Mix Formula is approved. Should a change in the source of materials be proposed, a new job
mix formula shall be forwarded by the Contractor to the Engineer for approval before the placing of the
material.
Clause 507.9 Rate

The contract unit rate for Dense Graded Bituminous Macadam shall be payment in full for carrying out all
the required operations 'except for the item of tack coat, as specified and shall include, to all
components listed in Clause 501.8, 8.2. The rate shall also include the provision of bitumen as per mix
design approved by the Engineer.
19. Clause 507 BITUMINOUS CONCRETE

The bitumen used shall be of modified bitumen obtained by adding polymer or crumbled rubber
to the base binder and modifying comprises to clause 521.
Clause 507.2.4 Filler

Filler shall consist of finely divided hydrated lime or cement as approved by the Engineer.
Clause 507.2.5 Aggregate Gradation

When tested in accordance with IS:2386 Part I (Wet grading method), the combined grading of the coarse and
fine aggregates and filler shall fall within the limits shown in Table 500-17. The grading shall be as specified in the
Contract.
Table 500-17 Composition of Bituminous Concrete Pavement Layers
Grading 1 2
Nominal aggregate size* 19mm
Layer thickness 50mm 30-40 mm
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IS Sieve' (mm) Cumulative % by weight of total aggregate passing

45
37.5
26.5 100
19 90-100 100
13.2 59-79 90-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38 ..
0.3 10-20 18-28
0.15 12-20
0.075 2-8 4-10
Bitumen content % by mass
Min 5.4**
of total mix
*The grading of the aggregate mix as used in work shall be a smooth curve within the approximate
parallel of the envelope in Table 500-18.
Clause 507.9 Rate

The contract unit rate shall include the provision of bitumen required as per mix design approved by
the Engineer.
20. Clause 801 TRAFFIC SIGNS

The details of the signs shall be as shown in the drawings and in conformity with the Code of
Practice for Road Signs, IRC: 67-2010. The various materials and fabrication of the traffic signs
shall conform to the following requirements:
Clause 801.2.1 Concrete

Concrete for foundation shall be of M 15 Grade as per Section 1700 or the grade shown on the
drawings or otherwise as directed by the Engineer.
Clause 801.2.2 Reinforcing Steel
Reinforcing steel shall conform to the requirement of IS:1786 unless otherwise shown on the
drawing.
Clause 801.2.3 Bolts, Nuts, Washers
High strength bolts shall conform to IS:1367 whereas precision bolts, nuts, etc., shall conform to
IS:1364.
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Clause 801.2.4 Plates and Supports

Plates and support sections for the sign posts shall conform to IS:226 and lS:2062 or any other
relevant IS Specifications.
Clause 801.2.5 Substrate

Sign panels shall be fabricated on aluminium sheet, aluminium composite panel, fibre glass
sheeting, or sheet moulding compound. Aluminum sheets used for sign boards shall be of
smooth, hard and corrosion resistant aluminium alloy conforming to IS:736-Material Designation
24345 or 1900. Aluminium Composite Material (ACM) sheets shall be sandwiched construction
with a thermoplastic core of Low Density Polyethylene (LDPE) between two thick skins/sheets of
aluminum with overall thickness and 3 mm or 4 mm (as specified in the Contract), and aluminum
skin of thickness 0.5 mm and 0.3 mm respectively on both side The mechanical proportion of ACM and
that of aluminum skin shall conform to the requirements given in Table 800-1, when tested in
accordance with the test methods mentioned against each of them.
Table 800-1: Specifications for Aluminum Composite Material (ACM)

S. Specification
Description
No. Standard Acceptable
A Mechanical Properties of ACM Test Value
Peel offstrength with retro reflective sheeting (Drum Peel
1 ) ASTM D903 Min. 4 N/mm
Test)
2 ) Tensile strength ASTM E8 Min. 40 N/mm2
3 ) 0.2% Proof Stress ASTM E8 Min. 34 N/mm2
4 ) Elongation ASTM E8 Min. 6%
5 ) Flexural strength ASTM 393 Min. 130 N/mm2
6 ) Flexural modulus ASTM 393 Min. 44.00 N/mm2
7 ) Shear strength with Punch shear test ASTM 732 Min. 30 N/mm2
B Properties of Aluminium Skin
1 ) Tensile strength (Rm) ASTM E8 Min. 65 N/mm2
2 ) Modulus of elasticity ASTM E8 Min. 70,000
3 ) Elongation ASTM E8 Min.22%
A50N/mm
4 ) 0.2% Proof Stress ASTM E8 Min. 10 N/mm2
Clause 801.2.6 Plate Thickness

Shoulder mounted ground sings with a maximum side dimension not exceeding, 600 mm shall
not be less than 1.5 mm thick with Aluminum and 3 mm thick with Aluminum Composite
Material. All other signs be at least 2 mm thick with Aluminum and 4 mm thick with Aluminum
Composite Material. The thickness of the sheet shall be related to the size of the sign and its
support and shall be such that it does not bend or deform under prevailing wind and other loads.
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Clause 801.2.7 In respect of sign sizes not covered by IRC: 67, the structural details
(Thickness, etc.) Shall be as per the approved drawings or as directed by the Engineer.
Clause 801.3 Traffic Signs having Retro-Reflective Sheeting

Clause 801.3.1 General Requirements
The retro-reflective sheeting used on the sign shall consist of the white or colored sheeting
having a smooth outer surface which has the property of retro-reflection over its entire surface.
It shall be weather-resistant and show colour fastness. It shall be new and unused and shall show no
evidence of cracking, scaling, pitting, blistering, edge lifting or curling and shall have negligible
shrinkage or expansion. A certificate of having tested the sheeting for co-efficient of retro-reflection,
day/night time colour luminous, shrinkage, flexibility, linear removal, adhesion, impact resistance,
specular gloss and fungus resistance and its having passed these tests shall be obtained from a
Government Laboratory/Institute, by the manufacturer of the sheeting. Guidance on the
recommended application of each class of sheeting may be taken from IRC: 67.

The measurement of standard cautionary, mandatory and information signs shall be in
numbers of different types of signs supplied and fixed, while for direction and place
identification signs, these shall be measured by area in square metres.
Clause 801.6 Rate

The Contract unit rate shall be payment in full for the cost of making the road sign, including all materials,
installing it at the site furnishing of necessary test certificates, warranty and incidentals to complete the work in
accordance with these Specifications.
Clause 802.7.1 Measurement for Payment

Aluminum or steel overhead sign structure shall be measured for payment by the specific unit
(each) complete in place as indicated in the Bill of Quantities and the detailed drawings(s).
Clause 802.7.2 Flat sheet aluminum signs with retro-reflective sheeting thereon shall be
measured for payment by the square metre, complete in place.
Clause 802.8 Rate
Clause 802.8.1 The Contract unit rate for overhead sign structure shall be payment in full
compensation for furnishing all labour, materials, tools, equipment, excavation for foundation,
concrete, reinforcement, painting of structural steel and sign back, fabrications and installation,
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furnishing of necessary test certificates, warranty and all other incidental costs necessary to
complete the work to these Specifications.
Clause 802.8.2 The Contract unit rate for aluminum sheet signs shall include the cost of
making the sign including all materials and fixing the same in position and all other incidental
costs necessary to complete the work to these Specifications.
21. Clause 803 ROAD MARKINGS

Clause 803.4 Hot Applied Thermoplastic Road Marking
The thermoplastic material shall be homogeneously composed of aggregate, pigment, resins and
glass reflectorizing beads. The colour of the compound shall be white or yellow (IS colour No.
356) as specified in the drawings or as directed by the Engineer.
Clause 803.4.1.2 Requirements:

i. Composition: The pigment, beads, and aggregate shall be uniformly dispersed in the resin.
The material shall be free from all skins, dirt and foreign objects and shall comply with
requirements indicated in Table 800-9.
Table 800-9: Proportions of Constituents of Marking Material (Percentage by Weight)

Component White Yellow
Binder 18.0 min. 18.0 min.
Glass Beads 30-30 30-30
Titanium Dioxide 10.0 min. --
Calcium Carbonate and Inert Fillers 42.0 max. See Note below
Yellow Pigments -- See Note below
Note: Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of the manufacturer, provided all other requirements
of thisSpecificationaremet.
ii. Properties: The properties of thermoplastic material, when tested in accordance with ASTM
D36/BS-3262- (Part I), shall be as below:
Luminance:
White: Daylight luminance at 45°-65 percent min. as per AASHTO M 249
Yellow: Daylight luminance at 45°-45 percent min. as per AASHTO M 249
Drying time: When applied at a temperature specified by the manufacturer and to the required
thickness, the material shall set to bear traffic in not more than 15 minutes.
Skid resistance: not less than 45 as per BS:6044.
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Cracking resistance at low temperature: The material shall show no cracks on application
to concrete blocks.
Softening point: 102.5°C ± 9.5°C as per ASTM D 36.
Yellowness index (for white thermoplastic paint): not more than 0.12 as per AASHTO M
249.
iii. Storage life: The material shall meet the requirements of these Specifications for a period
of one year. The thermoplastic material must also melt uniformly with no evidence of
skins or unmelted particles for the one-year storage period. Any material not meeting the
above requirements shall be replaced .by the manufacturer/supplier/ Contractor.
iv. Sampling and Testing: The thermoplastic material shall be sampled and tested in accordance
with the appropriate ASTM/BS method. The Contractor shall furnish to the Engineer a copy of
certified test reports from the manufacturers of the thermoplastic material showing results of all
tests specified herein and shall certify that the material meets all requirements of this
Specification.
Clause 803.4.2 Reflectorizing Glass Beads
Clause 803.4.2.1 General
This Specification covers two types of glass beads to be used for the production of reflectorised
pavement markings.
Type 1 beads are those which are a constituent of the basic thermoplastic compound vide Table
800-9 and Type 2 beads are those which are to be sprayed on the surface vide Clause 803.6.4.
Clause 803.42.2 The glass beads shall be transparent, colourless and free form milkiness,
dark particles and excessive air inclusions.
These shall conform to the requirements spelt out in Clause 803.4.2.3.
Clause 803.4.2.3 Specific Requirements
a) Gradation : The glass beads shall meet the graduation requirements for the two
types as given in Table 800-10.
Table 800-10 : Gradation Requirements for Glass Beads
Sieve Size Percent Retained

Type1 Type _ 2
1.18 mm 0 to 3 --
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850 micron 5 to 20 0 to 5
600 micron -- 5 to 20
425 micron 65 to 95 --
300 micron -- 30 to 75
180 micron 0-10 10 to 30
Below 180 micron -- 0 to 15
b) Roundness: The glass beads shall have a minimum of 70 percent
true spheres.
c) Refractive index: The glass beads shall have a minimum
refractive index of 1.50.
Free flowing properties: The glass beads shall be free of hard
lumps and clusters and shall dispense readily under any
conditions suitable for paint striping. They shall pass the free
flow-test.
Clause 803.6.8 Measurements for Payment
Clause 803.6.8.1 The painted markings shall be measured in sq. metres of actual area
marked (excluding the gaps, if any).
Clause 803.6.8.2 in respect of markings like directional arrows and lettering, etc., the
measurement shall be by numbers.
Clause 803.6.9 Rate

The Contract unit rate for road markings shall be payment in full compensation for furnishing all
labour, materials, tools, equipment, including all incidental costs necessary for carrying out the
work at the site conforming to these Specifications complete as per the approved drawing(s) or
as directed by the Engineer and all other incidental costs necessary to complete the work to
these Specifications.
22. Clause 805 Distance Indicator Posts

Clause 805.2 These posts shall be in "accordance with those prescribed in IRC:26 "Type Designs
for 200 Metre Stones" and IRC:8 "Type Designs for Highway Kilometre Stones". They may also be
provided in the form of sign systems on highways and roads.

The measurement will be in numbers of 200 metre, kilometer and 5th kilometer distance
indicator posts fixed at site, complete job as per these Specifications or as directed by the
Engineer.
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Clause 807.1 Scope

The work shall cover supply and fixing boundary stones as per designs and Specifications given in
IRC:25 "Type Designs for Boundary Stones" and at locations indicated in the drawings or as
directed by the Engineer. The material to be used shall conform to IRC:25.
Clause 807.3 Rate

The Contract unit rate for boundary stones shall be full compensation for furnishing all labour,
materials, tools, equipment for preparing, supplying and fixing and all other incidental costs
necessary to complete the work to these Specifications.
23. Clause 806 ROAD DELINEATORS
Clause 806.1 Scope
The work shall cover supplying and fixing roadway indicators, hazard markers and object markers.
Roadway indicators shall be properly installed to indicate the horizontal alignment and vertical
profile of the roadway so as to outline the vehicle path for safe driving. Hazard markers shall be
installed immediately ahead of obstruction of vehicular path such as just before a narrow bridge.
Object markers shall be erected where obstruction within the roadway starts such as
chennelising island in approaches to intersections.
Clause 806.2 The design, materials to be used and the location of the road delineators
(roadway indicators, hazard markers and object markers) shall conform to Recommended
Practice for Road Delineators, IRC:79, and to relevant drawings or as otherwise directed by the
Engineer. The steel drums such as empty bitumen drums shall not be used as they could pose
safety hazards, The delineators shall be retro-reflectorised as shown on the drawings or as
directed by the Engineer. The reflectors on the delineators shall be of retroreflective sheeting
with encapsulated lens and with the visibility of 300 m under clear weather conditions, when
illuminated by the upper beam of the car headlights.
Clause 806.3 Installation
The delineators shall be so installed that their posts do not change their orientation and the
reflectorised faces are always perpendicular to the direction of travel.
Clause 806.4 Measurement for Payments
The measurement shall be made in number of delineators supplied and fixed at site.
Clause 806.5 Rates
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The Contract unit rates of delineators shall be payment in full compensation for furnishing all
labour, materials, tools, equipment including incidental costs necessary to complete the work to
these Specifications.
24. Clause 807 BOUNDARY STONES
Clause 807.1 Scope
The work shall cover supply and fixing boundary stones as per designs and Specifications given in
IRC:25 "Type Designs for Boundary Stones" and at locations indicated in the drawings or as
directed by the Engineer. The material to be used shall conform to IRC:25.
The measurement shall be made in numbers of boundary stones supplied and fixed at site.
Clause 807.3 Rate
The Contract unit rate for boundary stones shall be full compensation for furnishing all labour,
materials, tools, equipment for preparing, supplying and fixing and all other incidental costs
v. Clause 808 FENCING
Clause 808.1 Scope
The work shall cover supply and installation of chain link fencing or barbed wire fencing with its
fixing on GI pipe posts or RCC posts and providing necessary stays and entry gates as shown in
the drawing(s) and/or as directed by the Engineer.
Clause 808.2 The GI posts shall conform to IS:1239. The GI pipe posts shall be embedded in
concrete to a sufficient depth below ground as indicated in the drawings. The steel shall be
fabricated and painted to conform to Section 1900 of these Specifications.
Clause 308.3 The chain link fencing shall conform to ASTM F 1553-06. They shall be firmly
secured to the posts such that the whole fencing remains intact.
Clause 808.4 Entry gate(s) shall be made of GI pipes or other metal as per the design shown in
the drawing(s).
Clause 808.5 The concrete in R.C.C. posts shall conform to M 25 grade or as indicated in the
drawings. The requirements of Section 1700 shall govern. Steel for reinforcement shall meet the
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requirements of Section 1600. The barbed wire fencing shall be galvanised steel barbed wire
conforming to IS:278-1978.
The measurement shall be in running metre of fencing including the entry gates.
Clause 808.7 Rate
The Contract unit rate for fencing shall be payment in full compensation for furnishing all labour,
materials, tools, equipment for fabrication and fixing at site and all other incidental costs
25. Clause 810 STRUCTURAL STEEL RAILING
Clause 810.1 Scope
The work shall cover supply, fixing and erecting structural steel railings as shown in the drawings
and/or as directed by the Engineer.
The structural sections such as angles, flats, rectangular hollow sections etc. shall conform to
Section 1900. They shall be painted or galvanised as specified in the Contract.
The railing shall be measured in linear metre including end and intermediate posts.
Clause 810.4 Rate
The contract unit rate for railing shall be payment in full compensation for furnishing materials,
labour, tools and equipment required for fabrication, connection, oiling, painting, galvanising,
erection, test and all other incidentals necessary to complete the work to these Specifications.
26. Clause 811 CRASH BARRIER

Clause 811.3.1.1 Metal Beam Crash Barrier
Metal beam rail shall be corrugated sheet steel beams of the class, type, section and thickness
indicated on the drawings. Railing posts shall be made of steel of the section, weight and length
as shown on the drawings. All complete steel rail elements, terminal sections, posts, bolts, nuts,
hardware and other steel fittings shall be galvanized. All elements of the railing shall be free from
abrasions, rough or sharp edges and shall not be kinked, twisted or bent.
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Clause 811.3.1.2
The "W" beam type safety barrier shall consist of a steel post and a 3 mm thick "W" beam rail
element. The steel post and the blocking out spacer shall both be channel section of 75 mm x150
mm & size 5 mm thick. The rail shall be 70 cm above the ground level and posts shall be spaced 2
m center-to-center. Double "W" beam barrier shall be as indicated in IRC:5-1998.
The thrie beam safety barrier shall have posts and spacers similar to the ones mentioned above
for "W" beam type. The rail shall be placed at 85 cm above the ground level.
The "W" beam, the thrie beam, the posts, spacers and fasteners for steel barriers shall be
galvanized by hot dip process (zinc coated, 0.55 kg per square metre; minimum single spot)
unless otherwise specified. The galvanizing on all other steel parts shall conform to the relevant
IS Specifications. All fittings (bolts, nuts, washers) shall conform to the IS:1367 and 1S:1364. All
galvanizing shall be done after fabrication.
27. Clause 812 ROAD TRAFFIC SIGNALS
Clause 812.1 Scope
The work shall cover supply and installation of Road Traffic Signals. The traffic signal, its
configuration, size and location shall be in accordance with IRC: 93 and IS:7537 and as shown in
the drawings or as directed by the Engineer. Prior to installation of signals, the Contractor shall
submit to the Engineer, for approval, detailed proposals showing the signal type, sizes, paint and
structural details of the signal posts including control system.
Clause812.2 The traffic signals shall have a complete electronic mechanism for controlling
The operation of traffic with an auxiliary manual controller. The time plan of signals shall be as
per drawing and shall be modified as directed by the Engineer.
28. Clause 813 TRAFFIC CONTROL AND SAFETY DEVICES IN CONSTRUCTION ZONE
Clause 813.1 Scope
The work shall cover supply and installation at site. Traffic Control Devices in the construction
zone comprising of signs delineators, traffic cones, drums, barricades, longitudinal barriers,
warning tapes, flagmen, refiedive jackets, headgears.
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29. Clause 816 ADVANCED TRAFFIC MANAGEMENT SYSTEMS (ATMS)
Clause 816.1 Scope
The work shall cover design, supply, installation, commissioning and/or operation and
maintenance of Advance Traffic Management Systems (which is one of the components of
Intelligent Transport Systems - ITS). The system would include out-door equipment including
emergency call boxes, variable message sign systems, meteorological data system, close circuit
TV camera (CCTV) system, traffic counting and classification system and transmission system. The
indoor equipment would comprise a large display board, central computer (with Network
Management System - NMS), CCTV monitor system, call centre system or management of
emergency call boxes housed in a control centre with uninterrupted power supply. Any new
technology, meeting the requirements specified in these specifications should not be excluded.
The systems shall meet following objectives:
 Smooth and Uninterrupted Traffic
 Flow Enhance Road Safety
 Real Time Information and Guidance to Users
 Emergency Assistance Round The Clock
 Alerts for Abnormal Road and Weather Conditions
 Reduced Journey Time and Inconvenience
Clause 900 Quality control for road works
Clause 901.1 All materials to be used, all methods to be adopted and all works to be performed
shall be strictly in accordance with the requirements of these Specifications. The Contractor shall
set up a field laboratory at locations approved by the Engineer and equip the same with
adequate equipment and personnel in order to carry out Quality Control for works and all the
required tests as per Specifications and/or as directed by the Engineer. The provision and
maintenance of the laboratory shall be as per Clause 120 and/or as directed by the Engineer. The
list of equipment and the facilities to be provided shall be got approved from the Engineer in
advance.
Clause 901.2 The Contractor's laboratory shall be manned by a qualified Materials

Engineer/Civil Engineer assisted by experienced technicians, and the set-up should be got
Clause 901.3 The Contractor shall carry out quality control tests on the materials and work to
the frequency stipulated in subsequent paragraphs. In the absence of clear indications about
method and or frequency of tests for any item, the instructions of the Engineer shall be followed.
Clause 901.4 For satisfying himself about the quality of the materials and work, quality control
tests will also be conducted by the Engineer (by himself, by his Quality Control Units or by any
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other agencies deemed fit by him), generally to the frequency set forth hereunder. Additional
tests may also be conducted where, in the opinion of the Engineer, need for such tests exists.
Clause 901.5 The Contractor shall provide necessary co-operation and assistance in obtaining
the samples for tests and carrying out the field tests as required by the Engineer from time to
time. This shall include provision of laboratory equipment, transport, consumables, personnel
including labour attendants, assistants in packing and dispatching and any other assistance
considered necessary in connection with the tests.
Clause 901.6 For the work of embankment, subgrade and pavement, construction of
subsequent layer of same or other material over the finished layer shall be done after obtaining
permission from the Engineer. Similar permission from the Engineer shall be obtained in respect
of all other items of works prior to proceeding with the next stage of construction.
Clause 901.7 The Contractor shall carry out modifications in the procedure of work, if found
necessary, as directed by the Engineer. Works falling short of quality shall be rectified/ redone by
the Contractor at his own cost, and defective work shall also be removed from the site of works
by the Contractor at his own cost.
Clause 901.8 The cost of laboratory building including essential supplies like water, electricity,
sanitary services and their maintenance and cost of all equipment, tools, materials labour and
incidentals to perform tests and other operations of quality control according to the Specification
requirements shall be deemed to be incidental to the work and no payment shall be made for the
same. If, however, there is a separate item in the Bill of Quantities for setting up of a laboratory
and installing testing equipment, such work shall be paid for separately labour and incidentals to
perform tests and other operations of quality control according to the Specification requirements
shall be deemed to be incidental to the work and no payment shall be made for the same. If,
however, there is a separate item in the Bill of Quantities for setting up of a laboratory and
installing testing equipment, such work shall be paid for separately.
Clause 901.9 For testing of soils/soil mixes, granular materials and mixes, bituminous materials
and mixes, cement concrete materials and mixes, aggregates, cores etc., samples in the required
quantity and form shall be supplied by the Contractor at his own cost.
Clause 901.10 For cement, bitumen, steel, emulsion, road marking paint, sign boards, geo-
synthetics and similar other materials where essential tests are to be carried out in the presence
of Engineer at the manufacturer's plants or at laboratories other than the site laboratory, the
cost of samples, sampling, testing and furnishing of test certificates shall be borne by the
Contractor.
Manufacturer's test certificate together with invoice or delivery challan shall be furnished for
every lot of supply apart from tests to be conducted at site laboratory for prime properties of the
material like cement, bitumen, etc. Where facilities for testing of materials are not available at
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site laboratory the same shall be tested at an outside laboratory in the presence of the Engineer.
For specialized items such as sign boards, road marking paint, etc. the Engineer may order for
third party test from an approved laboratory.
Clause 901.11 The method of sampling and testing of materials shall be in accordance with the
requirements of the relevant Indian Standards and these Specifications. Where they are
contradicting, the provisions in these Specifications shall be followed. Where they are silent,
sound engineering practices shall be adopted. The sampling and testing procedure to be used
shall be as approved by the Engineer and his decision shall be final and binding on the Contractor.
The cost of all tests shall be borne by the Contractor.
Clause 901.12 The materials for embankment construction shall be got approved from the
Engineer. The responsibility for arranging and obtaining the land for borrowing or exploitation in
any other way shall rest with the Contractor who shall ensure smooth and uninterrupted supply
of materials in the required quantity during the construction period.
Similarly, the supply of aggregates and other materials for construction shall be from sources
approved by the Engineer. Responsibility for arranging uninterrupted supply of materials from
the source shall be that of the Contractor
Clause 1409 WEEPS HOLES

