Methodology For Survey Works 1. Scope:: Prepared By: Checked By: Approved by

METHODOLOGY FOR SURVEY WORKS
1. Scope:
This work consist of marking of traversing, establishing of Horizontal Control monuments (HCM),
temporary bench marks (TBM), Centre line of proposed roadway and taking of OGL’s all along the
road with reference to data furnished by the Client and as mentioned in the contract drawings /
document. This item of work shall be dealt in compliance with section 109 of MORT&H
Specifications.
2. Equipment / Machinery:
a) Electronic Total stations with target sets and all required accessories.
b) Auto Level with accessories.
c) Mobile sets.
3. Materials:
Enamel Paint (White & Yellow), survey nails with round head, survey pegs, Punch Rod,
Hammer, plumb bob, steel tapes (5m, 30m and 50m lengths), safety cover, lime powder,
Umbrella and reference pillars.
4. Procedure
4.1 Traversing:
a) The control points of GPS (Global Positioning System) pillars fixed by NHAI (National
Highways Authority Of India) and handed over for execution of survey works having the
value of coordinate and levels shall be taken for consideration in Survey works.
b) Keeping the same GPS pillars as a reference, traversing of coordinate has to be done
between GPS pillar to GPS pillar and closing error of traverse, if any has to be adjusted by
bow-ditch method in between two GPS pillars.
c) Horizontal angle is to be observed by taking minimum of two sets of rounds from different
locations. All the observations are to be logged and the spread between observed rounds of
horizontal angles have to be checked for tolerances. (Two sets of angles agreed within 5
seconds).
d) In between GPS pillars, sub control pillars [Horizontal Control Monuments (HCM)] are to be
fixed at the end of/ within ROW (Right Of Way) at suitable intervals, along the road
alignment. The HCM pillars are to be painted for identification. Benchmark pillars shall be
concrete pillars of size 150 mm Diameter or any other suitable material locally available
Prepared By: Checked By: Approved By:
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with nail embedded inside and projecting 10 mm above the concrete pillar. During the
time of traversing the bearing is to be recorded on the point of rod projecting over the
HCM pillar. The coordinate value of each HCM pillar is to be arrived after traverse
adjustment by bow-ditch method. The traversed coordinate of HCM pillars along the
project alignment are to be recorded. Detailed copy of coordinate value of HCM pillar
along with chainage and location is to be given to clients and site Engineers for their
reference.
4.2 Establishment of Center Line:

a) The project alignment coordinate given by the client for the entire length of Project is to
be fixed over the existing road by 1- second accuracy Total Station.
b) The alignment point is to be marked at every 10 meter interval in straight portion and
5m. Interval on the curve portion by round head nail or as suitable as per site condition.
c) The same point is to be marked with yellow point and location (Chainage) shall be written
on the road for quick reference.
d) Fixing of the alignment for the entire length shall be checked by client / client’s
representative on daily basis.
4.3 Establishment of Temporary Bench Marks (TBM):

a) TBM’s shall be established with respect to G.P.S benchmark.
b) Fly leveling shall be carried out from G.P.S and closed to another G.P.S simultaneously
transferring the R.L to the reference Pillars and permanent structures available along the
alignment.
c) Fly leveling shall be carried both forwarded and backward for each kilometer taking three
stadia hair reading with an accuracy of 1mm. closing error in permissible limit may be
distributed proportionally.
d) During benchmark level transferring maximum observing distance shall not exceed 100 mtr,
keeping the fore sight and back sight distance equal.
e) The spread between observed range of vertical angles shall not exceed 10 seconds. The
closing error on a level circuit shall not exceed 12 root of K in mm (where K is distance in
Km.). The closing error has to be distributed over all the benchmarks in the network in
between GPS to GPS. The benchmark pillar (TBM) levels are to be checked by client.
f) Detailed benchmark list mentioning level, location and chainage is to be submitted to the
client and site engineers for their reference. This shall be checked as per frequency
stipulated in MORT&H.
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4.4 Toe Line Fixing:
a) The toe line is to be marked for every layer by means of calculating the thickness of
pavement layer multiplied by percentage of given formation slope.
b) The toe distance shall be measured from given alignment nail.
c) The cross section drawings can also be followed for toe line marking.
4.5 Taking O.G.L.’S and cross section data:

a) OGL’s shall be recorded at 10 meter interval for straight portion and 5 meter interval on
curve portion along the road and across the road at intervals specified in MORT&H.
b) Additional points as per site conditions shall be taken in both directions (along the road
and across the road) to arrive at the quantities.
c) O.G.L.’s shall be taken at approved grid intervals for structures.
4.6 Layout for CD Structures and Junctions:

a) Layout of CD structures shall be done as per site conditions for making any line, center line
of C/W, formation line for bridges / culverts the two pillars at each termination of line
sufficient far from working area shall be fixed.
5. Safety Measures:
a) Flagman in addition to the safety cones on both the end shall be used to safe ground personal,
instruments and controlling traffic.
b) Umbrella shall be used to protect the Instrument from rain, wind and sun light.
c) All personnel shall be provided with safety jackets.
6. Records and Documents to be maintained:

a) Horizontal control points (HCM data).
b) Vertical Control Points (TBM data).
c) OGL Books.
d) CD / Structure layout data.
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METHODOLOGY FOR SITE CLEARANCE
1. Scope:
This method involves cutting / felling of trees, removal & disposal of all unsuitable materials,
demolition of structures, etc… which according to the Engineer are unsuitable and fall within the
right of way. All works shall follow the guidelines of Clause 200 of the MORT&H Technical
Specification.
a) Hydraulic excavator, dozer or any other suitable machine.
b) Pneumatic tools.
c) Tippers or trucks.
3. Materials:
Lime powder.
4. Execution Procedure:
a) The right of way shall be surveyed and set out according to the data stated in the drawings &
C/L of the proposed alignment shall be marked.
b) Identification/Location of existing structures, trees, fencing, etc…shall be done with respect
to the centerline of the proposed alignment jointly with Client’s representatives.
c) Prior to removal/demolition of these, measurement shall be taken jointly with the
representative of the Engineer and recorded.
d) No topsoil shall be removed during this operation.
5. Safety Measures:
a) Suitable directional & mandatory warning sign shall be erected on stretches where works
are proposed to be taken up.

a) List of encumbrances.
b) Joint measurements.
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METHODOLOGY FOR CLEARING AND GRUBBING
1. Scope:
This method involves the stripping of the soil and preparation of bed to receive the first layer.
This item of work shall be dealt in compliance with section 200 of MORT&H Specifications.
a) Dozer.
b) Motor Grader.
c) Hydraulic Excavator.
d) Vibratory Soil Compactor.
e) Water Tanker.
3. Materials:
Lime powder and water.
4. Execution Procedure:
a) The site shall be cleared of all obstructions, trees and shrubs including their roots prior to
commencement of this operation.
b) After fixing of centerline, the required toe width shall be marked on the ground with lime
powder.
c) The formation width shall be made clear of any vegetation if present and shall be removed
not exceeding 150 mm depth. All the dozed top soil shall be removed from toe line and
disposed away from the area of work.
d) All the stumps, shrubs and roots shall be removed from the stretch with the help of manpower
/ machineries. Back filling of the pits shall be carried out if required with suitable material
and shall be compacted as required.
e) The procedure adopted shall be dozer have to doze the rut formation and roughly grade the
road surface.
f) The base is to be prepared, graded, watered and rolled giving determined no. of passes of
roller over which construction shall start.
g) The sample of existing shoulder shall be tested by project lab to determine modified proctor
density and CBR value shall in advance to calculate the compaction.
h) After bed preparation, field density tests should be carried out for ascertaining degree of
compaction.
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i) When the graded layer does not have 95% relative compaction with respect to the dry density,
the ground shall be loosened, and water shall be sprinkled uniformly at a controllable rate to
obtain optimum moisture content throughout the depth of the layer. Then the surface shall
be compacted by vibratory roller.
j) After compaction field dry density test shall be carried out to establish that base is prepared
and ready for next layer.
5. Safety Measures:
a) Suitable directional & mandatory warning sign shall be erected on stretches where works are
proposed to be taken up.
b) Precautionary retro-reflective signs shall be erected & safety cones shall be placed in areas
where this activity is being carried out