Weep holes shall conform to Clauses 2706 of these Specifications.
Clause 1501 DESCRIPTION
Formwork shall include all temporary or permanent forms required for forming the concrete of
the shape, dimensions and surface finish, as shown on the drawing or as directed by the
Engineer, together with all props, staging, centering, scaffolding and temporary construction
required for their support.
30. Clause 1502 MATERIALS
All materials shall comply with the requirements of IRC:87. Materials and components used for
formwork shall be examined for damage or excessive deterioration before use/re-use and shall
be used only if found suitable after necessary repairs. In case of timber formwork, the inspection
shall not only cover physical damages but also signs of attacks by decay, rot or insect attack or
the development of splits.
Forms shall be constructed with metal or timber. The metal used for forms shall be of such
thickness that the forms remain true to shape. All bolts should be countersunk. The use of
approved internal steel ties or steel or plastic spacers shall be permitted. Structural steel tubes
used as support for forms shall have a minimum wall thickness of 4 mm. Other materials
conforming to the requirements of IRC:87 may also be used if approved by the Engineer.
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STRUCTURAL CONCRETE
Clause 1701 DESCRIPTION
The work shall consist of producing, transporting, placing and compacting of structural concrete
including fixing formwork and temporary works etc. and incidental construction in accordance
with these Specifications and in conformity with the lines, grades and dimensions, as shown on
the drawings or as directed by the Engineer.
Clause 1711.2 Concreting in Hot Weather
When depositing concrete in hot weather, precautions shall be taken so that the temperature of
wet concrete does not exceed 30°C while placing. This shall be achieved by using chilled mixing
water, using crushed ice as a part of mixing water, shading stock piles of aggregates from direct
rays of the sun, sprinkling the stock piles of coarse aggregate with water to keep them moist,
limiting temperature of cement below 30°C at the time of use, starting curing before concrete
dries out and restricting time of concreting as far as possible to early mornings and late evenings.
When ice is used to cool mixing water, it will be considered as part of the water in design mix.
Under no circumstances shall the mixing operation be considered complete until all ice in the
mixing drum has melted. The Contractor will be required to state his methodology for the
Engineer's approval when temperatures of concrete are likely to exceed 30°C during the work.
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Part B : TECHNICAL SPECIFICATIONS – Structures
1. General
1. The General Technical Specifications comprise the “Specification for Road and
Bridge Works” (Fifth Revision) issued by the Ministry of Surface Transport
roads Wing, Government of India and published by the Indian Road Congress,
New Delhi and for items not covered by these specification Standard
Specifications edition, 1979, published by the Public Works Department,
Govt. of Maharashtra, are deemed to be bound into this document, unless
and otherwise specifically relaxed wholly or partly through a special clause in
the contract document.
2. GENERAL:
Scope of
Work
The work to be carried out Under the Contract shall consist of the various
items as generally described in the tender document under the heading Scope
of Work and as per drawings
.
3. FORM WORK FOR R.C.C. AND P.S.C. WORK:
3.1 General:
Shuttering for concrete work shall be in steel with appropriate
stiffeners to produce a smooth and uniform finish on all exposed
surfaces. The contractor shall f a b r i c a t e and provide formwork as
approved by the Engineer. The shuttering proposed to be used in
casting of concrete units and as approved by Engineer-in-charge shall be
positioned in such a manner that required access is available for operating
tools, equipments to be used during the casting process, reinforcement
and the finished components and to facilitate inspection of
Engineer-in-charge or his authorized representative. The number of
shuttering shall be commensurate with the construction programme and
as agreed by the Engineer-in-Charge. Formwork shall be made out of
3.15 mm thick M.S. plates with stiffeners (thickness not less than 5 mm).
Planning of formwork shall be got approved from the Engineer-in-charge
prior to actual mobilization and use.
Prior to any modification in the shuttering to cater for verification in
size etc. if required shall be notified to the Engineer-in-charge who shall
review the designs and communicate his approval/rejection/suggestion
as appropriate. These suggestions shall however not absolve the
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contractor of his full and final responsibility towards the safety and
serviceability of the formwork as well as men and equipment working
on them during the preliminary works before
concreting, during concreting and afterwards. Shutters shall be water
tight and fixed in perfect alignment and securely braced so as to be
able to withstand, without any displacement, deflection or movement
of any kind, the loads due to the pressure of concrete, the movement of
construction personnel, materials and plant.For portion of road in curve
if any curved formwork is required shall be providedas directed.
All formwork shall be designed by the expert and design shall be got
approved.
3.2 Pre-assembly of formwork:

It shall be obligatory on the part of the contractor to pre-assemble the
formwork on ground prior to actual use where required. The contractor
shall arrange for all material, labour, facilities etc. to facilitate first
hand checking and carry out necessary modifications as required to
make the formwork true to line, level and shape at no extra cost.
However, the contractor shall be responsible for the correctness of
the formwork when erected in position finally and rechecking of
formwork shall not be a ground for accepting any defective and bad
work produced by the Contractor.
3.3 Permissible Tolerance:
The formwork shall be so made as to produce a form finished
concrete, true shape, lines, levels plumb and dimensions as shown on
the drawings subject to the following tolerance for in-situ casting unless
otherwise specified or shown in drawings or directed by the Engineer-in-
charge.
a) Cross-sectional dimensions - +2
mm b) Maximum for entire length -
+ 2 mm
The tolerance given above are specified for local aberrations in the
finished concrete surface and should not be taken as tolerance for the
entire structure taken as a whole or for the setting and alignment of
formwork, which should be as accurate as possible to the entire
satisfaction of the Engineer-in-charge. Errors if noticed in any lift / tilt of
the structure after stripping of forms shall be corrected in the subsequent
work to bring back the surface of the structure to its true alignment
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provided always that prior approval of the Engineer-in-charge shall be

obtained in respect of acceptability of such corrective measures without
affecting the component structurally or aesthetically.
3.4 Preparation of formwork before concreting:
Suitable non-stain oil and shuttering releasing agents, if required may be
applied with the approval of Engineer-in-charge to the shuttering t o
facilitate easy removal and shall not be allowed to come into
contact with any reinforcement or prestressing tendons and
anchorages. Different release agents shall not be used in formwork for
concrete which will be visible on the surface of finished work. Formwork
shall be tight enough to prevent any loss of cement slurry during
vibrations. Immediately before concreting all form shall be thoroughly
cleaned.Contractor shall give the Engineer-in-charge due notice
before placing any concrete in the forms to permit him to inspect and
accept the forms as to the strength, alignment and general fitness, but
such inspection shall not relieve the contractor of his responsibility for
safety of men, machinery, materials and for result obtained.
All formwork before concreting shall be got clean using
compressor.
3.5 Concreting of narrow members:

Wherever the concreting of narrow member is required to be carried out
within shutters of considerable depth, temporary openings in the sides
of the shutters shall, if so desired by the Engineer-in-charge, be provided
to facilitate the pouring and consolidating of the concrete. Before any
concreting is commenced, shutters and centering shall be carefully
examined and the space to be occupied by the concrete be thoroughly
cleaned out. The concrete in such members shall be compacted using
suitable vibrator as appropriate.
3.6 Removal of Shutters:

The consent of the Engineer-in-charge shall be obtained in writing in all
cases before any shuttering is removed. The Contractor must notify the
Engineer-in- charge well in advance to enable him to inspect the
concrete, if he so desires. The contractor shall record in any approved
manner, the date on which concrete is placed in each part of the work
and the date on which the formwork is removed there from and have this
record checked and countersigned by the Engineer-in- charge. The
contractor shall be responsible for the safe removal of the formwork and
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any work showing signs of damage through premature removal of

formwork or loading shall be rejected and entirely reconstructed by the
Contractor without any extra cost to the Corporation. The Engineer-in-
charge may, however, instruct to postpone the removal of formwork if he
considers it necessary and no claim whatsoever shall be entertained on
this account. The side shuttering of precast units shall be released after
48 hours of casting the concrete or as directed by the Engineer-in-
charge.
3.7 Re-use of forms:
Before re-use, all forms shall be thoroughly scrapped, cleaned, joints and
planes examined and when necessary / repaired and inside surface
treated as specified herein before. Formwork shall not be used / re-
used if declared unfit or unserviceable by the Engineer-in-charge.
Nothing extra or any claim whatsoever shall be admissible on this
account.
The contractor is to make good at his own expenses any injury to the
concrete
work and any damage caused by, or arising from the removal and
striking of shutters and supports. Notwithstanding conditions and
requirements mentioned in the foregoing paragraphs the shuttering
should be such that all RCC and
prestressed concrete work remains form finished as per pattern
approved by the
Engineer-in-
charge.
3.8 Formed Surface and Finish (where these are
used):
All RCC, PSC members above ground or formation level or below
ground (exposed faces) shall have form-finished surfaces. In order to
maintain the desired quality, absolute care shall be taken while removing
shuttering plate. No undue force shall be applied for removing the
shuttering plate from the element to avoid damage to the concrete
element.
Special care shall be taken to ensure that no stains are left on the
formed concrete either from formwork or exposed reinforcement bars.
Such stains shall be removed by the contractor at no extra cost so as
to match with adjoining concrete surfaces to the satisfaction of the
Engineer-in-charge.
All visible shuttering joint shall be polished and matched with adjoining
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concrete panel.
4. STRUCTURAL CONCRETE:
The work shall consist of forming and placing of concrete. All concrete shall be
machine mixed concrete. Batching plant is mandatory. Honey combing in
concrete is generally not accepted. With approval of Engineer-in-charge
minor honeycomb if any, shall be rectified / repaired with polymer mortar
cement with quartz sand. Proportion o f polymer cement and sand shall be got
approved from Engineer-in-charge a per manufacturer specifications.
Manufacturer for supply of polymer shall be got approved. All material shall be
tested before use.
EQUIPMENT - T h e Equipment for production, Transportation and

compaction of concrete shall be as under
a) For Production of concrete - Automatic Batch type ready mix
concrete plant of minimum 30 Cum.hr
b) For Concrete Transportation - Concrete transit mixer, power
hoists.
Chutes, concrete distributor booms,
tremies and cranes with skips.
Only Ready Mix Concrete is allowed for all concrete
work.
Materials - No creek sand shall be allowed in concreting. Only river/natural

sand from approved sources shall be allowed and the percentage of
Crushed sand obtained from V. S. I. shall not be more than 15% of total fine
aggregate in the mix. The crushed sand should be as per IS 383 reaffirmed
1997 and IS 2386 (Part VII) gives standard test method for alkali aggregate
reactivity which can be used when dealing with suspicious aggregate. Aggregate
must be tested for Alkali aggregate reactivity before use in work. (e.g. Total fine
aggregate 100% = River/Natural sand
85%+ Crush Sand from V. S. I.
15%)
4.1 Admixtures :
Air entraining agents workability aids, plasticisers retarding agents may be
used if permitted by the Engineer. All such admixtures shall be I.S.I.
approved brands.
5. DURABILITY:
5.1 Minimum Cement Content:
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As per design criteria mentioned above.
5.2 Only Ordinary Portland cement of 43 grade conforming to I.S. 8112 is

permitted for this work. Use of Fly ash is restricted to maximum 25% by
the weight of cement for this work. Source of fly ash should be get
approved by the Engineer – in – Charge prior to execution of work.
5.3 Minimum clear cover to reinforcement for all grades of concrete shall
be as below:
As per design criteria stated above.
6. EXPANSION JOINTS:
As per design criteria stated

above.
7. WATER SPOUTS:
above.
8. WEARING COAT:
above.
9. SPECIFICATIONS, CODES FOR CONSTRUCTION TO BE FOLLOWED:
For the construction of road and other structure, MORTH specifications for
road and bridge work shall be applicable for this work, including testing of
material and various
items of work. Relevant IS specification and code for testing of material and
item as per specified will also be applicable.
2. MATERIALS FOR STRUCTURES
Clause 112 Arrangement for Traffic during Construction
The contractor shall implement all the safety measures and necessary diversions at site during
the entire period of construction. In no case shall the traffic using the road shall experience any
kind of hindrance due to the construction work.
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Clause 1500 Form Work

The formwork used shall be preferably of properly stiffened marine plywood, such as DOKA/PERI
type. Other requirements shall be as per Clause 1502.
Clause 1600 Steel Reinforcement Un-tensioned

Reinforcement of high yield strength deformed bars of uncoated shall be used.
Clause 1700 Structural Concrete

The work shall consist of forming and placing of concrete. All concrete shall be manufactured
with semi-automatic batching and mixing Plant with electronic controls as approved by the
Engineers representative.
Clause 1702 Materials

No creek sand shall be allowed in concreting. Only crushed sand and or river sand from approved
source shall be allowed. The suspicious aggregates shall be dealt in accordance with IS 2386 (part
VII) for alkali aggregate reactivity.
Clause 1707 Equipment

The Equipment for production, Transportation and compaction of concrete shall be as under
For Production of concrete
For all concrete work – semi automatic batching and mixing Plant as approved by the Employers
representative.
For concrete Transportation – Transportation of concrete form Concrete discharge point to the
point of deposition shall be such that the rate of concrete placing is commensurate with the
production of concrete. Transportation shall be such that there should not be any segregation of
concrete or formation of cold joints in the deposited concrete.
Clause 2907 Backfilling

The backfill shall be with selected granular material of approved quality.
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Part C – Tunnel work Specifications
Specifications for Tunnels Etc.

1.0 General
1.1 The Work shall be governed by all provisions set out in the Tender Documents and by
relevant provisions of the Indian Standards listed out elsewhere in these tender
documents and Technical Specifications set out hereinafter. Wherever these Technical
Specifications are at variance with the provisions elsewhere in the Tender Documents
and the Indian Standards, provisions of these Technical Specifications shall prevail and
shall be binding on the Contractor.
1.2 Description, dimensions of Clear Section of the Tunnels including their Cut and Cover
Sections and the Cross Passages indicated in the drawings as well description and
dimensions of the items of the supporting systems are final and binding on the
Contractor. All other drawings of the open cuts, etc. and their components indicated in
the tender documents or drawings are indicative. Actual construction will have to be to
suit the geotechnical conditions met with.
1.3 List of Items of Work expected to be required for execution of the Tunnel Work is given
in the Bill of Quantities.
1.4 Except for Clear Section of the Tunnels including their Cut and Cover Sections and the
Cross Passages indicated in the drawings as well description and dimensions of the items
of the supporting systems are final and binding on the Contractor. The profile and the
longitudinal section of the open cuts, tunnels etc. as indicated in the relevant drawings
are tentative. The finalized profiles and the exact locations from where tunneling
operations will be commenced will decided by the Engineer at the appropriate stage of
work.
1.5 The Contractor shall have to carry out the work strictly in accordance with the drawings
issued for construction and the technical specifications. Wherever there is variance
between the drawings issued for construction and the technical specifications,
provisions shown in the drawings issued for construction shall prevail and shall be
binding on the Contractor.
1.6 The new road will have two almost parallel tunnels, each accommodating three lanes
and a refuge lane. Each tunnel is expected to be about -------- long with about ------. long
cut & cover section at the each end. In the portion of the tunnels around Ch. ------- Km.
where the cover is low, it may become necessary to provide cut and cover sections. The
two tunnels will have ------ connecting tunnels / passages connecting them to one
another. The connecting tunnels / passages would serve as escape and diversion of the
extreme right traffic lane in case of emergency.
1.7 The carriageway will have concrete side drains on both sides. Side drains will be
covered with precast concrete slabs to form walkways with hand railing.
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1.8 The tunneling medium is likely to comprise various forms of amygdaloidal basalt with
varying degrees of jointing and weathering. In some locations and particularly in areas
with low cover above the tunnel, the tunnel could pass through highly weathered strata
and overburden. The rates quoted by the Contractor shall take into account above
geology and also all classes of rock/soils and no extra payment will be made for variation
in rock/soil.
1.9 Open cuts should be excavated to stable slopes and provided with surface treatment
such as soil nailing, rock bolting, shotcreting, etc. wherever necessary, so as to remain
within the right of way and as directed by Engineer.
1.10 Rock mass above the excavated portals of the tunnels should be strengthened by drilling
and pressure grouting and the exposed profile should be provided with surface
treatment such as soil nailing, rock bolting, shotcreting, etc. if and where necessary, as
per drawings issued for construction and as directed by Engineer.
1.11 Portion of the Tunnels passing through blocky and very heavily jointed rock near
excavated Portals of the tunnels and elsewhere in the tunnels should be provided with
fore-poles and supports in the form of immediate Steel Fiber Reinforced [S.F.R.]
Shotcrete, if and where necessary and Full Column Resin Grouted Rock bolts, Permanent
Steel Supports made of Rolled Steel Joists and embedded in Concrete Lining or Lattice
Girder Supports embedded in S.F.R. Shotcrete, if and where necessary, as per drawings
issued for construction and as directed by Engineer.
1.12 In some locations and particularly in areas with low cover above the tunnel, where the
tunnel could pass through highly weathered strata and overburden. Ground
improvement techniques such as advance grouting, fore-poling including pipe fore-
poling if and where necessary, shall be provided as per drawings issued for construction
and as directed by Engineer.
2.0 Scope of the Work

A) The Engineer-In-Chief, ---------- invites bids for the Construction of Tunnel and Road
between ---------------------------------------------------. The Bidders may submit bids for above
said works as per NIT.
B) General Information of work –
The Proposed Road / Tunnel will have two almost parallel unidirectional traffic tunnels,
each accommodating three lanes and a refuge lane. Each tunnel is expected to be about
----------. long with about --------. long cut & cover at the each end. The two tunnels will
have -------- connecting tunnels / passages connecting them to one another. The
connecting tunnels / passages should serve as escape and diversion of the extreme right
traffic lane in case of emergency. The tunnels will be furnished with ventilation, lighting,
fire-fighting and telecommunication arrangements.
The works include, but not limiting to the following:-
a) Demarcation of land and setting out alignment including boundary stones.
b) Exploring Survey, Rock investigation and testing for Twin Tunnel
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c) Soil investigation and testing for Foundation for structures

d) Excavation of Open Cuts in all types of soils and rock including provision of
treatment such as Soil Nailing, Rock bolting, Shotcreting, Grouting etc. to the
excavated profile as and where necessary as per drawings issued for
construction and as directed by Engineer
e) Tunnel Excavation in all types of soils and rock with concurrent Advance Probing
and if and where necessary, Grouting of the Strata ahead, Fore-poling,
Shotcreting, Rock bolting and Installation of Permanent Steel Supports with
precast Lagging and Lean Concrete back-packing, installation of Lattice Girder
Supports embedded in S.F.R. Shotcrete, as and where necessary as per drawings
issued for construction and as directed by Engineer.
f) Construction of Cut & Cover Portion and Concrete Portals with Backfill behind with
drainage arrangements, in the Approach Cuts.
g) Concrete Lining of the Tunnel where required and as directed by the Engineer.
h) Concrete in Side Drains, Kerbs and Crash Barrier etc. in the Tunnels, Cut & Cover
Portions and Open Cuts.
i) Installation of Furnishings such as Walkway Slabs, Hand Railing for the Walkways,
Fire Water Line etc. in the Tunnels, Cut & Cover Portions and Open Cuts.
j) Supply, Erection, Testing and Commissioning of Mechanical, Electrical and
Plumbing , Ventilation / Exhaust, Fire Protection, SCADA, low Voltage System &
Telecommunication system etc Services
k) Construction of Concrete Road
l) Construction of Twin Tunnel including all necessary works like shotcreting etc.
m) Operation & Maintenance of Twin Tunnel for 5 (Five) years
n) Utility relocation / protection etc.
o) Construction of Safety Barriers.
3.0 Special Features of the Work

3.1 The Contractor will use controlled blasting techniques so as to avoid damage to
adjoining and overlaying structures, electric power lines, telephone lines, etc.
3.2 The Contractor will have to plan the tunnel excavation activities in such a manner that at
no stage the gap between any two faces under excavation will be less than 50 m.
3.3 The area lies in Seismic Zone No. IV as defined by BIS Codes.
3.4 Intending Contractors should visit the site of the tunnels, cut and cover portions, open /
approach cuts and muck disposal areas and thoroughly acquaint themselves with the
local conditions obtaining at the site of the work.
4.0 Underground Excavation

4.1 Setting Out
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The reference points for starting the work will be handed over to Contractor by the
Engineer. The Contractor shall establish permanent reference marks on the centre lines
of tunnel etc. and their extensions near the portals, at both the ends as may be
necessary and as directed by Engineer. The permanent marks shall be inscribed on brass
pegs set in concrete blocks.
As the work progresses, centre line marks shall be transferred on pegs, inserted into the
roof of tunnels at suitable locations and at convenient intervals to the satisfaction of the
Engineer for checking alignment, grades, levels etc, and also the dimensions of the
excavated profiles.
The Contractor shall at all times remain responsible for the sufficiency and accuracy of
all such benchmarks, central line pegs and reference points. The cost of setting out
activity shall be deemed to have been included in the accepted rates for the work.
4.2 Accuracy of alignment, grades, levels etc.
a) Benchmarks and fixed reference points, with the value of the reduced levels and the
coordinates will be fixed by the Engineer, near the works area.
Plan showing the position, coordinates and levels of the salient pints of the various
underground works will be supplied to the Contractor. The Contractor will fix his
permanent points and benchmarks in relation to those handed over to him by the
Engineer. He shall take all precautions to see that the points fixed by the Engineer are
not disturbed by his work and shall make good the damage, if any, at his own cost. The
Contractor shall excavate the tunnels, cut and cover portion etc. true to alignment,
grades and levels and shall check them at frequent intervals as the work progresses. The
Contractor shall provide at his own cost all facilities like labour, equipment and
instruments etc. to the Engineer to check the alignment, grades and levels etc. whenever
and anytime they are asked for. Such checking by the Engineer or his representatives,
shall not absolve the Contractor from his responsibility of maintaining the accuracy of
the wok. Any discrepancy or error detected during the course of excavations and / or at
the end of the work when the excavated bore / faces meet shall be set right by the
Contractor at his own cost in a manner satisfactory to the Engineer without causing any
harm to the work already carried out. The Contractor, shall at all times during execution
of work, at least one electronic total station, two auto levels and two theodolites, duly
calibrated and in good condition, at site of work, at the disposal of the Engineer, for
proper control of line and level.
b) The Contractor shall arrange to check the excavated profiles periodically to ensure
excavation to required profile and undercuts, if any, found within the boundary of
minimum excavation line, shall be immediately removed.
4.3 Proposed Method of Work
a. The approx. cross sectional area of the clear / finished line section of each tunnel, as
shown in the drawings, is about --------- m2. The Contractor will carry out the work of
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tunneling by full face excavation or heading and benching method or multi-drift method
to suit rock conditions and to expedite the work and minimize tunnel hazards. The
Contractor can carry out tunnel excavation in heading and benching simultaneously with
suitable lag, to expedite progress. Contractor shall carry out Shotcreting, rock-bolting
and installation of permanent steel supports with lagging and lean concrete back-
packing and installation of lattice girder supports along with their embedment in S.F.R.
Shotcrete simultaneously with the excavation, as per site requirements and as directed
by the Engineer. Therefore, the Contractor should deploy adequate plant and
machinery, skilled labour, material etc. for such simultaneously activities of tunnel
excavation.
b. Assuming loss of time, breakdown of machines, power failure, less output due to rock
condition etc. the expected average monthly progress should be minimum 100 m. per
face per month for full face (i.e. heading plus benching) from fifth month after
commencement of tunneling with simultaneous operations installation of supporting
system.
c. The Contractor shall prepare and submit to the Engineer for his approval a complete
scheme detailing his proposed method of Tunneling (full face or top heading and
benching or multi-drift etc.), the pattern of holes and the charge, the type of explosives,
the methods of providing permanent and temporary – supports if required, the cycle of
operation and the rate of progress expected, the manner in which it is proposed to
minimize over-break, the nature of protective devices to minimize hazards to labour,
equipment etc. Even after such approval by the Engineer the Contractor shall not be
absolved of his responsibility in respect sufficiency and safety of the methodology.
d. The Contractor should plan his operations and carry them out in such a manner and in
such sequence that the entire work is completed within the time targets laid down.
e. No extra payments shall be made for temporary spreading of finer material or Quarry
dust for road maintenance during construction as well as cleaning of the tunnel before
lining.
4.4 Drilling and Blasting Procedure to be adopted
a) The drilling and blasting pattern should be such that the operations do not result in
undue over-break. Only wet drilling shall be adopted in all underground work and the
Contractor should make satisfactory arrangements for the water supply, at appropriate
pressure, required for drilling and other operations at his own cost.
b) The blasting should be controlled and conducted in such a manner so as not to cause
damage to or endanger the adjacent ground or property due to vibrations and fly-rock.
The Engineer reserve the right to decide the type, number, size and pattern of holes to
be drilled, the type and amount of explosives to be used, the firing methods to be
resorted to etc., having regard to safety and satisfactory workmanship. The Contractor
shall at all times abide by the instructions of the Engineer in this regard and shall not
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offer any claim for damages or loss due to any delay claimed to have occurred during the
progress of any part of the work as a result of following such instructions or adopting
such safety methods as the Engineer may have ordered from time to time.
No extra payments shall be made for adopting controlled blasting techniques.
4.5 Enlargement in Excavated Profile
If after completion of excavation in any length to any profile, it is subsequently decided,
by the Engineer, to enlarge the tunnel section, the same will be carried out by the
Contractor.
4.6 Trimming
After blasting, the whole area of excavation should be carefully examined and all loose
rock and projections, etc., removed in such a way that there shall be no piece of rock
falling down subsequently. Particularly the tunnel crown should be tapped frequently
during the course of work and any suspicious portions or rock which may fall down,
having worked loose form the vibrations of blasting should be sliced off. After the
section is excavated, infringements that may be found within the boundaries of the
minimum excavation line it should be carefully trimmed by using light explosive charges,
4.7 Disposal of Excavated Materials
a) All excavated materials and Rock fall material shall be taken over by the Contractor,
which he will re-use in the work with the approval of the Engineer and surplus material
shall be dispose with all leads & lifts. The payment of the Royalty will be the
responsibility of the Contractor for all excavated materials and Rock fall material.
b) The Contractor shall at all time keep the site free from all surplus earth, surplus
materials, and all rubbish which shall arise from the works and should dispose of the
surplus excavated materials as ordered by the Engineer, failing which it will be got
carried out at the cost of the Contractor and cost will be deducted from Contractor’s
dues.
c) The Contractor shall within 15 days of completion of entire works remove all unused and
surplus materials, tools and plants, staging and refuge or other materials produced by
his operations and shall leave the site in a clear and tidy conditions. (Delete)
d) Use of tunnel spoils for production of sand and aggregates may be permitted by
Engineer if and after the Contractor obtains a certificate of suitability of the material
form reputed / Govt. laboratory.
4.8 Drainage
The working faces and the tunnel should be kept free of stagnant water at all times.
Temporary drainage channels excavated by the Contractor outside the Pay Line profile,
during the course of tunneling should be filled back with backfill concrete of M 25 grade
by the Contractor at his own cost. The Contractor must take all precautions so as to keep
the work sites including the face of the tunnel free from stagnant water during all
seasons of the year.
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4.9 Measurement & Payment

a. Underground Excavation
Minimum Excavation Lines and Pay Lines have been indicated in the drawings showing
Cross-Sections of the Tunnel. Measurement and payment for Underground Excavation
up to Payment Lines shown in the drawings issued for construction will be made at the
Rate Quoted for relevant Item of the Bill of Quantities on the basis of per Cu.m. Volume
of excavation. The quoted rate is considered with cost of stone deducted, that means
the excavated material will be the property of the Contractor, which he will re-use in the
work with the approval of the Engineer and surplus material shall be dispose with all
leads & lifts. The payment of the Royalty will be the responsibility of the Contractor for
all excavated materials and Rock fall material.
b. Removing over fallen Muck:
Excavation occurring beyond the Pay Lines, which is caused due to natural causes such
as concealed joints, faults or other structural defects in rock and not due to lack of
reasonable care and skill in excavation on the part of the Contractor, will be considered
as Approved Over breaks.
Quantity of such over breaks will be considered as over fallen Muck.
Measurement and payment for Removal of Over fallen Muck will be made on the basis of
per Cu.m. of volume of Over break as approved by the Engineer at rates quoted for the
relevant item of work.
c. Subsequent Enlargement:
If after completion of excavation of any part of the tunnel, it is subsequently decided, by
the Engineer, to fully or partly enlarge the tunnel section, the same will be carried out by
the Contractor
Measurement and payment for such Subsequent Excavation will be made on the basis of
per Cu.m. of volume of Excavation as approved by the Engineer at rates quoted for the
relevant items of work..
5.0 Shot Concreting
5.1 General
a. The provisions contained in IS: 9012-1978 shall generally apply. The work consists of
provision and application of shotcrete to excavated profile of the open cuts and the
tunnels. All Shotcrete will be Steel Fiber Reinforced Shotcrete [SFRS] of thickness as
specified unless otherwise ordered by the Engineer. Shotcrete shall be applied on
excavated periphery of the tunnels or the open cuts at locations as directed by Engineer.
b. Shotcrete, for this work, shall be defined as sprayed premixed Portland cement concrete
as per approved design with admixtures including Micro-silica and additives (i.e. water
reducing agents/ thixotropic agent, accelerators etc.) form a spray nozzle by means of
compressed air using wet shotcrete machine. Shotcrete shall be applied in accordance
with relevant ACI/ASTM/EF/NARC specifications/guidelines.
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5.2 Materials
Ingredients of shotcrete will include cement, aggregate, admixtures, microsilica and steel
fibres. Specifications of ingredients are given below.
a. Cement: Low alkali cement is recommended.
b. Aggregate
Aggregate shall conform to requirements of relevant IS Code or as directed by Engineer
–in-charge. The aggregate size shall not exceed 10 mm. The grain size distribution of
aggregate shall be as under:
Sieve size Percentage passing through sieve
(mm) Minimum Maximum
10 100 100
8 90 100
4 73 100
2 55 90
1 37 72
0.5 22 50
0.25 11 26
0.125 4 12
The aggregate shall be well graded and no fraction, shall, constitute more than 30% of
the total mass.
c. Admixtures
Only proven admixtures which meet the requirement of the specification on field trials
and satisfactory performance on other projects already constructed in India and
elsewhere shall be used to ensure a homogeneous mix and better dispersions of various
constituents of shotcrete. A two component system to control the consistency shall be
used to ensure good workability and low rebound. The admixture system shall produce
slump killing effect and thixotropic consistency thus adhering in thick layers without
trickling and subsequently reducing the rebound. The Contractor shall submit along with
the design a certificate for satisfactory performance of admixtures and chemical
compatibility between two components, from the manufacturer.
Admixtures shall be of following types :
i Water reducing / thixotropic agents : -
These agents shall be added at the batching plant / concrete mixer to keep the Shotcrete
/ mix workable during transportation and to ensure pumpability at an acceptable low
W/C ratio. The chloride contents shall not exceed 0.1% by weight.
ii Accelerators :
Accelerators shall meet the following requirements:
 Only liquid alkali free accelerators shall be used.
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 Water glass (sodium silicate) shall not be used unless in a modified base form approved
by the Engineer.
 Only the minimum quantity of the accelerator as necessary shall be permitted in normal
shotcreting operations subject to maximum dosage of 5-6% by weight of cementitious
material.
 Accelerators should have pH values less than 12.
Accelerators shall be selected such that at the chosen dosage for use in the works, the
decrease in strength at 28 days compared with the base concrete without any
accelerators shall not exceed 10%. There shall be no further reduction in strength of the
shotcrete mix between 28 and 90 days.
d. Micro-silica (silica fumes)/ Metakaoline
Micro-silica / Metakaoline produced/ manufactured only by suppliers as approved by
Engineer shall be used for the work. The dose of silica fumes shall be 5 to 7% of cement
weight subject to site trials. Silica fumes shall have bulk density between 500 to 700 kg.
per cum. Few important requirement are reproduced below for guidance :-
i Chemical requirements
Sl. No. Property % Age Min Frequency of testing or
as Directed by Engineer
1 SiO2 > 85 Lot or 100 MT
2 SO3 <1 Lot or 100 MT
3 Loss on ignition <6 Lot or 100 MT
ii Physical requirements
Property % Age Min Frequency of testing
Sl. No. or as Directed by
Engineer
1 Accelerated pozzolonic activity 85 Lot or 100 MT
index with Portland cement at 7
days (Min %age of control)
2 Increase in drying shrinkage of 5 Lot or 100 MT
mortar bars at 28 days (Max
%age joints)
3 Reactivity with cement 80 Lot or 100 MT
reduction of mortar expansion
at 14 days
(Min %age)
Metakaoline shall conform to ASTM C 618 Class – N pozzolana specifications.
e Steel Fiber
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Steel Fiber produced / manufactured only by suppliers as approved by Engineer shall be

used for the work. No balling of steel fibers should occur at the time of mixing and
shotcreting. The dose of steel fiber shall be 40 kg. per cubic meter and achieve a min of
750 J energy absorption subject to site trails. However in case the quantity of steel fibre
is increased or reduced from 2 kg. per Sqm of shotcrete of 50 mm. thickness, in the
approved mix design, rate adjustment at Rs. 60 per kg. will be made for increased or
reduced quantity of steel fiber.
The Contractor shall submit test certificate from a reputed laboratory/ supplier for all
ingredients brought and intended to be used in shotcrete / SFRS by him. Engineer may
however get the samples of these materials tested independently at Contractor’s cost.
The cost of such test shall be deemed to be included in the quoted rates.
5. 3 Strength criteria
The final product shall meet the strength criteria as per relevant EFNARC/ACI standards.
The frequency of testing shall be as specified in the Codes or as directed by Engineer.
The strength requirements for SFRC/plain shotcrete are given below.
a. Steel fiber reinforced shotcrete:
The Shotcrete shall meet the following strength requirements :
i Compressive strength on cylindrical cores
(i) 3 days 10 Mpa
(ii) 7 days 18 Mpa
(iii) 28 days 25 Mpa
ii Flexural Strength
28 days 3.8 Mpa
iii Toughness
28 days 2.4 Mpa
b. Plain wet shotcrete:
The mix shall be designed to give the following strength requirements.
i Compressive strength on cylindrical cores
(i) 3 days 7 Mpa
(ii) 7 days 15 Mpa
(iii) 28 days 20 Mpa
ii Flexural Strength
28 days 3 Mpa
5.4 Mix design
The Contractor shall submit mix design to meet the strength as specified for prior
approval of Engineer prior to commencement of shotcrete/SFRS. Mix design should give
following details.
Ordinary Portland cement Kg
(Low alkali cement is recommended)
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(Minimum cement contents as per I.S 456,2000 for durability)

Micro silica/ Metakaoline Kg
Natural fine aggregate Kg
Crushed coarse aggregate Kg
Crushed fine aggregate Kg
Steel fibers Kg
Water reducer/ thixotropic agent Kg
Accelerator Kg
W/C ratio
Slump
Density (Wet)
Compressive strength on cylindrical cores. 3 days/ 7 days/ 28 days
Equivalent cubes strength 28 days

Flexural strength 28 days
Toughness 28 days
5.5 Test procedure

Tests of SFRS/ shotcrete shall be carried out as per relevant ASTM/JSCE/EFNARC
standard or as directed by Engineer. All equipments for testing shall be arranged by the
Contractor at his own cost. Some of the tests of the shotcrete/ SFRS are given below for
guidance.
a. Compressive strength
The specimen cylindrical cores measuring minimum 75 mm dia or concrete cubes of 100
mm size or as directed by the Engineer shall be drilled/sawn/extracted out of prepared
test panels. Panels for testing shall be at least 600 x 600 mm in size and shall be of
thickness as per design. The panel shall be prepared by shotcreting into vertical moulds
which shall be constructed of steel or other non-water absorbent material and shall have
side splayed out moulds at 15 degree to prevent the entrapment of rebound.
b. Flexural strength and energy absorption
Flexural strengths and energy absorption shall be measured in accordance with Japanese
standard JSCE/ASTM/EFNARC standards. The beam shall be cut out from splayed panels.
The beam shall be stored in water for a minimum of 3 days after sawing and
immediately, before testing and kept moist during testing. The test panel for energy
absorption shall correspond to EFNARC or SiA standard.
5.6 Placing equipment
Contractor should have wet shotcrete machine with Robot arm which can spray
shotcrete efficiently even in overhead positions. The machine should be able to place
shotcrete & SFRS as per design mix.
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a The air supply system shall be capable of supplying air at the pressure and volumes
needed for the efficient operation of the machine. No air supply system shall be used
that delivers air contaminated by oil or that is incapable of maintaining constant
pressure.
b In addition, a separate air hose and blowpipe shall be available to remove dust &
rebound during shotcrete application.
5.7 Method of application
a. Only wet mix method shall be used for the purpose spraying shotcrete.
b. Water cement ratio shall be 0.45 (maximum) by weight of cementitious material.
c. The workability shall be measured by slump test and should be between 10 to 15 cms.
The slump shall also be checked after interval of 15 minutes which should be within
prescribed limits. The shotcrete older than 2 hours and having slump not within
prescribed limits shall not be used unless treated with hydration control additives. If
SFRS is used, the spread shall be 40-55 cm.
d. The required workability shall be ensured before transporting the mix for execution at
batching plants/transit mixer itself.
e. Surface on which shotcrete is to be placed, shall be suitably prepared by scaling followed
by cleaning with compressed air and water under pressure through nozzle. All surface
shall be wet and clean at the time of applying shotcrete
f. Before filling mix in the hopper of the shotcrete machine, slurry shall be mixed and put
into the concrete hose.
g. The application procedure of Shotcrete shall be developed in the field to give minimum
rebound, minimum shrinkage etc. to the satisfaction of the Engineer.
h. The nozzle shall be held at a distance of approximately one meter but in no case greater
than 1.5 meter from the surface to be covered and positioned so that the stream of
flowing material shall be applied as early as possible at right angles to the surface to be
covered. Nozzle shall be held in steady motion so that the shotcreate is applied
uniformly to build up the required thickness of layer. Acceptable shotcrete shall consist
of dense and uniform concrete without rebound, segregation or discernible weakness of
bond between layers. The nozzle men shall apply shotcrete with a uniform consistency in
order to maximize binding cohesion and density, minimize rebound and segregation and
prevent sagging of applied shotcrete.
i. Shotcrete shall always be started from the bottom to avoid rebound material getting
locked in. Shotcrete will be applied in a single layer of 50 mm. thickness or successive
multiple layers of 50 mm. thickness as per directions of the engineer.
j. Before laying a new layer over a previously laid layer, the previously laid layer shall be
allowed to take its initial set and loose materials from the surface shall be removed.
k. Care shall be taken to ensure that no air pockets are formed behind the shotcrete.
l. All applied shotcrete shall be kept wet for at least 7 days or have internal curing agent to
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ensure proper curing of the shotcrete. Sufficient air shall be added at the nozzle to get
good compaction and higher compressive strength
m. All necessary precautions shall be taken to ensure that there is no damage to the
instruments installed in rock and to ensure that the drainage holes do not get plugged.
5.8 Proficiency of workmen
Nozzle man shall have had previous experience in the application of shotcrete on at least
two projects of comparable nature and shall work under immediate supervision of a
foreman or instructor with at least five years of experience. Proficiency of workmen will
be checked by the Engineer before allowing them to work.
5.9 Control of water
Water flow and seepage shall be controlled in such a manner that detrimental effects
are completely and permanently eliminated. The Contractor may drain such water by
pipes, chases or other appropriate methods approved by the Engineer.
5.10 Safety Measures
Alkali hydroxides and other chemicals contained in shotcrete admixtures are moderately
toxic and can cause skin and respiratory irritation unless adequate safety measures and
undertaken. In applying shotcrete containing toxic admixtures, the nozzle men should
wear protective masks to breath air, which shall be free of toxic or objectionable
material. Gloves and necessary protective clothing shall be worn to protect against
dermatitis.
5.11 Method of Measurement
Measurement and payment of shotcrete shall be made on the basis of per Sq. M. of 50
mm. thick layer of Shotcrete/SFRS as projected on the theoretical Minimum Excavation
Line shown in the drawings issued for construction or as directed by the Engineer. The
rate given in the Schedule for shotcreting item shall be deemed to include cost of all
materials and all operations, rebounds etc. as per specifications and as directed by the
Engineer. The account of actual consumption of cement, steel fiber, micro-silica, and
accelerators shall be maintained in the form as approved by the Engineer. No extra
allowance will be made to account for extra area due to surface undulations and for
Shotcrete lost due to rebounds or otherwise.
6.0 Supplying and Installing Rock bolts ;

6.1 Work of Supplying and Installing Rock bolts involves drilling about 40 mm. dia. Holes and
furnishing and installing therein of 25 mm. dia. Rock bolts grouted along their full length
with resin capsules and with all accessories such as face / bearing plates, spherical and
other types of washers and nuts etc., and tightening and stressing them as directed by
the Engineer. The rock bolts shall be installed, in the sides and arch of the tunnel in a
pattern as directed by the Engineer. Where found adequate, only spot bolting will be
carried out as directed by the Engineer.
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6.2 Sufficient number of Resin Capsules of approved quality should be used so as to provide
bond along full length of the rock bolts to be inserted into the holes. The resin capsules
manufactured only by approved agencies and approved by the Engineer shall be used.
6.3 The Engineer shall give instructions in writing for the provision of rock bolts, their length
and fixing arrangements etc. The rock bolts shall be in accordance with specification No.
IS 5876 (Part IV) – 1971. Also, pull out tests shall be carried out as per relevant IS codes.
All testing shall be carried out in the presence of Engineer or his representative. The cost
of testing shall be deemed to be included in the rate quoted. The Engineer reserves the
right to ask for pull out tests in any location where he deems them necessary. If during
the testing, any rock bolt fails due to improper workmanship or defective material, the
Engineer may order testing of all the adjacent rock bolts and all rock bolts so failing shall
be replaced and re-tested by the Contractor at his own cost.
6.4 Resin Grouted Rock bolts shall be as per IS 13517 : 199P and fabricated from high
strength steel bar conforming to grade F.410S ( see IS 226 : l-975 ) or steel designation
4OC-4 [see IS 1570 ( Part 4 ) : 1988 ]. Bearing plates shall be fabricated of F.41OS ( see IS
226 : 1975 ).and 7.3 Nuts shall conform to product Grade – C as specified in IS 1363 (
Part 3 ) : 1984.
The unit rate shall be per RMT (Running meter) of rock bolts installed at the Rate Quoted
for relevant Item of the Bill of Quantities which rate will include the cost of furnishing
and installation of rock bolts including drilling and cost of all materials, fixing, tightening
the bolts to the required technique, tools and plant, labour and all other works in
connection therewith complete as required under IS code of practice. Any bolts which
cannot serve their intended purpose because of caving or loosening shall not be paid for.
7.0 Permanent Steel Supports

7.1 Permanent Steel Supports
Permanent Steel Supports are those erected during the excavation of tunnel and left in
place forming part of the finished tunnel. These supports shall be provided as and where
required and as ordered by the Engineer.
7.2 Fabrication of Permanent Steel Supports
a. All materials and steel required for the fabrication and installation of permanent steel
supports shall be arranged by the Contractor at his cost. The supports shall be fabricated
by cold bending according to drawings issued by the Engineer. The rate for permanent
steel support includes cost of structural steel including transport to site of work,
handling, fabrication & erection, provision of bolts, nuts, rivets and washers with all
Contractors labour, materials, plants & equipments etc. complete.
b. Permanent Steel Supports fabricated out of R.S. Joists and Lattice Girder Supports
fabricated out of M. S. Rounds shall be fabricated by cold bending to the shape indicated
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in the relevant drawing supplied by the Engineer and the butt / junction plates etc. shall
then be welded on. When finished, the supports shall be true and free from all kinks,
twists etc. and shall not be defective or strained in any manner. The fabrication of the
supports shall be carried out in accordance with the provisions of the Indian Standard
Code I.S. 800-1956 and Codes applicable to Lattice Girders.
c. No painting of any sort is to be carried out on the steel support.
7.3 Erection of Supports
a. The supports shall be erected as per the drawings issued and under instructions of the
Engineer, whose decision in regard to the spacing at which the arch ribs and posts are to
be erected will be final.
b. The detailed drawings will be supplied to the Contractor form time to time for different
types of strata encountered and Contractor will be required to execute the work as per
these drawings. Nothing extra shall be payable for change in spacing and decision of
Engineer will be final & binding on the Contractor.
c. In zones where the supports have to be used for supporting the roof of the tunnel, it
may be desirable from the technical point of view to carry out the break out to full
section in two or multiple operations (a) break-out of the Heading in one or more
operations and (b) deepening of the Heading by Benching in one or more operations.
These types of break-out will be amenable to easy erection of the supports and avoid
hazards.
d. Where excavation of the heading is carried out by advancing Central Drift followed by
widening to full section of the heading, Arch of the Central Drift will be supported using
segments of the arch rib held in place by installation of temporary verticals and bottom
struts. The segment of the arch rib will have a cover plate on both ends so as to
facilitate its extension to form a full arch rib. When excavation for widening of the
advancing central drift to full section of the heading is carried out, the segments of the
arch ribs erected previously in the heading and now falling within the area where the
area on the sides has been blasted will get exposed. An extension segment of the arch
rib will be attached at each of the two now exposed ends so as to form a full arch rib.
Other end of these extension pieces will be made to rest and fixed onto a wall beam laid
on each side of the heading. In case of Supports fabricated out of R.S. Joists, concrete
lagging planks will be placed over the extrados of the supports and the annular gap
between the tunnel periphery and the lagging will be packed with backfill concrete of M
20 grade. Where steel rib supports are provided in already shotcrete section, the ribs
will butt against shotcrete periphery by use of chairs and wedges and concrete lagging
planks with backfill concrete will not be required. In case of Lattice Girder Supports, the
girders will be embedded in S.F.R. Shotcrete, as directed by the Engineer. Next cycle of
excavation of the heading will be resumed.
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When the break-out is achieved by dividing the face in two or more parts as aforesaid, it
will be necessary to install wall beam on both sides of the heading to correct line and
level and secure it in position on timber packing. The wall beam will act as a girder for
supporting the arch ribs when, during bench excavation, arch ribs get underpinned as
planned.. The length of the wall beams will depend on its design and load bearing
capacity when it is underpinned during bench blasting and till verticals are erected
below it. Length of bench advance will thus depend on the load bearing capacity of the
wall beams. New pieces of wall-beams laid on either side shall be connected loose to the
previously laid wall-beams by means of splice plates, bolts, nuts and washers etc. Arch
ribs shall then be guyed up, aligned, leveled and connected to the previously erected
arch ribs by means of tie-roads with double nuts.
e. Provision of the wall beams, shown in the drawings is obligatory. The Contractor will
have to design the wall beams and splicing and get it approved from the Engineer.
f. As soon as the arch ribs are erected, they shall be firmly blocked against rock surface /
shotcreted periphery at points not exceeding the spacing as shown in the relevant
drawing using timber packing and wedges. Blocking work shall be progressed from the
lower most point of the arch ribs towards the crown in a systematic manner. The
packings shall then be driven tight so as to close the gap if any, at the crown of the
support, to introduce the “Prestress” in the ribs. As soon as two consecutive supports
are erected, crown bolts, tie rod bolts and the gusset bolts on the post plates etc., shall
be tightened.
g. For structural steel plates and rounds record of sample weights shall be maintained
jointly by the Engineer & the Contractor.
7.4 Measurement & Payment:
a. Weight of bolts, nuts, washers, wedges etc. required for installation of the Steel
Supports will not be taken into account for the purpose of measurement and payment.
b. Measurement and payment for Fabrication and Installation of Steel Supports will be
made at the Rate Quoted for relevant Item of the Bill of Quantities on the basis of per
Metric Ton (MT) weight of Structural Steel Sections, Plates and Rods required as per the
drawings approved for construction or as directed by the Engineer. Temporary
supports, if any, erected during any stage of construction will not be measured and paid
for.
8.0 RCC Lagging with Concrete Back Packing