a) Existing soil test report – CBR & MDD.
b) Prepared bed report – FDD.
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METHODOLOGY FOR ROAD WAY EXCAVATION
1. Scope:
This work shall consist of excavation, removal and satisfactory disposal of all material necessary
for construction of roadways, side drains and waterways in accordance with the given
specifications and the lines grades and cross-sections shown in the drawings and as directed by
Engineer. All work shall be carried out in accordance with Clause 300 of MORTH Specifications.
The work shall include hauling and stacking of or hauling to sites of Embankment and Sub-Grade
Construction, suitable cut material as required, as also the disposal of unsuitable cut material in
specified manner and as directed.
2. Equipment / Machinery :
a) Hydraulic Excavator / Dozer / JCB.
b) Tipper.
c) Vibratory Compactor.
d) Survey Equipment.
3. Material:
Lime powder.
4. Procedure:
a) Set out Excavation toe-width at every 50 - meter intervals in plain terrain and at 20 - meter
intervals in all curve points true to lines, curves, slopes, grades and sections.
b) The levels of excavation shall be worked out from profile drawing. The area of disposal shall
be identified prior to start of activity.
c) Soil Classification on the basis of properties of soil is an important aspect before going for
construction operation. Classification shall be finalized based on laboratory testing.
d) The top soil over the site of excavation shall be stripped to specified depth if required. In
case of unsuitable black cotton soil or other soil such as clay, loam the same shall be stripped
to the depth as required.
e) Reusable material shall be identified by test record of existing shoulder. Suitable materials
available from excavation shall be satisfactorily utilized directly or may be stored within ROW
away from toe line as decided.
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f) All precaution shall be taken during executing excavation against soil erosion, water pollution
etc, along with appropriate drainage measures to keep the site free from water by trimming
sides of excavated area and making pond along with natural drainage to take place.
g) Excavation shall be done mechanically with the help of excavator to required sizes and depth.
All loose materials/debris on slopes of cutting shall be removed. All sides of excavated area
shall be trimmed to neat slopes.
h) The material obtained from the excavation of roadway, shoulders, drains, cross-drainage etc.
shall be disposed as required. Unsuitable and surplus material not intended for use within the
lead specified, shall also be transported with all lifts and lead upto 1000m to the area
earmarked or as directed. Disposed material shall be leveled wherever dumped in approved
location.
i) The cut formations shall be properly prepared to receive the upper layer as per the
requirement or as per the methodology submitted for the respective layer.
5. Safety :
a) Suitable barricades shall be erected on the sides / edges of excavation to prevent vehicles
from falling on the stretch.
b) Suitable warning signs shall be erected & traffic shall be warned before entering into such
sections.
c) Flagmen shall be stationed on either ends of the section to guide the traffic.
d) Precautionary retro-reflective signs shall be erected & safety cones / bamboos shall be placed
in areas where this activity is being carried out

c) Existing soil classification.
d) Levels before excavation & after Excavation.
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METHODOLOGY FOR EMBANKMENT
1. Scope:
This item of work deals with construction of road embankment with approved materials as per
the terms of contract agreement. This item of work shall be dealt in compliance with section 305
of MORT&H Specifications.
Prior to the commencement of this work, the materials proposed to be used for embankment
shall be sourced suitably. Different sources shall be earmarked for different stretches giving due
regard to the leads and most importantly the suitability and quantum of material availability.
The material used in embankment shall generally be soil, moorum, gravel, mixture of these or
any other approved material. The material shall be ensured to be free of logs, stumps, roots,
rubbish, any ingredients likely to deteriorate or affect the stability of the embankment. The
material resulting from the roadway excavation, if found suitable, shall also be used.
a) Hydraulic Excavator.
b) Motor Grader / Dozer.
c) Tippers.
d) Water Sprinkler.
e) Vibratory Soil Compactor.
3. Material :
a) All materials used shall be soil, moorum, gravel, or any other material approved by the
Engineer. Suitable excavated material approved by the Engineer shall also be used.
b) Where the materials are used from borrow areas they shall be tested and approval received
from the Engineer prior to use. Borrow areas shall be exploited in compliance with EMP
regulations and all necessary measures shall be taken.
4. Procedure:
a) The toe line and center line shall be marked and pegs shall be driven.
b) After OGL compaction is approved, the fill material shall be dumped at site at respective
location.
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c) The material shall be spread in layers of uniform thickness not exceeding 200 mm compacted
thicknesses over the entire width of the embankment by mechanical means and shall be
graded with grader/dozer to the required camber.
d) The moisture content of each layer shall be checked and it should be within the range of OMC
+1% to OMC -2%. If moisture content found out these limits the same shall be brought within
limits by addition of water or by aeration as the case may be.
e) The compaction shall be done with the help of vibratory roller of 80 to 100 KN static weight.
Each layer shall be thoroughly compacted to the density specified in the specifications.
f) On compaction of the particular stretch necessary field-testing shall be carried out.
g) If the required field density is not achieved, compaction shall be continued till required
density is achieved.
h) Loose pockets if any shall be removed and replaced with approved material.
i) The above stages shall be repeated till the top level of the embankment is reached to the
specified levels and grades.
j) The top levels shall be checked and shall be within +20 mm and -25 mm of designed level.
k) All relevant QA and QC documents shall be maintained for all stages of Embankment
Construction.
l) Where the ground supporting embankment is found to be unsuitable (material mentioned in
clause 305.2.1.2) or the original ground material is having free swell index greater than 50%
the same shall be removed up to desired depth and shall be replaced with approved material
as per clause 305.3.4
5. Safety:
a) Suitable barricades shall be erected on the sides / edges of embankment to prevent vehicles
from falling on the stretch in case of widening.
sections.
in areas where this activity is being carried out.