8.1 Precast R.C.C. Lagging will be of M 20 grade concrete and will be generally in the form of
50 mm. thick and about 150 mm. wide precast slabs and will be placed over the extrados
of the steel supports fabricated out of R.S. Joists, so as to provide a continuous wall and
ceiling. Length of the lagging will be such as to suit the spacing of Steel Supports ordered
by the Engineer. Lagging shall be in the form of pre-cast RCC slabs as per approved
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drawings. The work of providing the M 20 grade concrete back-packing shall be

progressed simultaneously with the work of fixing the laggings and form either side.
Measurement and payment for Providing and Fixing Precast R.C.C. Lagging will be made
at the Rate Quoted for relevant Item of the Bill of Quantities on the basis of per Cu.M. of
Concrete calculated from the neat dimensions of the lagging as shown in the drawings
approved for construction or as directed by the Engineer. Measurement and Payment
for Concrete Back-packing will be for the volume up to the excavated/ shotcreted profile
including Approved Over break and excluding un-approved over breaks under the
relevant Item of the Bill of Quantities. No separate Measurement will be made for
formwork, shuttering, scaffolding etc. and all other required operations and work and
cost thereof shall be deemed to be included in the Rate Quoted for relevant Item of the
Bill of Quantities. Reinforcement will be measured and paid for separately under the
relevant Item of the Bill of Quantities.
9.0 Lining of Tunnel

9.1 The work of Tunnel Lining involves providing and installing concrete lining in overt of the
tunnels and in overt of the connecting tunnels / passages for embedding the permanent
steel supports and at other places and locations as per the drawings of supporting
system issued and as directed by the Engineer, Suitable weep holes with 100 mm dia.
PVC pipes shall be provided in the lining. The cement to be used in the lining concrete
shall be low alkali cement. The rate shall include Costs of all operations including
placement of pipes for weep holes, drilling for and placement of pack grouting and
including provision of telescopic shutter for arch lining and mechanical means for mixing,
conveyance, placement, vibration and curing of concrete and including all other plant
and materials required for the work under this item and as specified by the Engineer.
9.2 Before the lining work is commenced at any location of the tunnel, the Engineer will
inspect the location to ensure that the excavation has been carried out properly and
space for lining of thickness as per approved design and drawings is available and all
temporary tunnel supports and other materials which cannot be allowed to be buried in
the lining have been removed.
9.3 Stages in Lining of the Tunnel
Lining of the tunnel can be carried out in single stage or can be divided in two parts, as
follows –
a. Lining in vertical sides up to the springing of the arch roof as shown in the relevant
drawing issued for construction.
b. Lining of arch roof of the tunnel.
Page 97
c. Sequence of above parts of lining shall be decided by the Engineer depending on the
strata / geological condition & his decision shall be final.
9.4 Steel form work for lining

a. Steel shutters of approved type shall be used for lining. If the lining is cast in two parts as
described in foregoing paragraphs 10.3 a and 10.3 b, shuttering for lining in sides can be
conventional and for lining arch the shuttering will be in the form of travelling collapsible
telescopic shutter. If the lining in overt is cast in one operation, the shuttering will be in
the form of travelling collapsible telescopic shutter. The Contractor should submit his
method of lining of the tunnel and the designs for steel forms proposed to be used by
him in lining the side walls and the roof area of the tunnel. These proposals with such
modifications as may be necessary will be approved by the Engineer. The Contractor
shall then be required to manufacture the forms and erect them in the approach cuts at
suitable places as decided by the Engineer for his inspection. The forms shall be used
only after approval by the Engineer. The forms shall be so designed as to limit surface
irregularity to the maximum of 6 mm in a length of 2400 mm. If the lining is cast in two
parts as described in foregoing paragraphs 10.3 a and 10.3 b, the profile of the forms for
the side wall lining and the arch lining shall be accurately gauged so as to avoid any
irregularity at the cold joints in concrete. If any irregularity is noticed in the joints, the
Contractor will be required to dress up the irregularity by rubbing it down with
abrasives. The steel forms shall be sufficiently rigid with suitable type of collapsing
arrangements shall enable smooth stripping of the form without any shock to the newly
laid concrete. If the lining is cast in two parts as described in foregoing paragraphs 10.3 a
and 10.3 b, forms for the side lining of the tunnel will be allowed to be stripped after 18
hours after the last batch of concrete is laid in position therein. Earlier stripping will
require the approval of the Engineer.
b. Sufficient number of windows of suitable size shall be provided in the forms to enable
pouring of the concrete, in situ vibrating the concrete for consolidation and inspection of
the work during the progress of concreting.
9.5 Placement of concrete
a. Tunnel lining will be commenced from a convenient location with a sufficient lag behind
the face under excavation.
b. All concrete to be placed in lining of tunnel shall confirm to I.S. Code 456-2000. Grade of
the concrete shall be as per drawing issued for construction. Low alkali cement shall be
used for concreting lining works where necessary and as ordered by the Engineer..
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c. All surfaces with which the concrete lining will come in contact shall be thoroughly
washed with jet of water and compressed air and brushed and cleaned to the
satisfaction of the Engineer.
d. In-situ concrete lining in the sides and in the arch roof of the tunnel shall be placed in
position by concrete pump of approved type and vibrated and consolidated by use of
immersion type vibrators operated through the windows and with form vibrators
attached to the steel forms used for lining of the tunnel and. The vibrators shall be
positioned and moved during the progress of concreting, so as to ensure perfect
consolidation of the concrete in the roof.
e. While concrete in the roof of the tunnel is being placed by concrete pumps, the
Contractor will be required to provide for air slugging of the freshly laid concrete to
ensure satisfactory consolidation of the concrete in the arch roof.
g. In order to improve workability and other properties of concrete, use of plasticizers and
other admixtures as per approved design will be permitted, if the Engineer is satisfied
regarding their need.
h. No construction joints are required to be provided in the lining of the tunnel, but cold
joints i.e. joints between the successive pours or between side walls and arch roofs shall
be treated as follows without any additional payment :-
i. Cold joints less than 24 hours old shall be scraped with wire brush and cleaned of
laitance/scum etc. and flushed with mortar of the same strength as the concrete
mix in the lining and immediately before fresh concrete is placed.
ii Cold joints which are more than 24 hours old shall be chipped for a depth of about
25 mm., washed, brushed, cleaned and flushed with mortar of the same strength
as the concrete mix in the lining before the placement of the fresh concrete.
iii The number of cube tests to be carried out should as per IS 456 : 2000.
iv A joint record in the form as approved by Engineer shall maintained to record the
consumption of cement.
i Concrete Lining Forms will have to remain in position for minimum 18 hours from the
time last batch of concrete is placed.
j After concrete lining has aged for over 28 days, Backfill Grouting and Contact/Pack
Grouting will have to be carried out as per the directions of the Engineer.
k Suitable embedment, as directed by the Engineer, will have to be fixed in the concrete
lining for installation of permanent Lighting & Ventilation System and for installation of
service Lines such as cables, fire fighting water line etc. Measurement and Payment for
these embedment will be made separately under relevant Item of the Bill of Quantities.
l 100 mm dia. PVC pipes will have to be fixed in the concrete lining to serve as weep
holes. Number of such pipes and their location will be as directed by the Engineer. Cost
Page 99
of providing and fixing these pipes will not be paid for separately and will be deemed to
have been included in the rate quoted for Concrete Lining.
9.6 Measurement and payment
Measurement and payment for Concrete Lining in Overt of the Tunnel will be made at
the Rate Quoted for relevant Item of the Bill of Quantities on the basis of per Cu.M. of
Concrete calculated from the dimensions of the lining between intrados and the
extrados of the concrete lining shown in the drawings issued for construction or as
directed by the Engineer. Concrete placed in approved over breaks will be measured
and paid for and no payment will be made for concrete placed in un-approved over
break. No separate Payment will be made for formwork, shuttering, scaffolding etc.,
Drilling for Backfill Grouting and Contact/Pack Grouting and Backfill and Contact/Pack
Grouting itself and providing and fixing drain pipes for weep holes and all other required
operations and work and cost thereof shall be deemed to be included in the Rate
Quoted. for the relevant Item of the Bill of Quantities. Reinforcement will be measured
and paid for separately under relevant items of the Bill of Quantities.
10.0 Drilling about 40 mm. dia., Probe Holes and Grout Holes
10.1 In order to assess the condition of the strata ahead of the advancing tunnel face, 40 mm.
probe holes will be drilled at locations as directed by the Engineer.
10.2 In order to control and arrest seepage of ground water through joints and to strengthen
jointed rock mass etc. in the Open Cuts and the Tunnels, 40 mm dia. grout holes will be
drilled at locations and as directed by the Engineer. Depth of the grout holes should be
about 4 m / 6 m.
10.3 Location and pattern of the Grout Holes and Probe Holes will depend on the actual site
conditions and will be as ordered by the Engineer. The holes will be drilled by
percussion drilling method.
10.4 Measurement and payment for Drilling of Probe Holes and Grout Holes will be made on
the basis of per M. depth of the holes drilled as shown in the drawings issued for
construction or as directed by the Engineer, at the Rate Quoted in the Bill of Quantities
for the relevant Item of Work.
11.0 Pressure Grouting of Rock Mass / Strata

11.1 For strengthening of jointed and fissured rock mass in the Open Cuts and the Tunnels,
Pressure Grouting with plain cement slurry or mortar, with addition of suitable additives,
as directed by the engineer, will have to be carried out at locations as required and as
directed by the Engineer.
11.2 Grouting will be commenced with a grout mix of 1 cement : 10 water by weight at a
pressure of about 2 Kg./Sq.Cm. If the grout is seen to flow freely into the hole, the
grout shall be progressively thickened by increasing the cement content or by adding
Page 100
fine sand, saw-dust and other additives. as directed by the Engineer and the grouting
pressure progressively increased up to 7 Kg./ Sq.Cm. and the grouting continued till
refusal.
11.3 Measurement and payment for Pressure Grouting will be made on the basis of per
Metric Ton (MT) of Cement injected into the Grout Hole as directed by the Engineer.
Payment for Washing of the Grout Holes, and other required operations and work will
not be made separately and cost thereof shall be deemed to be included in the Rate
Quoted in the Bill of Quantities for the relevant Item of Work. Measurement and
payment for use of sand and saw-dust and other additives will be made on the basis of
per kg. and paid at the Rate Quoted in the Bill of Quantities for the relevant Item of
Work.
12.0 Providing and Installing Embedment in Position

12.1 Embedment will have to be Provided & Installed in Concrete Works, Shotcreted Surface
and Excavated profile in the Open Cuts, Cut & Cover Portion and the Tunnels, at
locations and as directed by the Engineer.
12.2 The embedment will be fabricated as indicated in the drawings issued for constructions.
The work will be carried out in a neat and workman like manner.
12.3 Measurement and payment for Providing & Installing Embedment will be made on the
basis of per Metric Tone of Embedment calculated from the neat dimensions of the
Embedment as shown in the drawings issued for construction or as directed by the
Engineer. Payment for Anticorrosive Painting of exposed surfaces of the embedment and
all other required operations and work will not be made separately and cost thereof
shall be deemed to be included in the Rate Quoted in the Bill of Quantities for the
relevant Item of Work.
13.0 Tunnel Portals and Cut & Cover Portion :

13.1 It may be necessary to provide Cut & Cover Portions at both the ends of the tunnels.
Finished Section of the Cut and Cover Portions will be same as that for the Tunnel. The
Length of Cut & Cover Portions will be decided by the Engineer at appropriate time
These Cut & Cover Portions and Portals will have to be as per drawings issued for
construction
13.2 Permanent Steel Supports installed in the location of Cut & Cover Portion will be
measured separately and paid under relevant Item of the Bill of Quantities.
13.3 Concrete of the Portal Walls and Cut & Cover Portions will be minimum M 25 grade
Reinforced Cement Concrete. Reinforcement will be measured and paid for under
13.4 100 mm. dia. EW Pipes running through the stem of the Portal Walls will be fixed in a 2
m. x 2 m. pattern, to serve as Weep Holes.
13.5 Façade of the Portal should provided with, ‘v’ grooves, flutings etc. and should have
space for name plates for inserting name of the tunnel
Measurement & payment for Construction of Tunnel Portals and Cut & Cover Portions in
the Approach Cuts will be made on the basis of per Cu.M. of Concrete placed up to neat
lines shown in the drawings approved for construction or as directed by the Engineer.
No separate payment will be made for excavation for foundations and foundation rafts
Page 101
etc. and for fixing pipes for weep holes, rendering architectural finishes, formwork,
internal and external shuttering, scaffolding etc. and all other required operations and
work and cost thereof shall be deemed to be included in the Rate Quoted for the
relevant Item of the Bill of Quantities. Reinforcement will be measured and paid for
separately under relevant items of the Bill of Quantities.
14.0 Backfilling and Compacting Selected Fill Material behind Concrete Portal Walls and Cut
& Cover Portions :
14.1 Space between the excavated surface of the Approach Cuts and extrados of the Cut &
Cover Portions and rear face of the Portal Walls will be backfilled with selected hand
packed rubble topped with earth cushion as shown in the drawings issued for
construction and as directed by the engineer.
14.2 Measurement and payment for Backfilling Behind Concrete Portals and around Cut &
Cover Portions will be made at Rate Quoted for the relevant Item of the Bill of
Quantities, on the basis of per Cu.M. in-situ volume of the fill material actually placed
and compacted.
15.0 Providing and Fixing M.S. Reinforcement for Concrete Works

15.1 The work of Providing & Fixing M.S. Reinforcement involves Providing, Cutting, Bending,
Binding and Fixing Reinforcement in position for embedment into concrete.
15.2 Reinforcement for the Portal Walls should be in the form of Plain M.S. Rounds / tor
steel. For other concrete work the reinforcement would be either in the form of Plain
M.S. Rounds / tor steel or in the form of welded or woven wire mesh. Binding Wire
used for fixing the reinforcement should be minimum 10 gauge super annealed binding
wire.
15.3 Measurement and payment for Providing and Fixing Reinforcement will be made on the
basis of per Metric Tons (MT) weight of Reinforcement required as per the drawings
issued for construction or as directed by the Engineer. Payment for binding wire,
spacers, chairs etc. and all other required operations and work will not be made
separately and cost thereof shall be deemed to be included in the Rate Quoted for the
16.0 Providing and Installing Galvanized Iron Pipe Hand Railing for Walkways etc.
16.1 Walkways formed atop the side drains in the Tunnels, Cut & Cover Portions and Open
Cuts should be provided with G.I. Pipe Hand Railing. G.I. Pipe Railing may also be
required on the access ramps to the walkways and access to the Fire Fighting Water
Tanks etc. Hand railing shall be as per drawings issued for construction or as directed by
the Engineer.
16.2 The hand railing shall be erected on the embedment already provided for the purpose,
in the concrete of the kerbs and the crash barriers etc. The work will be carried out in a
neat and workmanlike manner so as to create aesthetic appearance.
16.3 Measurement and payment for Providing & Installing G.I. Pipe Hand Railing for the
Walkways etc. will be made on the basis of per Running Meter Length of the finished
Page 102
Hand Railing. Measurement for Painting and all other required operations and work will
not be made separately and cost thereof shall be deemed to be included in the Rate
Quoted for the relevant Item of the Bill of Quantities.
17.0 Providing and Installing Fire Fighting Water Line etc.

17.1 The work of Providing & Installing Fire Fighting Water Line in the Tunnels, Cut & Cover
Portion and Open Cuts, as per approved drawings involves the following :
a) Providing Galvanized Iron Heavy Class Pipes having 100 mm. dia. nominal bore and
suitable Hydrants at a spacing of about 60 m.
b) Welding to the embedment [already installed at 2 m. spacing for the purpose] suitable
brackets for supporting and fastening the Water Line and the Fire Hydrants .
c) Installing in position the Fire Fighting Water Line with Fire Hydrants.
d) Providing and constructing one Pressed Steel Water Tank of 150,000 litres capacity
above and in between the Portals of the Tunnels.
17.2 Measurement and payment for Providing & Installing Fire Fighting Water Line with Fire
Hydrants in the Tunnels, Cut & Cover Portions and Open Cuts will be made on the basis
of per Running Meter Length of the Fire Fighting Water Line. Payment for providing
and installing hydrants, brackets and all other required operations and work will not be
made separately and cost thereof shall be deemed to be included in the Rate Quoted for
the relevant Item of the Bill of Quantities. Payment for providing and constructing
Pressed-steel Water Tank and all other required operations and work and will not be
made separately and cost thereof shall be deemed to be included in the Rate Quoted for
the Item of Providing & Installing Fire Fighting Water Line with Fire Hydrants in the
Tunnels, Cut & Cover Portions and Open Cuts.
18.0 Construction of In-situ Kerbs, Crash Barriers, Side Drains and Pre-cast Concrete Slabs for
Drain-cover/ Walkway :
18.1 Crash Barriers and Kerbs shall be constructed with M-45 grade concrete and with
HYSD/TMT Fe 415/ Fe500 grade reinforcement conforming to IRC: 21. Floor and Side Walls
of the side drains and pre-cast concrete slabs to serve as drain cover/ walkway slabs are
to be provided as per drawings issued for construction:
18.2 Concrete in the kerbs, crash barriers and side walls of the drain shall be laid using forms
of approved type. The form shall be erected carefully to ensure perfect line and level for
the alignment of the drain wall and smooth finish.
18.3 Pre-cast RCC slabs :
The Pre-cast slabs will generally be about 1 m. long.
18.4 In-situ Concrete for Drains, Kerbs and Crash Barriers :
i.) Concrete of the drain walls adjacent to the sides of the tunnel will abut against the
shotcrete or concrete lining installed on tunnel sides, as the case may be. Concrete in
floor of the drains will be laid on excavated invert.
Page 103
ii.) 100 mm N.B. PVC Pipes running through the inner drain walls and kerbs will be fixed at
5m spacing, to serve as drain pipes. Wherever provided, the down-take pipes fixed in the
overt of the tunnel will be embedded in the drain concrete.
iii.) Suitable embedment, as directed by the Engineer will have to be fixed in the concrete
for installation of fire water lines, walkway slabs and pipe hand-railing etc. Measurement
and Payment for this embedment will be made separately under relevant item of the Bill
of Quantities.

18.4.1 Measurement and payment for construction of Kerbs and Crash Barriers will be made on
the basis of per cum of Concrete placed up to finished / neat lines shown in drawings
approved for construction or as directed by the Engineer, at Rate Quoted for the
18.4.2 Measurement and payment for construction of walls and floor of the side drains and for
precast slabs for drain covers / walkway slabs will be made on the basis of per cum of
Concrete placed up to finished / neat lines shown in drawings issued for construction or
as directed by the Engineer, at Rate Quoted for the relevant Item of the Bill of
Quantities. Where the concrete placed is to abut against excavated periphery of the
tunnel or shotcreted periphery of the tunnel, payment will be made for theoretical
volume of concrete including concrete placed in approved over-breaks and excluding
concrete placed in unapproved over-breaks.
18.4.3 Reinforcement will be measured and paid for separately under relevant items of the Bill
of Quantities.
18.4.4 No separate payment will be made for providing and fixing of drain pipes embedded in
the kerbs / side walls of the drains, other embedment, formwork shuttering, scaffolding
etc. and all other required operations and work and the cost thereof shall be deemed to
be included in the rate. Reinforcement will be measured and paid for separately under
relevant items of the Bill of Quantities.
19.0 Treatment of Seepage Water :

19.1 In order to tap seepage water and lead it to the side drains, in certain areas of the
tunnel, the Engineer may order installation of half round PVC Pipes 100 mm. dia. clinging
to the excavated periphery of the overt of the tunnels using ‘U’ clamps. Lower end of the
pipes will be terminated in to the side drains. The pipes will later be embedded in
shotcrete placed as an initial support.
19.2 Measurement and payment for Providing & Installing half-round 100 mm. dia. PVC Pipes
in the Tunnels will be made on the basis of per Running Meter Length of Pipes at the
Rate Quoted for relevant Item of the Bill of Quantities. Separate payment will not be
made provision of ‘u’ clamps and other operations.
Page 104
20.0 Installation of Spray Applied Waterproofing Membrane: (Delete)

21.0 Pipe Roofing :
21.1 Pipe Roofing is a method of supporting potentially unstable and challenging ground
conditions such as soil, weak rock and shallow overburden, ahead of the excavation face,
in association with steel sets or lattice girders
21.2 In this method, steel pipes which serve as support elements are driven ahead of the
steel sets or lattice girders to form an umbrella or canopy around the excavation line.
The umbrella stabilizes and protects the roof and face of the tunnel and increases the
load
bearing capacity of the ground ahead. These elements provide temporary overhead
protection while excavation for and installation of the next set or girder is accomplished.
The pipes are driven at an inclination of 40 to 60.
21.3 The work involves installing in ground ahead, about 12 m. long Pipe roofing of 114 mm.
outer dia. and 8 mm. wall thickness around the periphery of the arch of the tunnel face
so as to form a protective canopy for advancement of the tunnel face up to about 8 m.
with steel sets or lattice girders to match the increasing height of the profile.
21.4 The pipes shall be of S 355 grade as per EN10025 standard or ST 52-3 as per DIN 17100
standard with a minimum yield strength of 355 N / mm2.
21.5 Delete.
21.6 Measurement and payment shall be made at the Rate Quoted for relevant Item of the
Bill of Quantities on the basis of per RMT (Running meter) of roofing pipe installed which
rate will include the cost of furnishing and installation of pipes and accessories including
drilling and cost of all left in place drill bits and other materials required for installation
including all tools and plant, labour and all other works in connection therewith.
22.0 Rod fore poling:

22.1 Rod Forepoling is a method of supporting unstable ground conditions such as weak rock
and shallow overburden, ahead of the excavation face, in association with steel sets or
lattice girders
22.2 In this method, steel rods which serve as support elements are driven ahead of the steel
sets or lattice girders to form an umbrella or canopy around the excavation line. The
umbrella stabilizes and protects the roof and face of the tunnel and increases the load
bearing capacity of the ground ahead. These elements provide temporary overhead
protection while excavation for and installation of the next set or girder is accomplished.
The rods are driven at an inclination of 50.
22.3 The work involves installing in ground ahead, about 6 m. long, 32 mm. dia. High Tensile
M.S. Rounds around the periphery of the arch of the tunnel face so as to form a
protective canopy for advancement of the tunnel face up to about 4 m. with steel ribs or
lattice girders to match the increasing height of the profile.
22.4 Delete.
22.5 Measurement and payment shall be made at the Rate Quoted for relevant Item of the
Bill of Quantities on the basis of per MT of rod forepoles installed which rate will include
the cost of furnishing and installation of pipes and accessories including drilling and cost
of all left in place drill bits and other materials required for installation including all tools
and plant, labour and all other works in connection therewith.
Page 105
23.0 Prevention & Mitigation of Tunneling hazards

23.1 The Contractor shall at all times adopt such methods of work as will ensure structural
safety and the safety of labour working in the Tunnel.
23.2 In the use of explosives for blasting, the Contractor shall strictly abide by the provisions
in Indian Explosives Act and the Metaliferrous Mines Regulations and Rules there under,
as well as the relevant provision of the Act and Rules as may be enacted and laid down
by the State and Central Government from time to time in respect of such works. The
Contractors’ attention is specially drawn to relevant conditions of General Conditions of
Contract.
23.3 If at any time during the work, the Engineer finds the methods of safety arrangements
inadequate or unsafe, the Contractor shall take immediate corrective measures to set
them right as per the provisions of relevant Acts or Rules and as directed by the
Engineer. The Engineer’s directions in the matter shall in no way absolve the Contractor
of his responsibility to adopt appropriate safety arrangements for safe working methods.
23.4 Roof and sides of the excavated tunnels sections shall be rendered with necessary safe
and sturdy supporting arrangements. The exact locations from where support work is
considered necessary will be as per decision of the Engineer which in this regards will be
final.
23.5 Should any hazards occur the Contractor should notify the Engineer immediately and the
Engineer or Committee of ------------------------------------- [-----------]’s Engineers as may be
decided by the ------------------------------------- [-----------]’s, will inquire into the
circumstances, leading to the hazarde and assess the extent of responsibility befalling on
the Contractor. The Contractor shall give all reasonable assistance and full information
to the Engineer/the Inquiry Committee appointed for this purpose by [-------------]. The
findings of the Engineer shall be final and binding on the Contractor. The committee will
consist of two experienced tunneling engineers & one Expert Geologist and one
Geotechnical Expert.
23.6 In the case of hazards for which the responsibility does not rest with the Contractor,
wholly or partly, as adjudged from the findings of the committee, the Contractor shall be
entitled to an extension of time as in the opinion of the Engineer is necessary and also to
the payment wholly or partly, as may be judged by the ------------------------------------- [------
-----]’s for the restoration work at a rate under relevant items of the Bill of Quantities or
at the rates set forth in the Standard Schedule of Rates adopted for similar types of
works by ------------------------------------- [-----------]’s or rates to be mutually negotiated
between the ------------------------------------- [-----------]’s and the Contractor. The Contractor
shall also be under obligation to expeditiously carry out the restoration work.
23.7 In the case of hazards, for which the responsibility rests with the Contractor, the
Contractor shall carry out, at his own cost, the restoration work and such other works as
temporary supports, hand packing, plugging with concrete, provision of extra or new
permanent supports etc., as considered necessary by the Engineer. The Contractor shall
always keep sufficient ready stock of supports to meet the emergencies likely to be
caused during tunnel hazards.
Page 106
24.0 Lighting (Required during execution of the work)

The whole of the approaches, the tunnel faces and tunnel length up to the working
faces, the areas where plant and machinery is in operation and other areas as may be
indicated by the Engineer shall be adequately lit by electric lights or by other means by
the Contractor at his cost and as required by relevant Codes and to the satisfaction of
the Engineer. Proper illumination shall be provided also during non-working hours as
may be required at each location. The cost of providing, installing, operating and
maintaining all the lighting to the required standards shall be considered as included in
the rates quoted for various items of Bill of Quantities.
25.0 Ventilation (Required during execution of the work)

25.1 All underground excavation works shall be properly and adequately, ventilated by
system of pipes and fans as required by relevant Codes and to the satisfaction of the
Engineer. Adequate artificial means of ventilation shall be deployed and shall be in
operation at all times when people are working underground. Adequate ventilation shall
be provided at all the working cavities and drifts etc.
25.2 The cost of furnishing, installing, maintaining and operating of the ventilation system
shall be deemed to have been included in the rates quoted by the Contractor for various
items of work.
25.3 After breakthrough of the tunnel excavation from both ends, mechanical ventilation
system will still be still necessary in the tunnel till its final handing over to the ---------------
---------------------- [-----------]’s
26.0 Dewatering
No separate Payment will be made for Dewatering. Contractor will have to make all
necessary arrangements for dewatering and for keeping the work area dry at all times.
Cost of such Dewatering will be deemed to be included in the rates quoted for all the
Items of Work of the Bill of Quantities.
27.0 Submittals (Delete)

28.0 HEA Panels :-
Technical specifications of Wire Rope Panel (HEA Panel) and DT Mesh for Rock fall
Protection Work
a) Properties of Steel Wire Rope for HEA Panel :-
Material of a wire Rope : Wire Rope made of galvanized steel

i. Nominal diameter :- 9 mm
ii. Grade of Steel Rope :- 1770 N/Sqmm
iii. Minimum Breaking Load of Wire Rope :- 41.5 KN
iv. Zinc Coating confirming to Class B of IS 1835:1976
v. Tensile Strength of Wire Rope confirming to IS 2266:2002
Page 107
b) Properties of HEA Panel :-
i. Mesh Opening size : 400 X 400 mm
ii. Apparture Size : 400 X 400 mm Rhomboidal Shape D

iii. Dimensions : 4 X 10m, 4 X 9m, 4 X 8m, 4 X 7m, 4 X 6m, 4 X5m, 4 X4m
Construction of net joints must be in double knot.
c) Specification of Anchor Fasteners :-
Material for Anchor Fastner must be made up of 12 mm dia. Electroplated high tensile
steel with 5 micron thick electroplated Zinc coating followed by yellow chromonising.
d) Specification for DT Mesh :-
Internal diameter of DT wire mesh should be 2.7 mm and external diameter should be
3.7 mm. the DT wire mesh must be galvanized steel wire of min. 2.7 mm diameter
covered with 0.5 mm thick PVC coating. Tensile strength must be ranging between 500
N/Sqmm to 380 N/Sqmm. Aperture type of DT mesh is 10 X 12. Width of each DT mesh
roll OS 4m. Diameter of galvanized steel lacing rope shall be 8 mm with grade of steel as
1770 N/Sqmm. Diameter of PVC + Zinc coated lacing wire must be 3.2 mm and internal
diameter of galvanized steel lacing wire must be 2.2 mm.
e) Specification for Anchor Bar :-
HYSD bars used for Anchor Bars must epoxy coated. Top Anchor Bars must be 25 mm in
diameter and 2 m long. Bottom Anchors must be 16 mm in diameter and 1 m length.
Both top and bottom anchors shall have galvanized M. Stanchor plates of size 150mm X
150mm X 6mm.
Page 108
CODES OF PRACTICE / ACTS / RULES TO BE FOLLOWED
FOR TUNNELLING WORK

The following Codes / Acts / Rules and their revised / updated versions, if any, will be applicable
to the tunneling work. This list is not exhaustive and all other relevant Codes / Acts / Rules and
their revised / updated versions, if any, will be deemed to be applicable to the tunneling work.
IS 5878 1971 [Part I] Precision Survey and Setting out.
IS 5878 1971 [Part II, Section 1] Underground Excavation in Rock, Section I
Drilling and Blasting.
IS 5878 1971 [Part II, Section 2] Underground Excavation in Rock, Section 2,
Ventilation, Lighting, Mucking and Dewatering.
IS 5878 1971 [Part II, Section 3] Underground Excavation in Rock, Section 3,
Tunneling Methods for Steeply Inclined Tunnels, Shafts and Underground
Power Houses.
IS 5878 1971 [Part III] Underground Excavation in Soft Strata.
IS 5878 1971 [Part IV] Tunnel Supports.
IS 5878 1971 [Part V] Concrete Lining.
IS 5878 1971 [Part VI] Grouting.
IS 4081 1967 Safety Code for Blasting and other related Blasting Operations.
IS 4756 1978 Safety Code for Tunneling Work.
IS 9103 1979 Admixtures for Concrete.
IS 9012 1978 Recommended Practice for Shotcreting.
IS 3764 1966 Safety Code for Excavation Work.
IS 4138 1977 Safety Code for Working in Compressed Air.
IS 7293 1974 Safety Code for Working with Construction Machinery.
IS 823 1964 Code of Practice for Manual Metal Arc Welding of Mild Steel.
IS 816 1969 Code of Practice for Manual Metal Arc Welding for General
Construction in Mild Steel.
IS 1566 1967 Hard-drawn Steel Wire Fabric for Concrete reinforcement.
IS 817 1966 Code of Practice for Training and Testing of Metal Arc Welder
[Revised]
IS 226 1975 Structural Steel [Standard Quality].
IS 456 1978 Code of Practice for Plain and Reinforced Concrete.
IS 4086 1967 Methods of Tests for Distributors.
IS 1893 1975 Criteria for Earthquake Resistant Design of Structures.
IS 1200 1971 [Part XXV] Method of Measurement of Building and Civil
Engineering Works.
IS 1200 1971 [Part XXV] Method of Measurement of Building and Civil
Engineering Works - Tunneling.
Page 109
IS 1905 1980 Code of Practice for Structural Safety of Buildings.

IS 1256 1967 Code of Practice for Building Bye-laws.
IS 800 196 Code of Practice for Use of Structural Steel in General Building
Construction.
Indian Explosives Act.
Indian Explosive Rules.
Page 110
CONTENTS
Page
1. Definitions ............................................................................................................ 3
2. Responsibility for Completeness........................................................................ 4
3. Sub-letting of Work .............................................................................................. 4
4. Stacking Materials ............................................................................................... 4
5. Imported Material ................................................................................................. 5
6. Leading to Site ..................................................................................................... 5
7. Lines and Levels .................................................................................................. 5
8. Steel ...................................................................................................................... 5
9. Pins and Expansion Rollers ................................................................................ 6
10. Steel Castings....................................................................................................... 7
11. Bronze Plates....................................................................................................... 7
12. Maintenance of Records by Fabricators ............................................................. 7
13. Manufacture .......................................................................................................... 7
14. Templates ............................................................................................................. 7
15. Flattening and Straightening ............................................................................... 7
16. Planing and Shearing ........................................................................................... 8
17. Flame Cutting ....................................................................................................... 8
18. Drilling and Sub-punching ................................................................................... 8
19. Parts in Contact .................................................................................................... 9
20. Making of Joints ................................................................................................... 9
21. Erection and Equipment ....................................................................................10
22. Bearings and Anchorages ..................................................................................11
23. Rivets and Rivetting ............................................................................................11
24. Field Rivets, Bolts, Nuts and Service Accessories ...........................................12
25. Smithed Work ......................................................................................................13
26. Welding ................................................................................................................13
27. Sequence of Welding and Weld Pass ................................................................13
28. Bolts, Nuts and Washers ....................................................................................14
29. Connecting Pins ..................................................................................................14
30. Pin Holes ..............................................................................................................14
31. Bearing and Expansion Gear ..............................................................................15
32. Erection in Contractor’s Works ..........................................................................15
33. Interchangeability ................................................................................................15
iii
Page
34. Camber ................................................................................................................ 16
35. Testing................................................................................................................. 16
36. Check on Tests Made at Contractor’s Work ..................................................... 17
37. Analysis............................................................................................................... 17
38. Inspection - General ........................................................................................... 17
39. Oiling, Painting and Metallising ......................................................................... 17
40. Name Plate .......................................................................................................... 19
41. Erection Mark ...................................................................................................... 19
42. Packing................................................................................................................ 19
43. Despatch or Shipping Marks.............................................................................. 20
44. Loading ............................................................................................................... 20
45. Weight of Steel Work for Payment..................................................................... 21
46. Quantities ............................................................................................................ 21
47. Tracings and Printings ....................................................................................... 21
48. Rivets and Bolts Lists ........................................................................................ 21
49. Photographs ....................................................................................................... 21
50. Attestation of Tracings etc. ............................................................................... 22
51. Inclusive Price .................................................................................................... 22
52. Deviations from this Specification .................................................................... 22
53. Alterations in Work ............................................................................................. 22
54. Additional Specification for Locomotive Turn- Tables .................................... 22
Appendix-I Records to be Maintained ……………………………………… 25

Appendix-II Manufacturing Tolerances ……………………………………….. 27
Appendix-III Erection of Open Web Girder Span ……………………………… 30
Appendix IV Permissible Deviations for Driven Rivets ………………………… 31
Appendix-V Proforma for Welding Procedure Specification Sheet …………. 32
Proforma for Welding Procedure Qualification Record ……….. 33
Appendix-VI Tolerances & Specification for Knuckle and Roller Bearings 34
Appendix-VII Specification for Metallising with Sprayed Aluminium ………. 35
for Bridge Girders
Figure 1-4 ……………………………………………………………………….. 37
iv
Indian Railway Standard
Specification for Fabrication and Erection of Steel Girder Bridges and
Locomotive Turn-Tables
(FABRICATION SPECIFICATION)
0.1 This Specification is issued under the IS: 123 Ready mixed paint,
fixed serial number B1. The final number brushing, finishing, semi
indicates the year of original adoption as gloss, for general
standard or in the case of revision the year purposes to Indian
of last revision. This Specification was Standard colours.
adopted in 1934 and revised in 1936, 1947,
1962, 1979 and 2001. IS: 209 Zinc ingot.
IS: 210 Grey iron casting.

0.2 This Specification is intended mainly
to cover technical provisions relating to IS: 549 Split pins.
fabrication and erection of steel girder
IS: 808 Dimensions for hot rolled
bridges and locomotive turn-tables, including
steel beam, coloumn,
supply of the materials through contract or
channel and angle
Railway Engineering Workshops.
sections.
0.3 This Specification makes reference IS: 814 Covered electrodes for
to the following Indian Standard, Indian manual metal-arc welding
Railway standard and RDSO‟s of carbon and carbon
Specifications:- manganese steel.
0.3.1 Indian Standard (IS) Specifications IS: 816 Code of practice for use
of metal-arc welding for
general construction in
IS: 34 Basic carbonate of lead for
mild steel.
paints.
IS: 822 Code of procedure for
IS: 51 Zinc chrome for paints.
inspection of welds.
IS: 57 Red lead for paints and
IS: 887 Animal tallow.
other purposes.
IS: 958 Temporary corrosion
IS: 75 Linseed oil, raw and
preventive grease, soft
refined.
film, cold application.
IS: 77 Linseed oil, boiled for
IS: 962 Code of practice for
paints.
architectural and building
IS: 102 Ready mixed paint, drawings.
brushing, red lead, non-
IS: 1030 Carbon steel castings for
setting, priming.
general engineering
IS: 104 Ready mixed paint, purposes.
brushing, zinc chrome,
priming.
1
IS: 1148 Hot rolled steel rivet bars IS: 2004 Carbon steel forging for
(upto 40mm dia) for general engineering
structural purposes. purposes.
IS: 1149 High tensile steel rivet IS: 2016 Plain washers.
bars for structural
purpose. IS: 2062 Hot Rolled Low, Medium
& High Tensile Structural
IS: 1363 Hexagon head bolts, Steel.
screws and nuts of
product grade C. IS: 2074 Ready mixed paint, air
drying, red oxide-zinc
IS: 1364 Hexagon head bolts, chrome, priming
screws and nuts of
product grade A and B. IS: 2339 Aluminium paint for
general purposes, in
IS: 1367 Technical supply dual container
conditions for threaded
fasteners. IS: 2590 Primary aluminium
ingots for remelting for
IS: 1458 Railway bronze ingots general engineering
and castings. purposes.
IS: 1673 Mild steel wire cold IS: 2638 Flat split cotters.
heading quality.
IS: 3063 Fastners-single coil
IS: 1730 Steel plates, sheets, strips rectangular section
and flats for structural and spring washers.
general engineering
purposes-dimensions. IS: 3502 Steel chequered plates.
IS: 1745 Petroleum hydrocarbon IS: 4899 Ferritic and martensitic

solvents. steel casting for use at
low temperatures.
IS: 1852 Rolling and cutting
tolerances for hot rolled IS: 5369 General requirements for
steel products. plain washers and lock
washers.
IS: 1875 Carbon steel billets,
blooms, slabs and bars IS: 5372 Taper washers for
for forging. channels.
IS: 1929 Hot forged steel rivets for IS: 5374 Taper washers for I
hot closing (12 to 36 mm beams.
diameter). IS: 5666 Etch primer.
IS: 2002 Steel plates for pressure IS: 5905 Sprayed aluminium and
vessels for intermediate zinc coatings on iron and
and high temperature steel.
service including boilers.
IS: 6586 Recommended practice
for metal spraying for
protection of iron steel.
2
IS: 6610 Heavy washers for steel T-12 Flat bottom railway rails.
structures.
P-31 Zinc chromate read-oxide
IS: 7215 Tolerances for primer.
fabrication of steel
structures 0.3.3 RDSO's Specifications
IS: 7283 Hot rolled bars for M&C/PCN/102/96 Epoxy zinc

production of bright bars phosphate
and machined parts for primer.
engineering applications.
M&C/PCN/103/86 Epoxy
IS: 9954 Pictorial surface micaceous
preparation standards for iron oxide.
painting of steel surfaces
M&C/PCN/109/88 Polyurethane
IS: 9595 Metal-arc welding of red oxide.
carbon and carbon
manganese steels- M&C/PCN/110/88 Polyurethane
recommendations. aluminium.
0.3.2 IRS Specifications M&C/PCN/111/88 High build

Epoxy paint.
R-19 Wheels and axles for 0.4 Wherever reference to the
carriages and wagons. standards mentioned in clause 0.3 appears
M-3 Class I ,II ,III & IV steel in the Specification, it shall be taken as a
forgings, blooms for reference to the latest version of the
forgings and Billets for re- standards.
rolling.
0.5 Any revision or addition or deletion
M-28 Classification, testing and of the provisions of this Specification shall
approval of metal-arc be issued only through the correction slip.
welding electrodes for use No cognizance shall be given to any policy
on Indian Railways. directives issued through other means.
M-39 Classification, testing and
1. Definitions
approval of submerged-
arc welding wire flux
1.1 Throughout this Specification the
combination.
following definitions shall be applicable.
M-41 Corrosion resistance steel.
1.1.1 „The Purchaser' means the
M-42 High strength low alloy President of India or his/her representative
structural steel with unless otherwise stated in the case of
enhanced corrosion stores ordered for the Indian Railways.
resistance.
M-43 High strength low alloy 1.1.2 'The Indentor' means an officer
structural steel rivet bars authorized by the Purchaser to order
with enhanced corrosion stores.
resistance.
3
1.1.3 'The Engineer' means the Consulting prepared by the Contractor or Sub-
Engineer or officer authorised by the Contractor for materials or other parts of
Purchaser to act as an Engineer. the work involved in the contract or for tests
carried out, either by the Contractor or by
1.1.4 'The Inspecting Officer‟ means the the Engineer/Inspecting Officer.
person, firm or department nominated by the
Purchaser to inspect the stores on his/her 2.2 Any fitting, accessory or apparatus
behalf and the Deputies of the Inspecting which may not have been mentioned in this
Officer so nominated. Specification, but which are usual or
necessary in the execution of such work,
1.1.5 „The Contractor‟ means the person, are to be provided by the Contractor
firm, or company with whom the order for the without extra charge. The whole work must
supply/ fabrication/ erection is placed and be completed in all details, whether
shall be deemed to include the Contractor‟s mentioned in this Specification or not, with
successors (approved by the Purchaser), the exception of such work as has been
representatives, heirs, executors and specified in the Schedule of Requirements
administrators as the case may be unless to be separately provided for by the
excluded by terms of the contract. Purchaser.
1.1.6 „The Sub-Contractor‟ means any 3. Sub-letting of Work

person, firm, or company from whom the
Contractor may obtain any material or 3.1 Before ordering sub-letting of work,
fittings to be used in the supply or the Contractor shall submit the names of
manufacture of the stores. the Sub-Contractors proposed for the
approval of the Engineer and shall
1.1.7 'The Exhibited Drawings' refer to the afterwards send the Inspecting Officer a
drawings, which are exhibited or issued for copy of the orders for the sub-letted work.
the guidance of persons tendering. The
number for each of these drawings is given 3.1.1 The Contractor shall be responsible
in the schedule. for all the sub-letted work. Such work shall
be inspected and verified by the Inspecting
1.2 The drawings, supplied by the Officer.
Contractor, as per which the fabrication is to
be executed, when approved by the 4. Stacking Materials
Engineer will become „Fabrication
Drawings‟. Also on completion of the work, 4.1.1 On receipt of materials at the bridge
the Contractor should supply „Completion yard they shall be carefully unloaded
Drawings‟ along with alterations if any. examined for defects, checked, sorted and
stacked securely on a level bed out of
2. Responsibility for Completeness danger from flood or tide and out of contact
with water or ground moisture. All material
2.1 The Contractor shall be entirely shall be available for inspection by the
responsible for the execution of the contract Engineer or Inspecting Officer.
in all respects in accordance with the terms
of this Specification and the conditions of 4.1.2 Materials shall be verified with the
contract, notwithstanding any approval markings shown on the marking plan of
which the Engineer/Inspecting Officer may part list, which shall be supplied by the
have given to the detailed drawings manufacturers or the Engineer.
4
4.1.3 Any material found damaged during together with the requisite number of
transit or while unloading should be stacked copies of all necessary documents, to
separately and damaged portions shall be enable inspection to be carried out prior to
indicated by paint with distinctive colour. All despatch. The cost of such inspection and
such materials shall be dealt with under the supervision of tests in connection therewith
orders of the Engineer without delay. If any will be borne by the Purchaser, the Sub-
component after receipt at site, has in the Contractor providing free of charge all
opinion of the Engineer or Purchaser, been material, labour and appliances for carrying
damaged in transit, such component shall be out tests made in his/her works and any
replaced or repaired to the satisfaction of the material which may be required for
Engineer or Purchaser free of cost. independent tests and analysis.
6. Leading to Site
4.1.4 All such damaged material shall be
dealt with as per the orders of the Engineer.
Badly damaged portions may require 6.1 Care must be taken by the
replacement. Slightly distorted parts may be Contractor to see that the parts at site are
straightened by gradual pressure without available in proper sequence.
heat or annealing. Badly distorted or broken
parts must be dealt with as the case 7. Lines and Levels
demands and as directed by the Engineer.
7.1 All lines and levels should be given
4.1.5 Where the work has been passed in by the Engineer and all stakes and marks
the manufacturer‟s works as strictly so given shall be carefully preserved by the
interchangeable, all members bearing the Contractor who shall give all necessary
same marks can be stacked together without assistance and facilities to establish or
reference to any particular span. check the lines and levels and to measure
the work.
4.1.6 The Contractor shall unload the 8. Steel
material promptly on delivery; otherwise
he/she shall be responsible for demurrage 8.1 IS:2062, Quality “A” Grade
charges. Designation E250 (Fe 410 W) as rolled
semi-killed or killed shall be used for foot-
4.1.7 On receipt of rolled steel at workshop over bridges and other structures subjected
or fabrication yard they shall be carefully to non-critical loading.
unloaded and stacked properly to avoid
8.2 IS:2062, Quality “B” Grade
bending, twisting, corrosion etc.
Designation E250 (Fe 410 W) fully killed
5. Imported Material and normalized/controlled cooled, where
service temperature does not fall below
5.1 In case of work fabricated in India, 00C, shall be used for welded/riveted
where any material or component is girders subjected to Railway loading.
imported, such material or component will be Plates less than 12mm thick need not be
inspected, if desired by the Contractor, normalized/controlled-cooled.
Purchaser or Inspecting Officer, and passed
in the country of origin before despatch to 8.3 IS:2062, Quality “C” Grade
India. In such cases the Contractor shall Designation E250 (Fe 410 W) fully killed
submit to the Inspecting Officer details on and normalized/controlled cooled,
prescribed form in quadruplicate of the ensuring impact properties at (-) 200 C or
materials or components to be inspected
5
(-) 400 C shall be used for sub-zero strength low alloy structural steel rivet bars
temperature areas for welded/riveted girders with enhanced corrosion resistance for use
subjected to Railway loading. Plates less in bridges, steel shall comply with the
than 12mm thick need not be requirement of IRS:M-43.
normalized/controlled-cooled.
8.10 The dimensions of all rolled
NOTE: Rolled Sections like angles, sections must agree with the contract
channels, I-sections etc., drawings or as agreed to between the
conforming to IS:2062 Quality Purchaser and the Contractor.
„A‟ may be used in structures till
such time rolled sections 8.11 The rolling and cutting tolerances
conforming to IS: 2062 Quality shall be in accordance with IS:1852 or as
B/C are not available in the agreed to between the Purchaser and the
market. Contractor if closer tolerances are desired
8.4 High tensile steel shall comply in they shall be shown in the drawing.
all respects with the requirement of
IS:2062-2006 Grade Designation E 410 (Fe 8.12 All the steel sections used in the
540) or E 450 (Fe 570) Quality D (both fabrication must have mill test certificate
copper bearing quality) according to the clearly indicating the specification to which
welded or riveted work respectively. the steel conforms and whether steel is
killed and normalized. All the cast mark
8.5 For superior and enhanced corrosion numbers/ heat mark numbers, shall be
resistance for sections, plates and bars for recorded along-with the number of plates in
welded, rivetted or bolted construction, the a register as soon as the plates are
material shall comply with the requirement received in the workshop. Whenever the
of IRS:M-42,Gr I or Gr.II for rivetted/bolted steel is received without any test certificate,
or welded work respectively. a sample test piece from plate of each cast
mark number is to be cut and sent for
testing. Only when it is established that the
8.6 Steel, which is to be cold pressed,
plates are of required specification, these
shall comply with the requirements of
shall be processed for cutting.
IS:2002.
8.13 Use of steel of any quality other