a) Field density tests as stated in Table 900-3, Clause 900.
b) Level for top layer.
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METHODOLOGY FOR SUBGRADE
1. Scope:
This item of work deals with construction of sub-grade with approved materials as per the terms
of contract agreement. This item of work shall be dealt in compliance with section 305 of
MORT&H Specifications. The construction shall confirm to the specific alignment, lines and grades
given in the drawing.
Prior to the commencement of this work, the materials proposed to be used for such subgrade
shall be sourced suitably. Different sources shall be earmarked for different stretches giving due
regard to the haulage leads and most importantly the suitability and quantum of material
availability.
The material used in subgrade shall generally be soil, moorum, gravel, a mixture of these or any
other approved material. It shall be ensured that the material is free of logs, stumps, roots,
rubbish, any ingredients likely to deteriorate or affect the stability of the subgrade. The material
resulting from the roadway excavation, if found suitable, shall also be used. Material which is
having minimum CBR 8% shall be used in sub-grade.
a) Hydraulic Excavator.
b) Motor Grader.
c) Tippers.
d) Water tanker with Sprinkler.
e) Vibratory Soil Compactor.
3. Material:
a) All materials used shall be soil, moorum, gravel, or any other material approved by the
Engineer. Suitable excavated material approved by the Engineer shall also be used.
b) Where the materials are used from borrow areas they shall be tested and approval received
from the Engineer prior to use. Borrow areas shall be exploited in compliance with EMP
regulations and all necessary measures shall be taken.
4. Procedure:
a) The toe line and centre line shall be marked and pegs shall be driven.
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b) On completion of embankment fill & approval of testing, the material shall be dumped at
site at respective location.
c) The material shall be spread in layers of uniform thickness not exceeding 200 mm
compacted thicknesses over the entire width of the subgrade by mechanical means and shall
be graded with grader to the required camber.
d) The moisture content of each layer shall be checked and it should be with in the range of
OMC +1% to OMC -2%. If moisture content is found out of these limits the same shall be
brought within limits by addition of water or by aeration as the case may be.
e) The compaction shall be done with the help of vibratory roller of 80 to 100 KN static weight.
f) On compaction of the particular stretch necessary field-testing shall be carried out.
g) If the required field density is not achieved, compaction shall be continued till required
h) Loose pockets if any shall be removed and replaced with approved material.
i) The above stages shall be repeated till the top level of the subgrade is reached to the
specified levels and grades. The top levels shall be checked and shall be within ±20 mm of
designed level.
j) All relevant QA and QC documents shall be maintained for all stages of sub-grade
Construction.
k) In case the original ground is in sub-grade level or is in cutting and if the density after
compaction is not 97% minimum, the ground shall be loosened up to a depth of 150 mm and
shall be compacted in accordance with 305.3.5 and 305.3.6 of MORT&H specifications.
5. Safety:
a) Suitable barricades shall be erected on the sides / edges of subgrade to prevent vehicles from
falling on the stretch in case of widening.
sections.