8.7 Steel for bolts shall conform to
than those mentioned above would require
property class 4.6 or 6.6 as specified in
the prior approval of the Engineer.
IS:1367 accordingly, as the structural steel
specification is for mild steel or high tensile
steel. 9. Pins and Expansion Rollers
8.8 Steel for drifts shall be in accordance 9.1 Pins and Expansion Rollers shall be
with IS:1875 for forged quality steel or made from steel conforming to IS:2004
IS:7283 for hot rolled bars. (Class 3 steel).
8.9 Steel for rivets shall comply with the 9.2 Expansion rollers may, alternatively
requirement of IS:1148 for hot rolled rivet be turned from approved carriage and
bars for general structural purposes and wagon axles. Only axles manufactured
IS:1149 for high tensile steel rivet bars for after 1931 shall be used for the
high strength structural purposes. For high manufacture of rollers. USFD test shall be
conducted to ensure freeness from internal
6
flaw. Test pieces shall be left as an integral ii) All spans to be made strictly
part of the roller with the stamp of the interchangeable as specified in
supplier on it so that the Accepting Authority clause 33.
can cut-off the test pieces and check if
required. 13.2 The Contractor shall maintain a
master steel tape of approved make for
10. Steel Castings which he/she has obtained a certificate of
accuracy from any National Test House or
10.1 Steel casting shall comply with Government recognised institutions
IS:1030 for normal temperature zone and to competent to do so.
IS:4899 for use at low temperature zone.
14. Templates
11. Bronze Plates
14.1 The templates through out the work
11.1 Bronze plates shall be of phosphor shall be of steel. The template shall be
bronze complying with IS:1458 Class I. used for marking of cutting material and as
well as profile machining for girders of
12. Maintenance of Records by railway loading. Templates shall be used
Fabricators for marking of drilling holes in steel
structures other than girder of Railway
12.1 The records of fabrication shall be loadings. In case where actual materials
maintained in the registers as per the from a bridge have been used as templates
formats given in the Appendix I. for drilling similar pieces the Inspecting
Officer will decide whether they are fit to be
13. Manufacture used as part of the finished structure.
13.1 The whole work shall be 15. Flattening and Straightening

representative of the highest class of
workmanship. The greatest accuracy shall 15.1 All steel materials, plates, bars and
be observed in the design, manufacture and structural‟s shall have straight edges, flat
erection of every part of the work to ensure surfaces and be free from twist. If
that all parts will fit accurately together on necessary, they shall be cold straightened
erection. For manufacture of the or flattened by pressure before being
components of all spans to be made strictly worked or assembled unless they are
interchangeable as specified in clause 33, required to be of curvilinear form. Pressure
approved set of same jigs and assembly applied for straightening or flattening shall
fixtures shall be used. The tolerances in be such as it would not injure the material
manufacture shall be in accordance with as and adjacent surfaces or edges shall be in
shown in Appendix II. The Contractor shall close contact or at uniform distance
state which of the following alternative throughout.
methods of manufacture he/she intends to
adopt. 15.2 Flattening and straightening under
hot condition shall not be carried out unless
i) The whole of work to be erected authorized and approved by the Inspecting
complete and pieces marked to place. Officer.
7
16. Planing and Shearing straight, plates may be cut to shape and
beams and other sections cut to length with
16.1 Except where otherwise indicated, a gas cutting torch, preferably oxyacetylene
cutting of all plates and sections shall be gas should be used.
affected by shearing or sawing. All edges
shall be clean, reasonably square and true. 17.2 All flame cut edges shall be ground
Wherever possible the edges shall be cut in to obtain reasonably clean square and true
a shearing machine, which will take the edges. Draglines produced by flame cut
whole length of the plate in one cut. should be removed.
16.2 Should the inspection find it 17.3 Unless machining has been
necessary, the cut edges shall be ground specifically provided for, special care is to
afterwards. be taken to ensure that ends of all plates
and members are reasonably in close
16.3 Planing or machining of the edges or contact and the faces are at right angles to
surface shall be carried out when so the axis of the members and joints, when
specified in the contract drawings or where made, are also reasonably in close contact.
specifically ordered by the Engineer. Where
machining is specified, the plates or all 17.4 Use of multi-head flame cutting
sections shall be cut in the first instance to machine having multiple oxy acetylene
such a size so as to permit not less than torches is desirable for higher productivity
3mm of metal being removed from each and reducing the distortion due to cutting
sheared edge or end, in the case of plates or operation. Plasma-arc cutting method can
sections of 12mm or less in thickness and also be employed. This process offers less
not less than 6mm of metal being removed heat input causing less distortion.
in the case of plates and sections
exceeding 12mm in thickness. 18. Drilling and Sub-punching
16.4 The butting ends of all booms and 18.1 All holes shall be drilled but the
struts where spliced shall be faced in an end Contractor may, if he/she so prefers sub-
milling machine after members have been punch them to a diameter 6mm less than
completely fabricated. In the case of that of finished holes, e.g. a punched hole
compression members the face shall be which is to be drilled out to 25mm in
machined so that the faces are at right angle diameter shall not exceed 19mm in
to the axis of the members and the joint diameter at the die end. When the rivet
when made, will be in close contact holes are to be sub-punched, they shall be
throughout. At the discretion of the marked with a centre punch and made with
Inspecting Officer, a tolerance of 0.4mm a nipple punch or preferably, shall be
may be permitted at isolated places on the punched in a machine in which the position
butting line. of the hole is automatically regulated. The
punching shall be so accurate that when
17. Flame Cutting the work has been put together before
drilling, a gauge 1.5mm less in diameter
17.1 Flame cutting by mechanically than the size of the punched holes can be
controlled torch/torches shall be accepted passed easily through all the holes. Holes
both in the case of mild steel and high for countersunk heads of rivets, bolts or
tensile steelwork. Provided the edge as screws shall be drilled to the correct profile
given by the torch is reasonably clean and so as to keep the heads flush with the
8
surface Holes for countersunk heads of but their use on heavy members should be
rivets, bolts or screws shall be drilled to the restricted to securing them in their correct
correct profile so as to keep the heads flush positions. In no case, shall drifting be
with the surface allowed to such an extent that holes are
distorted.
18.2 No sub-punching shall be allowed in
the main truss members of open-web 19.3 Drifting to enlarge unfaired holes is
girders. prohibited. The holes that will have to be
enlarged to admit rivets should be reamed
18.3 Holes for turned bolts, should be provided the Engineer permits such
1mm under drilled in shop and should be reaming after satisfying himself about the
reamed at site to suit the diameter of turned extent of inaccuracy and the effect of
bolt. reaming on the soundness of the structure.
The Purchaser retains the right to reject all
18.4 Where the number of thicknesses to steel work if the holes are not properly
be rivetted exceeds three or the total matched.
thickness is 90mm or more, the rivet holes,
unless they have been drilled through steel- 20. Making of Joints
bushed jigs, shall be drilled out in place
3mm all round, after assembling. In such 20.1 Cleaning of permanent contact
cases the work shall be thoroughly bolted surfaces:- Surfaces which will have
together. permanent contact shall be removed of
paints and mill scale down to bare metal,
18.5 The steel bushes shall be case clean and dried and immediately a coating
hardened by an approved process and of zinc chrome red oxide priming to IS:2074
checked for diameter after the heat- shall be applied. Care shall be taken to
treatment. The bores of bushes shall initially see that all burrs are removed and no
have a tolerance of -0mm, 0.1mm. The surface defects exist before the parts are
tolerance shall be checked from time to time assembled.
and when the bores exceed a tolerance of, -
0mm, +0.4mm, the bushes shall be rejected. 20.2 Bolting and Drifting:- Only barrel
For this purpose, go and no-go gauges are drifts as per Fig. 2 shall be used in
to be used. Tolerances for checking jigs erection. They may be used for drawing
from master plates shall be +0mm-0.13mm. light members into position; but their use
on heavy members shall be restricted to
18.6 The work shall be taken apart after securing them in their correct position. Any
drilling and all burrs left by the drill and the apparent error in shop work, which
sharp edges of all the rivet holes completely prevents the assembling and fitting up of
removed. the parts by the proper use of these drifts,
shall be investigated immediately. As all
19. Parts in Contact work is rigidly inspected in the
manufacturers work before despatch, these
19.1 All steel work intended to be rivetted difficulties should not arise and the cause
or bolted together shall be in contact over should be first be sought in the use of
the whole surface. incorrect components or the transposition
of a correct part. It is usually important that
19.2 Drifts as shown in Fig. 2 may be parts should be correctly handled. Should
used for drawing light members into position error still persist, the matter shall be
9
immediately reported to the Engineer who that when in position, the girder has the
will decide what action is to be taken. No camber as per drawing.
reaming shall be undertaken without the
written authority of the Engineer, except for 20.6 Emergency Jointing:- In the event of
the under drilled holes meant for turned an emergency arising such as the staging
bolts. If approved, the Contractor shall is in danger of being carried away by floods
supply, at his/her own expense, any special before the rivetting can be completed, the
rivets that maybe required. Copies of all joints shall be made secure by filling 40%
correspondence relative to the recourse to of the holes with cylindrical drifts and equal
reaming and the use of over-size rivets shall number with service bolts fully tightened .
invariably be sent by the Engineer for
information to the inspectorate concerned. 21. Erection and Equipment
20.3 Joints shall normally be made by 21.1 The Contractor shall provide at
filling not less than 50% of the holes with his/her own cost all tools, machinery,
service bolts and barrel drifts in the ratio of equipment and erection material necessary
four to one. The service bolts are to be fully for the expeditious execution of the work
tightened up as soon as the joint is and shall erect the structural steel and iron
assembled. work, in every respect as covered by the
contract and in accordance with the
20.4 Special methods of erection other drawings and specifications.
than described in Appendix III. In
cases where the joints have to withstand 21.2 If any labour, material, plant staging
stresses arising from special method of haulage and storage facilities are to be
erection, provision is to be made to take the provided by the Purchaser, details of such
whole stress that will or may occur. items and the conditions under which these
Cylindrical drifts and turned bolts shall be are to be supplied shall be clearly specified
used to withstand such stresses and no in the contract agreements. In the absence
reliance is to be placed on the service bolts of any such provisions in the agreement,
for this purpose. Upto maximum of 40% of the Contractor shall make his/her own
the holes of each member of the joint are to arrangement for such items.
be filled with drifts and balance of strength
required is to be attained with turn bolts. The 21.3 Before starting the work, the
position and number of the drifts and bolts Contractor shall advise the Engineer fully
will be intimated by the Engineer. The as to the method he/she proposes to follow
condition of clause 20.1 must be observed and the amount and character of
and the bolt fully tightened up as soon as the equipment he/she proposes to use, which
joint is made. shall be subjected to the approval of the
Engineer. The approval of the Engineer
20.5 Where the manufacturing of girders shall not be considered as relieving the
has been done in accordance with clause 33 Contractor of the responsibility for the
relating to steel girder bridges, the erection safety of his/her method or equipment or
shall be done in accordance with Appendix from carrying the work in full accordance
III. However, if the Contractor desires to with the drawings and specifications.
adopt any other method of erection, he/she
shall submit the scheme and obtain the 21.4 All temporary work shall be properly
approval of the Engineer. It shall be ensured designed and substantially constructed for
the loads, which it will be called upon to
10
support. Adequate allowance and provision The bolts shall be set accurately and fixed
of a lateral forces and wind loads shall be with cement grout or any other grouting
made according to local conditions and material as approved by the Engineer
ensure that support shall not settle during completely filling the holes.
erection.
23. Rivets and Rivetting
21.5 Careful and periodical inspection of
plants shall be made by the Contractor to 23.1 The dimensions on the drawings
ensure that all tackle, ropes, chains and referred to the diameters of the rivet holes
other important lifting gear and machinery and their finished rivets. The rivet holes
are in good order and fit for service and well shall be 1.5 mm greater than the diameter
upto the capacity for which they are of the rivet bars used. The rivets shall be
required. made to IS:1929. The shanks of the
undriven rivets shall be made of a length
21.6 When chains are used for lashing, sufficient to fill the holes thoroughly and
care must be taken to protect the edges of form the head. The clearance i.e. the
members to avoid the marking and distortion difference in diameter between the rivets
otherwise caused. measured under head before being heated
and the rivet hole shall not be less than
21.7 Span erected upon staging shall be 0.75mm. Before riveting is commenced, all
supported upon suitable blocks, which shall works shall be properly bolted so that the
ensure that the girders shall be at the correct sections rivetted are in close contact
elevation and alignment when completed. If throughout. Rivets shall completely fill the
other methods of erection be adopted where holes and shall be machine driven by
staging in situ is not employed, special means of pressure or percussion rivetters
means shall be used to ensure this. of approved design.
21.8 The method used for lifting and 23.2 All rivets shall be properly heated to
slinging flexible members shall be brought to straw heat for the full length of the shank,
the notice of the Engineer and shall be firmly backed and closed. The head of the
subject to his/her approval. rivet, particularly in long rivets, shall be
heated more than the point and in no case
21.9 Temporary bracing shall be provided shall the point be heated, more than the
to take care of stresses from erection head. Sparking or burnt rivets shall not be
equipment or other loads carried during used. Where it is impossible to back up by
erection. normal method of holding up, „double
gunning‟ may be resorted to. Alternatively
22. Bearings and Anchorages pneumatic holding device may be used.
22.1 Bed plates shall be set to required 23.3 Gauges for rivet dimensions and
level and fixed accurately in position by contours shall be provided by the
giving full and even bearing by setting them Contractor for the use of the Inspecting
on a layer of cement sand and cast iron Officer.
chips as approved and directed by the
Engineer. 23.4 Rivets when driven shall completely
fill the holes, have the heads concentric
22.2 The Contractor shall drill the holes with the shanks and shall be in full contact
where necessary and set the anchor bolts. with the surface. Driven rivets when struck
11
sharply on the head with the 110-gm. rivet being used only to give the correct form of
testing hammer, shall be free from head.
movement or vibration.
23.10 When all the rivets of joints have
23.5 While rivetting built-up members been finally passed, they shall be painted
great care should be exercised to ensure as under.
that the set of holes for field rivets in each
flange of the built-up member, is aligned a) one coat of ready mixed zinc
dead-square in relation to that in the other chrome primer to IS:104
flange and not „aborrated‟. Use of assembly followed by one coat of ready
fixtures shall be made to ensure this. mixed paint red oxide zinc
chrome primer to IS:2074
23.6 All loose and burnt rivets and rivets b) Finishing coat as per clause 39
with cracks badly formed, eccentric or
deficient heads shall be cut out and 24. Field Rivets, Bolts, Nuts and
replaced. Permissible deviation of driven Service Accessories
rivets shall be as per Appendix IV. Rivets
shall also be cut out when required for the 24.1 The work is to include supply of all
examination of the work. Actual method of units, bolts, nuts, washers etc. required to
cutting out shall be approved by the complete erection at site with an allowance
Engineer. Recupping and caulking shall in for wastage etc. of 12.5% of the net
no circumstances be resorted to. number of field rivets, bolts and washers
required subject to a minimum number of
23.7 Rivetting shall not be started until five in each item.
such time as the Engineer has personally
satisfied himself that the alignment of the 24.2 The Contractor shall be responsible
girders is correct, the verticals plumb for supplying site rivets of approved length.
laterally, the camber according to that shown The length of such rivets shall be verified
on the camber diagram with camber jacks by snapping a few rivets of each length in
screwed tight, all the joints and cover plates the presence of the Inspecting Officer. In
well up, service bolts tight and field rivet the case of rivets with long grips (with grip
holes coinciding. Special care should be exceeding 6 times the diameter) specimen
taken that service bolts are frequently re- rivets on the test piece shall be cut to see if
tightened as the rivetting proceeds. the holes are totally filled even though the
rivets are tight under the usual hammer
23.8 All field rivets shall be tested as tests.
directed by the Engineer.
24.3 Black hexagonal bolts (Service
23.9 Where practicable all rivetting shall bolts) with nuts and ordinary platter‟s
be done by pneumatic or hydraulic rivetting washers and drifts for use in the erection of
machine. The working pressure to be the work shall also be supplied at 60%
employed when using pneumatic or (45% bolts and 15% drifts) of the number of
hydraulic tools shall be approved by the field rivets per span in each size (this
Engineer. Hand rivetting shall only be done includes wastage). The Purchaser may
when sanctioned by the Engineer. In such however, specify a reduction in the
cases, means shall be adopted to ensure quantities of service bolts etc. if more than
the rivets being used in their entire length so one span of each type is ordered.
as to fill the rivet holes completely, the snap
12
25. Smithed Work distortion and minimise residual shrinkage
stresses. Properly designed jigs should be
25.1 All joggles shall be performed by used for assembly. The welding techniques
pressure. Craned sections or knees can be and sequence, quality, size of electrodes,
formed by forging or by gas cutting and voltage and current required shall be as
welding by any approved electric arc prescribed by manufacturers of the material
process. Any bending, forging, cutting or and welding equipment. The Contractor
welding shall be carried out in such a should submit full details of welding
manner as not to impair the strength in the procedure in proforma given at Apppendix
metal. Forging shall be annealed as V.
indicated in the drawing.
26.5 Site welding should not be
25.2 If drop forging through dies is undertaken except in special
resorted to, excessive forging in one circumstances with the approval of the
operation shall be avoided. Where Chief Bridge Engineer. Site welding should
necessary, a series of intermediate stage be confined to connections having low
dies shall be manufactured and used. stresses, secondary members, bracings
etc.
26. Welding
26.6 Manual metal arc welding may be
26.1 Welded construction work shall be done taking adequate precautions as per
carried out generally in accordance with the IS:9595 and under strict supervision.
provisions of Indian Railway Standard
Welded Bridge Code and subject to further 27. Sequence of Welding and Weld
specifications given in the following Pass
paragraphs.
27.1 For fabrication of welded composite
26.2 All welds should be done by girders, channel shear connectors shall be
submerged-arc welding process either fully welded on top flange plate prior to
automatic or semi-automatic. Carbon di assembly of I-section. This facilitates
oxide welding or manual metal-arc welding correction of any distortion of flange plate
may be done only for welds of very short developed during the welding of channel
runs or of minor importance or where access shear connectors.
of the locations of weld do not permit
automatic or semi-automatic welding. 27.2 In making a typical I-section four
fillet welds are to be made. The welding
26.3 Except for special types of edge sequence to be followed is indicated by
preparation, such as single and double „U‟ number 1 to 4 as shown in the Fig. 3.
single and double „J‟ the fusion edges of all
the plates which are to be joined by welding 27.3 Whenever a square butt weld in a
may be prepared by using mechanically 10 or 12mm thick plate is required to be
controlled automatic flame cutting equipment made, the sequence to be adopted is
and then ground to a smooth finish. Special shown in Fig. 3.
edge preparation should be made by
machining or gouging.
26.4 Welding procedures:- The welding

procedure shall be such as to avoid
13
28. Bolts, Nuts and Washers Limit of Shank of Hole(mm)
tolerance bolt(mm)
28.1 Bolts, Nuts and Washers shall be in
accordance with the following High 0.000 +0.125
specifications:- Low - 0.125 0.000
(i) Black hexagonal bolts to IS:6639 28.7 The shank of each turned bolt shall
and Nuts to IS:1363. be of such a length that it is in full contact
with the work, throughout, the screwed
(ii) Precision and turned bolts with portion being made at least 1.5mm less in
nuts and hexagonal screws to diameter than the shank or to suit the next
IS:1364. smaller size of screw thread. The shank
(iii) Plain washers to IS:2016 and portion shall be joined to the threaded
IS:5369. portion by a 450 chamfer within the
thickness of the washer. Washers with
(iv) Spring washers - IS:3063.
perfectly flat faces should be provided with
(v) Taper washers - IS:5372 and all turned bolts.
IS:5374.
28.8 The washers under the nut shall
28.2 Manufacture, workmanship, Marking,
have a hole of 1.5mm larger in diameter
Packing etc. for Bolts and Nuts shall comply
than the shank of the bolt and shall have a
with the requirements of IS:1367.
thickness of not less than 6mm so that the
nut, when screwed up, shall not bear on
28.3 Where the head and nuts bear on the shoulder of the bolt.
timber, square washers having the length of
each side not less than three diameters of
29. Connecting Pins
the bolt and the thickness not less than one
quarter of the diameter shall be provided.
29.1 All connecting pins shall be finished
Steel, wrought iron or malleable cast iron
accurately to gauge and parallel
taper washers shall also be provided for al
throughout, straight and with smooth
heads and nuts bearing on bevelled
surface entirely free from flaws and of
surfaces.
sufficient length to ensure that all parts
connected thereby shall have a full bearing
28.4 For black bolts a clearance
on the pin. They shall be turned to a
(difference in diameter) of 1.5mm for all
smaller diameter at the end for the thread
sizes of bolts shall be allowed.
and driven to place with a pilot nut, where
necessary to preserve the thread.
28.5 Where turned bolts are required they
shall be carefully turned and shall be parallel
30. Pin Holes
throughout the barrel. Holes for turned bolts
should be 1mm underdrilled in shop and
30.1 Pinholes shall be bored smooth
should be reamed at site to suit the diameter
straight and true to gauge and at right
of the turned bolts.
angles to the axis of the member. Boring
shall only be done after the member has
28.6 The following limits of tolerances,
been rivetted up and the diameter of the
shall be permitted upon the diameter of the
pin shall not be less than that of the hole by
shank of turned bolts and of the holes
more than 0.5mm.
which they are to fit:
14
31. Bearing and Expansion Gear No drift shall be used anywhere in the work
larger in any part than the hole in which it is
31.1 All steel bed and bearing plates or to be driven. Holes for turned bolts, which
plates over saddle castings, shall be made have been 1 mm underdrilled in shop,
perfectly level and all rivet heads on their should be reamed at site by the erecting
bearing surfaces shall countersunk and agency.
dressed flush.
33. Interchangeability
31.2 The saddles, knuckle-bearers and
roller bed-plates shall be planed on all 33.1 Every span is to be temporarily
bearing surfaces and elsewhere as indicated erected complete in Contractor‟s works
on the Contract Drawings and all bolt-holes adopting the method of giving camber as
shall be drilled. The bottom edge of ribs explained in clause 34 and all parts as
should be machined and welded to the marked to their place, unless the whole of
bottom slabs after which the top edges of the work is made completely
the ribs should be machined as a whole and interchangeable by the use of steel jigs and
the top plate welded. Subsequently the top hard steel bushes controlled by master
and bottom surfaces should be machined to gauges, in which case the first span must
the specified tolerances as given in be completely erected to test the accuracy
Appendix VI. Generally in connection with of the templates. Further spans or part
the bearing gear all meeting surfaces span assemblies built from parts selected
including the sides of the roller frames, shall at random by the Inspecting Officer shall be
be machined, all bolts except anchor bolts erected from time to time to check the
turned and fitted, all washers faced, the accuracy of the work as the Inspecting
rollers knuckles and pins polished to smooth Officer may require.
surface and the whole finished in the style of
first class machined work. 33.2 If the work is considered
interchangeable by the Inspecting Officer a
31.3 Tolerances shall be as specified in simplified scheme of marking will be
Appendix VI and shall be shown on the permitted, i.e. all pieces which are identical
drawings. shall bear one distinguishing mark
irrespective of the span to which they
32. Erection in Contractor‟s Works belong. Should the interchangeability not to
the satisfaction of the Inspecting Officer,
32.1 The work shall be temporarily the whole of the spans must be erected
erected complete at the Contractor‟s Works complete and all parts marked to their
for inspection by the Inspecting Officer, with place without additional charge. The
the exception of such rivetting as has to be tenderers must state in their tenders
done at site, so that accuracy of fit and whether they intend to adopt complete
perfection of workmanship may be assured. interchangeability or not.
The work shall be put together with sufficient
numbers of parallel drifts or turned bolts or 33.3 Under special arrangement with the
both to bring the pieces into place. When so Purchaser, it shall be permissible for
erected all holes left to be filled at site shall approved portions of the work to be
be so fair that a parallel gauge turned to a despatched before complete erection of the
diameter 0.8mm less than that of the hole, of first span, provided the Contractor satisfies
a length equal to the depth of the hole, can the Inspecting Officer that such portions of
be passed through them without difficulty. the work are strictly interchangeable and
15
will assemble correctly and accurately in the 34.7 In the case where the girders are
complete structure. erected on yielding supports such as a
service span, due allowance shall be made
34. Camber for the anticipated yield when the camber
blocks are set out.
34.1 In order to ensure that the fabrication
and erection of main girders shall be such as 34.8 Frequent checks shall be made of
to eliminate secondary stresses in the the camber of girders during erection and
loaded span, the nominal length (i.e. the care taken to see that the camber as per
lengths which will give no camber) of drawing is obtained when the girder is
member shall be increased or decreased by completely assembled. When span is
the amount shown on the camber diagram supported on ends and intermediate
supplied by the Purchaser. supports are removed the dead load
camber shall be recorded and entered in
34.2 For setting of the angles of bridge register. This will provide the
intersection of the chords and web members reference to compare the camber checked
and also for templating the gusset, full size during technical inspection to ascertain the
of panels with nominal lengths of the loss of camber.
members, shall be used. Similarly, the
machining of all chords butts shall be to suit 35. Testing
the nominal outline as defined in clause No.
34.1. 35.1 The Inspecting Officer shall be
empowered, at his/her discretion to make
34.3 The procedure for erecting the span or have made under the supervision, any of
at Contractor‟s work shall be as specified. the tests specified in the specifications
The site rivetting holes shall be rivetted or mentioned herein in addition to such other
bolted and drifted as specified in Appendix tests as he/she may consider necessary, at
III. any time upto the completion of the
contract and to such an extent as he/she
34.4 When supported on blocks or may think necessary to determine the
stagings, the girders shall be erected to the quality of all materials used therein. In
camber specified in the fabrication drawings doing so, he/she shall be at liberty under
according to which the girders have been any reasonable procedure, he/she may
manufactured. A camber diagram indicating think fit to select, identify, have cut-off and
the relevant height of each panel point when take possession of test pieces from the
erected on blocks at the manufacturing material either before, during or after its
works shall be supplied by the Engineer. being worked up into the finished product.
34.5 The cambering of the main girders 35.2 He shall also be empowered to call
alongwith pre–stressing, when all panel for a duly authenticated series of
points are supported on the blocks or mechanical tests to be obtained from the
stagings, shall be carried out in accordance maker for this materials used in the work
with Appendix „A‟ of Steel Bridge Code. and to accept the same in lieu of other
tests to the extent he/she deems fit. The
34.6 Special methods of erection will Contractor shall supply the material
require special erection drawings approved required for the test pieces and shall also
by the Engineer, which must not be deviated prepare the test pieces necessary.
from.
16
35.3 The test shall be carried out by the reasonable times and shall be at liberty to
Contractor, for which Contractor shall inspect the process of manufacture at any
provide all facilities including supply of such time and to reject in whole or part,
labour and plant. Inspecting officer may at any work or material that does not conform
his/her discretion direct the Contractor to to the provisions of this Specification and
despatch such tests pieces as he/she may may order the same to be removed,
require to the National Test House or replaced or altered at the expense of the
elsewhere as he/she may think fit for such Contractor. All gauges and templates
testing purposes. necessary to satisfy the Inspecting Officer
of the complete interchangeability of parts
36. Check on Tests Made at must be supplied by the Contractor free of
Contractor‟s Work cost.
36.1 The Inspecting Officer may at his/her 39. Oiling, Painting and Metallising
discretion, check test results obtained at
Contractor‟s work by independent tests at 39.1 No part of the work shall be painted
National Test House. or coated, packed or despatched, until it
has been finally inspected and approved by
36.2 The Inspecting Officer shall at all the Inspecting Officer. Dry Film Thickness
times be empowered to examine and check shall be measured by elcometer or any
the working of the Contractor‟s plant before other approved method.
and after using it. Should the Contractor‟s
plant be found, in the Inspecting Officer‟s 39.2 When so specified by the
opinion, unreliable, he/she is empowered to Purchaser, the whole of the work except
cancel any tests already carried out in this machined surfaces shall be given
contract and have these tests carried out at protective coating using one of the systems
any National Test House or elsewhere, as of painting or metallising given in clauses
he/she may think fit. 39.2.1 to 39.2.4. Prior to the application of
protective coating , the surface of work
37. Analysis shall be carefully prepared removing mill-
scale, rust, etc. using wire brushes, sand or
37.1 The Contractor shall supply grit blasting as stipulated and approved by
authenticated copies of analysis of any the Purchaser.
materials used in the contract when required
to do so by the Inspecting Officer who shall 39.2.1 For locations where the girders are
be empowered to accept them to the extent subjected to salt spray such as in close
he/she thinks fit. In addition to the above vicinity of the sea and/or over creeks etc.
samples may, at the Inspecting Officer‟s the protective coating by metallising with
discretion be subjected to complete analysis sprayed aluminium as given in the
at the National Test House or elsewhere as Appendix VII followed by painting as per
the Inspecting Officer may determine, the painting schedule given below may be
cost of the same to be borne by the applied:
Purchaser.
(i) One coat of etch primer to
38. Inspection - General IS:5666.
(ii) One coat of zinc chrome primer
38.1 The Inspecting Officer shall have free to IS:104 with the additional
access to the works of the Contractor at all proviso that zinc chrome to be
17
used in the manufacture of (b) Intermediate Coat
primer shall conform to type 2 of
IS:51. Apply by brush/ airless spray
one coat of Epoxy Micaceous
iii) Two coats of aluminium paint to
Iron Oxide paint to RDSO
IS:2339 brushing or spraying as
Specification No. M&C/PCN/
required. One coat shall be
103/86 to 100 microns minimum
applied before the fabricated
DFT of 100 and allow it to hard
steel work leaves the shop. After
dry.
the steel work is erected at site,
the second finishing coat shall be (c) Finishing Coat
applied after touching up the
primer and the finishing coat if Apply by brush/airless spray two
damaged in transit. coats of polyurethane aluminium
finishing to RDSO Specification
39.2.2 For locations where girders are No. M&C/PCN-110/88 for
exposed to corrosive environment i.e. coastal locations or
flooring system of open web girders in all polyurethane red oxide (red
cases, girders in industrial, suburban or oxide to ISO 446 as per IS:5) to
coastal areas etc., protective coating by RDSO Specification M&C/PCN-
metallising followed by painting as 109/88 for other locations to 40
mentioned in clause 39.2.1 or by painting microns minimum DFT giving
using epoxy based paints as per the sufficient time gap between two
following painting schedule may be applied: coats to enable the first coat to
hard dry. The finishing coats to
i) Surface Preparation
be applied in shop and touched
after erection if necessary.
a) Remove oil/grease from the
metal surface by using petroleum 39.2.3 For other locations, protective
hydrocarbon solvent to IS:1745. coating by painting as per painting
schedule given below may be applied:
b) Prepare the surface by sand or
grit blasting to Sa 2-1/2 to a) Primer coat
IS:9954 i.e. near white metallic
surface. One coat of ready mixed paint
zinc chrome priming to IS:104
(ii) Painting followed by one coat of ready
mixed paint red oxide zinc
(a) Primer Coat chrome priming to IS:2074.
Apply by brush/airless spray two or

coats of Epoxy Zinc Phosphate
primer to RDSO Specification No. Two coats of zinc chromate red
M&C/PCN/102/86 to 60 microns oxide primer to IRS:P-31.
min, dry film thickness( DFT)
giving sufficient time gap b) Finishing coat
between two coats to enable the
Two finishing coats of red oxide
first coat of primer to hard dry.
paint to IS:123 or of any other
approved paint shall be applied
over the primer coats. One coat
18
shall be applied before the 39.5 All machined surfaces are to be well
fabricated steel work leaves the coated with a mixture of white lead to IS:34
shop. After the steel work is and Mutton tallow to IS:887.
erected at site, the second
finishing coat shall be applied 39.6 For site painting the whole of the
after touching up the primer and steel work shall be given the second
the finishing coat if damaged in finishing coat after finally passing and after
transit touching up the primer and finishing coats if
damaged in transit.
39.2.4 Where the life of protective coating is
required to be longer to avoid frequent
40. Name Plate
paintings, the problem of accessibility of
locations and for other locations where
40.1 A neat casting bearing the name of
metallising or epoxy based painting is
the Contractor, the place and year of
recommended vide Clause 39.2.2 but there
manufacture, drawing number, the contract
are no facilities available for the same,
number and the standard of loading to be
protective coating by painting as per
specified by the Purchaser shall be bolted
following painting schedule may be applied
conspicuously on each span. The drawing
with the approval of the Purchaser:
of the name plate shall be approved by the
a) Primer coat Engineer.
One coat of ready mixed zinc 41. Erection Mark

chrome priming to IS:104
followed by one coat of zinc
41.1 Every portion of the work shall be
chrome red oxide priming to
distinctly stencilled with paint with letter
IS:2074.
size not less than 10 mm for guidance in
b) Finishing Coat the erection in the field, and stamped with
the letters specified in the drawings. In the
Two coats of aluminium paint to
case of non-interchangeable work, the
IS:2339 shall be applied over the
system of marking shall be in accordance
primer coats. One coat shall be
with the drawings prepared by the tenderer
applied before the fabricated
and approved by the Purchaser.
steel work leaves the shop. After
the steel work is erected at site,
the second coat shall be applied 42. Packing
after touching up the primer and
the finishing coat if damaged in 42.1 All projecting plates or bars shall be
transit. kept in shape by timber or angle bars
spiked or bolted to them , and the ends of
39.3 Surfaces which are inaccessible for the chord lengths, end posts and plate
cleaning and painting after fabrication shall girders at their shipping joints shall be
be applied one heavy coat of zinc chrome protected and stiffened so as to prevent
red oxide priming to IS:2074 before being damage or distortion in transit as the
assembled for rivetting/welding. Inspecting Officer may direct.
39.4 All rivets, bolts, nuts, washers etc. 42.2 All threaded ends and machined
are to be thoroughly cleaned and dipped into surfaces are to be efficiently protected
boiled linseed oil to IS:77 against damage in transit. The parts shall
19
be sent out in lengths convenient for 43. Despatch or Shipping Marks
transport.
43.1 Each package, case or bundle is to
42.3 All straight bars and plates except have clearly stencilled on it in good oil paint
small pieces are to be sent out in convenient the address as stated in the order of
bundles temporarily rivetted or bolted contract, gross and net weight description
together or bound with wrought iron or of contents and such marks as may be
suitable wire as the Inspecting Officer may required by the Purchaser must be shown
direct. All rivets, bolts, nuts, washers, plates against each item in the invoice. The
under 300 mm square and small articles Contractor is to provide necessary stencil
generally are to be packed separately for plates for marking. Every piece of bundle
each span in cases each weighing, when shall be marked and in the case of material
full, not more than 350 kg, or in strong (shipped to India) all cases or casks shall
petroleum casks, or in barrels approved by be clearly cut or branded, not merely
the Inspecting Officer. If not entirely filled by painted, with their net and gross weights
the contents the space left shall be closely and with such shipping marks and other
packed with wood shaving or other suitable particulars as the Inspecting Officer may
material. Bolts and rivets of different sizes direct and each bundle shall also have a
shall be separately packed in bags, each metal label securely attached with wire
bag having a label indicating its contents. A stamped with similar marks. The marking
list of the contents shall be placed in the top shall be done with thick oil paint and in
of each case or cask. such a manner that it cannot be washed off
or obliterated.
42.4 In the case of imported material all
cases shall be made of 32mm boards with 44. Loading
ends nailed with 90mm wire nails
strengthened by battens and 38mmx 1.6mm 44.1 All trucks or wagons are to be
(No. 16 BG) hoop -iron and made thoroughly loaded to as near their full capacity as is
secure for transit to India. All casks shall be consistent with safe transport. While
in sound condition, and if not entirely filled loading the material in wagon, truck or
by the contents the space left shall be trailor, care should be taken that heavier
closely packed with wood-wool or other material is loaded first and lighter material
suitable material. The heads shall be firmly is kept on top so that lighter material is not
secured by means of hoops in the usual damaged due to heavy weight. While
way, and in addition each head shall be transporting the material by road, adequate
further secured by a strong wooden batten safety precautions shall be taken as per
and not less than two strips of 1.6mm(No.16 extant instructions.
BG) hoop-iron passing over the head and
nailed to the staves on both sides. The hop- 44.2 The Contractor shall apply all
iron shall be long enough to pass over two dunnage and lashing required to hold the
hoops on each side of the cask and be material securely in position free of charge.
nailed in such a manner that the hoops
cannot slack back. Bolts and rivets of 44.3 While handling any girder or girder
different sizes shall be packed in a separate component it shall be ensured no damage
canvas bags, each bag having a label in to material takes place in the form of
dictating its contents. End field holes to be dent/cut mark etc. Wooden blocks, rubber
bolted in case of members having split in pads shall be used to avoid direct contact
plate and channels.
20
between materials to be handled and preparing his/her tender, he/she does so
handling equipment. at his/her own risk, as he/she will not be
entitled to make any claim or demand nor
45. Weight of Steel Work for Payment to raise any question whatsoever, on
account of any error or miscalculations in
45.1 Any steel work the weight of which or misunderstanding of the said quantities,
differs by more than 2.5% from the as these are given for the convenience of
calculated weight determined from the the Purchaser.
nominal weight of the sections shall be liable
to rejection. 47. Tracings and Printings
45.2 Payment shall be made on the 47.1 Excepting in the case of standard
tendered weight to be calculated in spans fabricated without any modifications
accordance with the nominal weight of the to the standard drawings the Contractor
sections as specified on the contract shall supply free of charge, one set of
drawings. An addition in weight for welds neatly executed tracing on linen. They shall
and rivet heads should either be specified in be fully dimensioned and contain all
the schedule or be made as follows: erection marks, notifications as to the
colour the work has been printed, the name
a) 3% in case of rivetted or of the Contractor and any alterations from
composite (rivetted and welded) the contract drawings, which may have
work; and been made in executing the work. The
b) 1 % in case of purely welded drawings shall conform to standard sizes
work. as given in IS:962 and shall not exceed AO
size. The drawings shall not be folded but
45.3 Should the actual weight fall short of rolled outwards on a roller, in addition to
the calculated weight by more than 2.5%, three sets of full size copies on strong
the material if accepted, will be paid for the paper made by an approved process.
actual weight only. Should the actual weight
exceed the actual calculated weight, 48. Rivets and Bolts Lists
payment will be made for calculated weight
only. 48.1 The Contractor shall also supply,
without charge, three complete lists of the
45.4 No separate payment shall be made rivets, bolts, service bolts, washers and
for the items mentioned in clause 24. drifts required for erecting the work at site,
showing the parts of the work to which the
45.5 In the event of a dispute arising as to various rivets and bolts belong and having
the weight of a portion of steelwork, a each item marked so as to indicate the
weighment shall be made in the presence of particular case in which it will be found.
the Inspecting Officer.
49. Photographs
46. Quantities
49.1 If required by the Purchaser the
46.1 In case where the estimated Contractor shall also supply without
quantities are given with the schedule, it charge, two sets of large well-executed,
must be understood that the Purchaser will unmounted photographs of the first span of
not be responsible for their accuracy and if each description of plate girder or truss
the Contractor makes use of them in bridge when erected, taken from two points
21
of view and showing the erection marking as 53. Alterations in Work
clearly as possible Photographs of rolled
beam, trough girder or trough plate girder 53.1 The Contractor shall not in any case
bridges will not be required. or in any circumstances have authority to
make any alterations in, modifications of,
50. Attestation of Tracings etc. substitution for, addition to, or omission of
work or any method or system of
50.1 The tracings, photographs and lists construction, unless an alteration order in
shall be examined and signed by the writing directing such alteration,
Inspecting Officer. They shall be supplied modification, substitution, addition,
with the first instalment of the work omission or change shall have been given
delivered. by the Purchaser prior to the
commencement of the work or part of work
51. Inclusive Price nor shall the Contractor be entitled to any
payment for or in respect of any such
51.1 The cost of all painting, temporary alteration, modification, substitution,
erection and tests at the Contractor‟s works, addition, omission or change may have
marking, packing and delivery F.O.R. or been actually made and executed and no
C.I.F. as called for in the schedule is to be course of conduct shall be taken to be a
included in the price named on the tender. waiver of the obligation and conditions
The cost of erection at site, if done by the hereby imposed.
Contractor, is to be entered separately.
53.2 All altered, modified, substituted,
52. Deviations from this Specification additional and changed work, labour and
materials and all omitted work shall be
52.1 Should a tenderer desire to depart in valued by the Purchaser on the basis of the
any respect from the provisions of this rates specified in the schedule.
Specifications either on account of
manufacturing practice or for any other 54. Additional Specification for
reasons, he/she must do so in an alternative Locomotive Turn- Tables
tender which may not be considered, with a
covering letter explaining in detail each and 54.1 General - The locomotive turn-
every departure he/she proposes to make tables shall be complete in every respect
from the Specification. including rails for the deck and pathway,
locking pockets and gear with turning
52.2 Manufacturer‟s standard specification handles or levers, foundation bolts and
may be submitted but all discrepancies must plates, supply of grease for the bearings,
be carefully drawn attention to, both in and set of case-hardened black finished
covering letter and in appendices to be spanners for the suspension bolts etc. all
annexed to the specification. necessary fish-plates and bolts, spikes etc.
for the table and pathway rails, and all
52.3 The intention is to adopt bolts, rivets and other fastenings requisite
manufacturer‟s standard equipment as far as for the erection of the locomotive turn-
possible but these standards must in all tables together with the percentage for
respects comply with the conditions of this spares given in clause 24 above shall be
Specification regarding safety from break- included in the contract. Unless otherwise
down, output, capacity, performance etc. specified a complete spare set of balls and
22
races shall be supplied with each locomotive hardened. This piece after being hardened
turn-table. must be submitted to the Inspector for
his/her approval. When broken, the depth
54.2 Steel Forgings and Bars for Shafts of the case hardening must be at least
- Steel forgings and bars for shafts shall be equal to that specified for the centre pivots.
made from Class 4 steel to IS:2004.
54.13 Cast Iron/Cast Steel Centre Pillar
54.3 Ball and Roller Bearings - Ball and - The cast iron centre pillar shall be finished
roller bearings when and where used shall on top to suit the type of bearing specified
be of approved make. by the Purchaser. The oscillation of the
table shall be taken by a cup and pivot
54.4 Case Hardened Steel for Bearings fitted into a cast steel container and the
- Case hardened steel for bearings shall be bearing cup respectively. The cup and pivot
of Class I Steel to IS:1875. shall be machined from well hammered
Class I Steel forgings to IRS M-3. After
54.5 Balance/Race Wheels - being machined the bearing surfaces of the
Balance/Race wheels shall be of chilled cast cup and pivot shall be compressed by the
iron to IRS R19 or cast steel to IRS M2 and hydraulic pressure. The cup and pivot shall
the dimensions shall be as shown on the then be case hardened to a depth of not
drawings. less than 3.0 mm (1/8 inch) and then
accurately finished to the correct profile. In
54.6 Split Cotters - Flat split cotter shall the case of ball bearings the housing shall
be to IS:2638. be dust proof and oil retaining. Adequate
means shall be provided for lubrication of
54.7 Split Cotter Pins - Split cotter pins the centre bearing and the pivot.
shall be to IS:549.
54.14 Race Wheels - The pathway
54.8 Set Screws - Set screws shall be to wheels are to be fitted with ball bearings of
IS:1364. approved make and are to run on steel
spindles fixed in cast iron brackets,
securely bolted to steel joists. Plain bearing
54.9 Table and Race Rails - Rails shall
will be accepted if specified by the
be to IRS T-12 to T-18.
Purchaser.
54.10 Suspension Bolts - The screwed
54.15 Locking Pockets - Locking pockets
ends of the steel suspension bolts shall not
for one position of the locomotive turn-table
be welded but formed from the solid bar.
only are to be provided unless otherwise
stated by the Purchaser.
54.11 Bearing Caps - Bearing caps shall
be provided with two eye bolts for lifting.
54.16 Erection and Testing at
Contractor‟s Works - The locomotive turn-
54.12 Case Hardening - All case
table shall be temporarily erected complete
hardening shall be done in a furnace with
at the Contractor‟s works for inspection by
animal charcoal or other approved
the Inspecting Officer so that accuracy of fit
composition. No potash hardening will be
and perfection of workmanship may be
allowed. A test piece of the material used 30
ensured. The erection work shall be done
mm dia. turned and finished must be put in
as indicated in clause 32.1. Each
the furnace, with the articles to be case
locomotive turn-table shall also be tested
23
for deflection which under specified load receipt of materials at site or 3 months after
shall not exceed the amount specified by the the date of erection whichever is earlier.
Purchaser in accordance with the design
adopted. The locomotive turn-table shall be 54.18 Removal of Unused Material etc -
turned not less than 15 times in each On the completion of the work the
direction with an equivalent uniformly Contractor shall remove all used and
distributed test load in the presence of the surplus material, plant, stagings and
Inspecting Officer and to his/her satisfaction refuse, or other material produced by
his/her operations and shall leave the site
54.17 Contractor‟s Guarantee - The in a clean and tidy condition.
Contractor shall guarantee for supply of
materials, and working of the locomotive 54.19 Weight of Steel Work for
turn-table for a period of one year after Payment- Erection shall be paid for on the
weight as per Clause 45.
24
APPENDIX - I
(Ref. Clause 12)
Records to be Maintained
1) JIGS REGISTER
This register shall be maintained for keeping record of details of jigs, their approval and
modification/rectification to the jigs. One page should be allotted for each jig and details mentioned
in the following proforma:-
1. Description of jig:
2. Jig No.:
3. Shipping mark of the component for which jig is made:
4. Drawing No. for the component:
Date of inspection Observation/inspection notes Compliance action Initial of Supervisor

Incharge
1 2 3 4
In the beginning of Register, a statement of jigs shall also be placed in the following
proforma:
Jig No. Description Shipping mark of Drg.No. as per which jig is Inspecting official‟s
of Jig. the component. made/modified approval details
1 2 3 4 5
2) RIVET CHECKING REGISTER
This register shall be maintained for keeping record of rivet quality checking and
replacement of defective rivets. Register shall be maintained in the following proforma:-
Component Date of Rivetting Number and Number of Initial of Supervisor

description rivetting party nature of defective defective rivets Incharge.
rivets replaced
1 2 3 4 5 6
After rivetting, component has been inspected and defective rivets have been replaced,
the Supervisor Incharge of rivetting should put a stencil mark on the component to this effect.
3) MATERIAL OFFERING AND INSPECTION REGISTER
This register shall be maintained separately for each work order for keeping record of
material offered for inspection, inspection remarks and passing details. One page should be
allotted for individual members or fittings. Proforma shall be as under:-
1. Description of component/fitting:
2. Shipping mark:
3. Quantity required per span:
Span Initial of Supervisor Inspecting Compliance Seal & initial of Despatch &
No. offering material for officials action Inspecting consignee details.
inspection. Remarks official
1 2 3 4 5 6
25
4) RDSO INSPECTION NOTES AND COMPLIANCE REGISTER
This register shall be maintained for record of compliance action taken on RDSO
Inspection notes. In this register one copy of the inspection note received from RDSO shall be
pasted and compliance action recorded against each item.
5) WELDING PROCEDURE DATA REGISTER
In this register complete details of welding of welded girders shall be maintained in the
proforma as under:
Name of work:_______________________________________________________
Contract/Work Order No. ______________________________________________
Span No.________________________________
Date of Girder component Weld joint description Name of WPSS No. followed
welding and its Sl.No. welder/Ticket No.
1 2 3 4 5
Welding Welding parameters Weld Run on/Run Radiograph Initial of

consumable used repair off tabs. No. no. if any Supervi-
details if any sor
Incharge.
Electrode Flux Current Arc Travel 11 12 13 14
/ wire (amp.) Voltage Speed
(volt) (m/min)
6 7 8 9 10
The welding data record to be submitted to RDSO while offering the welded girders for
inspection, shall be prepared based on the details recorded in this register.
6) RADIOGRAPHIC INSPECTION REGISTER
Record of radiographic inspection of welded girders shall be maintained in the register in

the proforma given below:
Name Span Girder Weld joint Date of Radio- Obser- Result Initial of
of No. Part description radiographic graph vation Supervisor
work inspection. No. Incharge.
1 2 3 4 5 6 7 8 9
7) STATEMENT OF MATERIAL TEST CERTIFICATES

Name of Work_____________________________
Contract/Order No..______________________
Span No..______________________
Girder Type and Material Cast Steel Steel Initial of
Component Size of rolled Test No. quantity as Manufacturer/ Super-
description and section Certificate per the test Supplier visor
identification No. certificate Incharge
No. .
1 2 3 4 5 6 7
One page should be allotted for each span.
26
APPENDIX - II
(Ref. Clause 13)
Manufacturing Tolerances
1. Plate girders
Tolerances in Notation
mm in the
Figure
(plus) (minus)
No.1
(a) Overall length of the girder 6 3 a
(b) Distance between centres of bearings 1 1 b
(c) Depth over angles 3 1 c

(d) Corner of flange angle to edge of web at 0 2 d
any place
(e) Diagonal at either end of the assembled 3 3 e
span
(f) Centres of intersection of diagonals with 3 3 f
girder flange measured along the girder
flange
(g) Butting of compression ends
i) throughout 0 0.15 g
ii) locally 0 0.25 g
(h) Butting edge at web splices 0 1 h
(i) Straightness of girder bottom laid on the

ground and checked with piano wire:
(i) vertical plane
Convexity 0 3 j
Concavity 0 0 j
(ii)Horizontal plane 2 2 j
2. Open web girders
(a) Over-all length of girders 1 1 k
(b) Distance between centre to centre of 1 1 l

bearings
(c) Cross diagonals of assembled bays 1 1 m
(d) Centre to centre of cross girders 1 1 n
(e) Centre to centre of rail bearer 1 1 p
(f) Panel length in lateral bracing system 1 1 q
27
(g) Distance between inter section line of 1 1 r
chords vertical and horizontal
(h) Butting edges of compression members:
(i) throughout 0 0.15 s
(ii) locally 0 0.25 s
(i) Twist in members 0 0 t
(j) Lateral distortion between points of lateral .001 L .001 L u
supports
3. Holes-
(a) Between any two holes in group 0.5 0.5 v
(b) Between holes of one group and another 1 1 w
(c) Edge distance 0.5 0.5 x
(d) Distance of „GO‟ gauge open holes in two 0 0.8 y

or more thicknesses
(On nominal diameter of hole)
4 Special Fabrication Tolerances as applicable to Welded Plate Girder.
Description. Tolerances in mm
1. Depth at the centre of web +2 to -1
2. Flange out of square for compression member 1/200 or 3 max

and beams
From edge whichever is
less.
3. Displacement of vertical axis of the web with 2
reference to flange.
4. Box width of member 0 to +3
5. Verticality of stiffener or diaphragm out of plumb. 2
6 Overall length of girder + 6 to -3
7 Depth of the girder at the ends + 3 to -1
8 Depth of the girder at the centre of span + 2 to -1
9 Distance between centre of bearings + 1 to -1
10 Diagonal at either end of assembled span + 3 to -3
28
11 An allowable limit for web buckling or undulation shall be flatness at right angles
to plate surface measured parallel to longer side in either direction calculated
from the formulae
G y
x  or 4mm which ever is the lesser.
165 355
Where
x = Maximum deviation from straightness within a specific gauge length other
values are constant
σy = Yield stress of steel in N/mm2‟
G = length of measuring gauge in meter
( G= a where a<2b and G=2b where a>2b)
29
APPENDIX - III
(Ref. Clauses 20 & 34)
Erection of Open Web Girder Span
1. The joints of the chords shall be drifted, bolted and preferably rivetted to their
geometric outline.
2. All other members are to be elastically strained into position by external forces,
so that as many holes as possible are fair when filled with rivets.
3. Drifting of joints shall be avoided as far as possible, and when necessary should
be done with greater care and under close expert supervision. Hammers not
exceeding 1 kg.(2 lb) in weight should be used with turned barrel drifts and a
number of holes drifted simultaneously, the effect of the drifting being checked by
observation of adjacent unfilled holes.
4. The first procedure during erection consists of placing camber jacks in position
on which to support the structure. The camber jacks should be set with their top
level and with sufficient run-out to allow for lowering of panel points except the
centre by the necessary amount to produce the required camber in the main
girders. It is essential that the camber is accurately maintained throughout the
process of erection and it should be constantly checked. The jacks shall be
spaced so that they will support the ends of the main girders and the panel
points. The bottom chord members shall then be placed on the camber jacks
carefully levelled and checked for straightness and the joints made and rivetted
up.
5. The vertical and diagonal web members, except the end posts, shall then be
erected in their proper position on the bottom chords. Temporary top gussets, the
positions of the holes in which they are corrected, for the camber change of
length in the members, should be used to connect the top ends of the members.
This will ensure that the angles between the members at the bottom joints are as
given by the nominal outline of the girders. The verticals and diagonals shall then
be rivetted to the lower chords.
6. All panel points, except the centre, shall now be lowered by the amount to
produce the correct camber in the main girders as shown on the camber
diagram.
7. The top chord shall be erected piece by piece working symmetrically starting
from the centre outwards, each piece being cambered in turn
8. The temporary top gussets, if used, shall be replaced by the permanent gussets
in the same sequence as the erection of the top boom members.
9. The end posts shall be erected last. The upper end connection should preferably
be made first and if there is no splice in the end raker, the final closure made at
the bottom end connection. If there is a splice, the final closure should be made
at the splice.
10. When cantilever method of erection is used, the above procedure does not apply.
30
APPENDIX - IV
( REF. TO CLAUSE - 23 )
PERMISSIBLE DEVIATIONS FOR DRIVEN RIVETS

S.NO. DESCRIPTION OF DEVIATIONS SKETCH TOLERANCE
1. SHANKING OR SHIFTING OF THE HEAD UNDER
THE KNOCKS OF HAMMER. NOT ALLOWED
2. CAULKING OF THE HEAD

NOT ALLOWED
3. IMPROPER BEARING OF THE HEAD ON THE
NOT ALLOWED
ELEMENT WHILE RIVETTING ALONG THE
ENTIRE CONTOUR OF HEAD.
4. IMPROPER BEARING OF THE HEAD ON THE

ELEMENT WHILE RIVETTING ALONG THE NOT ALLOWED
ENTIRE PART OF CONTOUR OR RIVET.
5. PRESENCE OF CRACKS IN THE HEAD. NOT ALLOWED
6. NOTCH IN THE HEAD. 2 mm
7. SHIFTING OF HEAD FROM THE AXIS OF RIVET. b < 0.1d
a
b
8. BAD SHAPE OF HEAD ALONG THE PART OF a + b < 0.1d
CONTOUR OF RIVET.
a
b b
9. BAD SHAPE OF HEAD ALONG THE ENTIRE a + b < 0.1d
CONTOUR OF RIVET. d
b a
c
10.
a + b < 0.1d
HEAD OF REDUCED DIMENSION.
d
c < 0.5d
11. CROWN NEAR THE HEAD. NOT ALLOWED
12. NOTCHING OF STEEL BY SNAP. NOT ALLOWED
a
13. UVEVENNESS OF THE SURFACE OF THE HEAD. a < 0.3 mm
DEVIATION UP TO
3% OF THICKNESS.
14. OBLIQUE RIVETTING.
THICKNESS OF JOINT
ELEMENTS BUT NOT
MORE THAN 3mm.
31
APPENDIX - V
(Ref. Clause 26)
1. Proforma for Welding Procedure Specification Sheet
Name and address of Fabricator:

Welding procedure specification No
1. Weld joint description:

2. Base Metal :
3. Welding Process :
4. Welding position :
5. Welding consumables :
5.1 Electrode/wire Class :
Dia :
Drying method:
5.2 Flux Class :
Type:
Drying method:
5.3.1 Shielding gas:
6.0 Base Metal preparation:
6.1 Joint design details:
(Give sketch showing arrangement
of parts, welding groove details,
weld passes & their sequence etc.)
6.2 Joint preparation:
7. Welding current: Type:
Polarity:
8. Welder qualification:
9 Welding parameters and technique:
9.1 Welding Parameters:
Weld Electrodes/ Current Arc Wire feed Travel Electrical Gas flow
Pass wire (amp) Voltage speed speed stickout rate
No. dia.(mm) (volt) (m/min)) (m/min) (mm) (litre/min.)
1 2 3 4 5 6 7 8
9.2 Welding sequence and technique:

(Give sketch showing sequence and
direction of welding).
10. Provision of run in and run-off tabs:
11. Cleaning of weld bead before laying next weld bead:
12. Root preparation before welding other side of groove weld:
13 Preheating and inter pass temperature:
14 Peening
15 Post weld treatment:
16 Rectification of weld defects:
17 Inspection of weld.
18. Any other relevant details
Prepared by
Signature_____________________________
Designation __________________________
Date ________________________________
(for & on behalf of Fabricator).
32
2. Proforma for Welding Procedure Qualification Record
NAME AND ADDRESS OF FABRICATOR

1. Description of weld joint:
2. Welding procedure specification no.:
3. Name of welder:
4. Date of preparation of test piece:
5. Dimensions of test piece:
6. Base Metal:
7. Welding Process:
8. Welding position:
9. Welding Current: Type:
Polarity:
10 Weld joint design details:
11 Welding consumables:
11.1 Electrode/wire Class:
Dia:
Brand:
11.2 Flux Class:
Type:
Brand:
11.3 Shielding gas:
12. Welding parameters:
Weld Electrode Current Arc Wire feed Travel Electrical Shielding gas
pass wire dia (amp) voltage speed speed stick out flow rate
No. (mm) (volt) (m/min.) (m/min.) (mm) (lit/min.)
1 2 3 4 5 6 7 8
13. Preheating and interpass temperature:
14. Results of Qualification Tests:
Test Specimen No. Result.
1 2 3
Non-destructive tests:
i) Visual examination:
ii) Dye penetrant test:
iii) Magnetic particle test:
iv) Radiographic/Ultrasonic test:
Destructive tests:
i) Macro-examination:
ii) Hardness survey:
iii) Fillet weld fracture test:
iv) Transverse tensile test:
Tensile strength
Yield Stress
Location of fracture
v) All-weld tensile test:
Tensile strength
Yield Stress
Elongation %
vi) Guided bend test:
Root bend test
Face bend test
Side bend test
vii) Any other tests:
Signature _______________________
Designation ___________________
Date _________________________
(for & on behalf of Fabricator).
33
APPENDIX - VI
(Ref. Clause 31)
Tolerances & Specification for Knuckle and Roller Bearings
1. Rollers
No roller shall vary in diameter, from that shown on the contract drawings, by
more than ±0.04mm.
2. Knuckle castings and pins (Interchangeable work)
a) Knuckle Pin
The diameter shall not be greater than D, nor less than D-0.2 mm.
b) Knuckle Castings
The knuckle castings must be bored greater than D, but not greater than
D+0.3 mm.
Where D, in all cases is the diameter given on the contract drawings.
3. Knuckle castings and pins(non-interchangeable work)
If sets of bearings are not made interchangeable but are made separately and the
pins and knuckles all fitted together than the minus tolerance on the pin, and the
plus tolerance on the bore of the knuckles may be varied provided that the
difference between the diameter of the pin and the diameter of the knuckle does
not exceed 0.5mm. also in this case all sets of bearing are to be given a
consecutive number and each component part shall have this allotted number
stamped upon it and encircled in white paint in the manner shown on the sketch.
4. Marking
Accurate centre marks should be made on the four sides of the bottom slab of the
bearing to facilitate positioning during erection.
5. Thickness of castings (Interchangeable and non inter-changeable work )
No minus tolerance will be allowed in the thickness of any part of any of the
castings. The edges of all ribs shall be of the thickness shown on the contract
drawings and shall be parallel throughout their length.
34
APPENDIX - VII
(Ref.Clause 39)
Specification for Metallising with Sprayed Aluminium for Bridge Girders
1. Surface Preparation
The surface shall be thoroughly cleaned and roughened by compressed air blasting or
centrifugal blasting with a suitable abrasive material in accordance with Clause 3 of
IS:6586. Immediately, before spraying it shall be free from grease, scale, rust,
moisture or other foreign matter. It shall be comparable in roughness with a reference
surface produced in accordance with appendix A of IS:5905 and shall provide an
adequate key for the subsequently sprayed metal coating
2. Metal Spraying
The metal spraying shall be carried out as soon as possible after surface preparation
but in any case within such period that the surface is still completely clean, dry and
without visible oxidation. If deterioration in the surface to be coated is observed by
comparison with a freshly prepared metal surface of similar quality which has
undergone the same preparation, the preparation treatment should be repeated on
the surface to be coated.
The wire method shall be used for the purpose of metallising the diameter of the wire
being 3mm or 5mm. Specified thickness of coating shall be applied in multiple layers
and in no case less than 2 passes of the metal spraying unit shall be made over every
part of the surface. At least one layer of the coating must be applied within 4 hours of
blasting and the surface must be completely coated to the specified thickness within 8
hours of blasting.
2.1 Purity of Aluminium
The chemical composition of aluminium to be sprayed shall be 99.5% aluminium
conforming to IS:2590.
2.2 Appearance Of The Coating
The surface of the sprayed coating shall be of uniform texture and free from lumps,
coarse areas and loosely adherent particles.
2.3 Thickness Of The Coating
The nominal thickness of the coating shall be 150 µ(microns).The minimum local
thickness, determined in accordance with procedure given in clause 3.1 below, shall
be not less than 110 µ(microns).
3. Shop Painting
Any oil, grease or other contamination should be removed by thorough washing with a
suitable thinner until no visible traces exist and the surfaces should be allowed to dry
thoroughly before application of paint. The coatings may be applied by brush or spray.
If sprayed, pressure type spray guns must be used. One coat of wash primer to
IS:5666 shall be applied first. After 4 to 6 hours of the application of the wash primer,
one coat of Zinc chrome primer to IS:104 with the additional proviso that zinc chrome
to be used in the manufacture of primer shall conform to type 2 of IS:51 shall be
applied. After hard drying of zinc chrome primer, one coat of Aluminium paint to
IS:2339 (brushing or spraying as required) shall be applied.
35
4. Site Painting
After the steel work is erected at site a second cover coat of Aluminium paint to
IS:2339 (brushing or spraying as required) shall be applied after touching up the
primer and the cover coat given in the shop if damaged in transit
5. Method for the Determination of Local Thickness
5.1 Equipment
Any magnetic or electro-magnetic thickness meter that will measure local thickness of
a known standard with an accuracy of ± 10 percent.
5.2 Calibration of Instrument
Calibrate and check the meter on one of the following standards(as appropriate):
(I) (Applicable to magnetic and elecro-maganetic meters other than the pull-off type)
A soft brass shim ,free from burrs, in contact with the grit-blasted surface of the base
metal prior to its being sprayed. The thickness of the shim shall be measured by micro
meter and shall be approximately the same as the thickness of the coating.
(ii) A sprayed metal coating of uniform known thickness approximately the same as
the thickness of the sprayed coating to be tested, applied to a base of similar
composition and thickness to the article being sprayed, grit-blasted in accordance with
Clause 1.
5.3 Procedure
For each measurement of local thickness, make an appropriate number of
determinations, according to the type of instrument used.
With instrument measuring the average thickness over an area of not less than 0.645
cm2, the local thickness shall be the result of the one reading.
With instruments having one or more pointed or rounded probes, the local thickness
shall be the mean of three readings within a circle of 0.645 cm2 area.
With meters having two such probes, each reading shall be the average of two
determinations with the probes reversed position.
6. Method Of Test For Adhesion
Using a straight edge and hardened steel scriber which has been ground to a sharp
30 degree point, scribe two parallel lines at a distance apart equal to approximately 10
times the average coating thickness. In scribing the two lines, apply enough pressure
on each occasion to cut through the coating to the base metal in a single stroke.
7. Inspection
7.1 Determination of Local Thickness
The minimum local thickness shall be determined by the method described above.
7.2 Adhesion
The sprayed metal coating shall be subjected to an adhesion test using the method
described above. If any part of the coating between the lines breaks away from the
base metal, it shall be deemed to have failed the test
Articles, which have been rejected shall have the defective sections blasted clean of
all sprayed metal prior to respraying. Where the rejection has been solely due to too
thin a coating, sprayed metal of the same quality may be added provided that the
surface has been kept dry and is free from visible contamination.
36
FIG – 1
REF: APPENDIX-II
37
38
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Consultancy Services for preparation of Feasibility Study and

Detailed Project Report for Access Controlled Nagpur-Mumbai

DETAILED PROJECT REPORT

VOLUME- V – Technical Specifications

Part B : TECHNICAL SPECIFICATIONS – Structures

Part C : TECHNICAL SPECIFICATIONS – Tunnel

7.0 Permanent Steel Supports ............................................................................................. 94

PART A - TECHNICAL SPECIFICATIONS -Roads

2.2 Part – I: General Technical Specifications

2.3 Additional Details to MORT&H Specification

2. Clause 201 CLEARING AND GRUBBING

Clause 201.1 Scope

Clause 201.4 Disposal of Materials

Clause 201.5 Measurements for Payment

i) Above 300 mm to 600 mm

Clause 201.6 Rates

3. Clause 202 DISMANTLING CULVERTS, BRIDGES AND OTHER

Clause 202.1 Scope

Clause 202.2 Dismantling Culverts and Bridges

Unless otherwise specified, the superstructure portion of culverts/bridges shall be entirely

Clause 202.3 Dismantling Pavements and Other Structures

Clause 202A Back-filling

Clause 202.5 Disposal of Materials

Clause 202.6 Measurements for Payment

i) Dismantling brick/stone masonry/ cu.m

ii) Dismantling flexible and cement cu.m

iii) Dismantling steel structures tonne

iv) Dismantling timber structures cu.m

v) Dismantling pipes, guard rails, kerbs, linear(m)

vi) Utility services No.

Clause 202.7 Rates

4. Clause 301 EXCAVATION FOR ROADWAY AND DRAINS

Clause 301.3.3 Excavation – General

Clause 301.3.4 Methods, Tools and Equipment

Clause 301.3.6 Marsh Excavation

Clause 301.3.8 Excavation for Surface/Sub-Surface Drains

Clause 301.3.9 Slides

Clause 301.3.10 Dewatering

Clause 301.3.11 Use and Disposal of excavated materials

Clause 301.3.12 Backfilling

Clause 301A Plying of Construction Traffic

Clause 301.6 Preparation of Cut Formation

Clause 301.7 Finishing Operations

Clause 301.8 Measurements for Payment

3 . Preparing rocky subgrade ...sq.m

4 . Stripping including storing and reapplication of topsoil ...cu.m

Clause 301.9 Rates

Where presplitting of rock is prescribed it shall be governed by Clause 303.5.

5. Clause 302 BLASTING OPERATIONS

a) A copy of the relevant rules regarding safe storage both in English

b) A statement of up-to-date stock in the magazine,

c) A certificate showing the last date of testing of the lightning

d) A notice that smoking is strictly prohibited.

Clause 302.2 Materials, Tools and Equipment

Clause 302.3 Personnel

Clause 302.4 Blasting Operations

Clause 302.5 Misfire

In case of misfire, the following procedure shall be observed:

Clause 302.6 Account

6. Clause 303 PRESPLITTING ROCK EXCAVATION SLOPES

Clause 303.1 General

Presplitting is defined as the establishment of a specified excavation slope in rock by the