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METHODOLOGY FOR GRANULAR SUB BASE
1 Scope:
This Method Statement outlines the procedure for production and laying of Granular Sub Base
(GSB) in accordance to clause 401 of the MORT&H Technical specification. The construction shall
confirm to the specific alignment, lines and grades given in the drawing.
Prior to the start execution of this work, the materials proposed to be used for shall be sourced
suitably and checked for its suitability and conformity to the Specifications. The Material to be
used for the work shall be natural sand, moorum, gravel, crushed stone, or combination thereof
depending upon the grading required.
2 Equipment / Machinery :
a) GSB Crusher / Screening Plant / Pug mill as the case may be.
b) Loader.
c) Tippers.
d) Motor Grader.
e) Water tanker with Sprinkler.
f) Vibratory Compactor.
3 Material:
The material used shall be moorum, gravel, crushed stone or a combination these. The materials
shall be free from organic matters/deleterious materials and confirm to any one of the grading
given in Table 400–1 of the MORT&H Specification.
4 Procedure:
a) G.S.B. shall be laid in areas where sub grade has been approved. A trial section shall be
prepared under the full supervision of Engineer and tested before commencing the operation
on full scale.
b) The toe line and center line are shall be marked and pegs shall be driven.
c) The material gradation shall be checked for confirming to the specified limits.
d) The material shall be dumped in site at respective location.
e) The material shall be spread in layers of uniform thickness not exceeding 200 mm compacted
thicknesses as per drawings over the width of the subgrade by mechanical means and shall be
graded with grader to the required camber.
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f) The moisture content of each layer shall be checked and it should be with in the range of
OMC-1% to -2%. If the moisture content is found out of these limits, the same shall be brought
within limits by addition of water or by aeration as the case may be.
g) The compaction shall be done with the help of vibratory roller of 80 to 100 KN static weight.
h) In portions having unidirectional cross fall, rolling shall commence from the lower edge and
progress gradually toward the upper edge. Thereafter roller should progress parallel
centerline of road uniformly overlapping each preceding track by at least one third width until
the entire surface is rolled. The number of passes shall be as established during the trial
stretch.
i) On compaction of the particular stretch, necessary field-testing shall be carried out to check
Field density.
j) If the required field density is not achieved, compaction shall be continued till required
k) Loose pockets if any shall be removed and replaced with approved GSB material.
l) The top levels shall be checked and shall be within ±10 mm of designed level.
m) All relevant QA and QC documents shall be maintained for all stages of Granular sub base
Construction.
5 Safety:
a) Suitable barricades shall be erected on the sides / edges of GSB to prevent vehicles from
sections.
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6 Records and Documents to be maintained:
c) Gradation report.
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METHODOLOGY FOR WET MIX MACADAM
1. Scope:
This Method Statement outlines the procedure for production and laying of Wet Mix Macadam in
accordance to clause 406 of the MORT&H Specification. The construction shall confirm to the
specific alignment, lines and grades given in the drawing.
a) WMM Plant (Pug Mill).
b) Loader.
c) Tippers.
d) Motor Grader / Paver Finisher.
e) Vibratory Compactor.
3. Material:
The material shall be an approved combination of crushed stone or crushed gravel aggregate
premixed with water as stipulated in the clause 406 of MORT&H Specification. In addition, the
physical properties of the crushed aggregates shall comply with clause 406.2.1.1 of the Special
Specification.
4. Procedure:
4.1 Preparation of Mix:
a) The individual materials and combined gradation shall be checked and proportions shall be
fixed. The combined gradation confirming to table 400-13 shall be arrived.
b) The job mix formula shall be established at project laboratory by trial & error method. The
trial mix shall be approved by Client.
c) The individual bins of wet mix plant shall be calibrated for the particular size of material.
d) Material shall be fed to the mixing plant bins provided for individual sizes of aggregates to
meet the required gradation.
e) Mixing plant shall be of suitable capacity having provision for controlled addition of water.
f) While adding water, loss due to evaporation shall be taken into account.
4.2 Preparation of Base:
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a) The sub base shall be checked for proper lines and levels. It shall be made free from dust.
Before start of laying, it should be made slightly wet and rolled with one pass of roller if
required.
b) The lateral confinement for wet mix shall be provided by placing material in the adjoining
shoulder portion.
4.3 Laying of Wet Mix Macadam:

a) WMM shall be laid on sections where GSB has been approved by the Engineer. A trial section
shall be prepared under the full supervision of Engineer and tested before commencing the
operation on full scale.
b) The wet mix shall be transported from the mixing plant to the site with tippers.
c) The mix material shall be laid with Grader / Paver. The mix shall be laid manually in places
where the grader / paver movement is not possible. High or low spots shall be rectified by
adding or removal of materials as the case may be. The material shall be uniform and free of
pockets of fine material.
d) The compaction of wet mix shall be done as per clause 406.3.5. The rolling shall be done with
80-100 KN vibratory roller.
e) In portions having unidirectional cross fall, rolling shall commence from the lower edge and
progress gradually toward the upper edge. Thereafter roller should progress parallel
centerline of road uniformly overlapping each preceding track by at least one third width until
the entire surface is rolled. The number of passes shall be as established during the trial
stretch.
f) Care shall be taken at every stage so that there shall not be any segregation.
g) The finished layer shall be checked for compaction in accordance to the specifications given
below. The top shall be checked for level control and shall be within +10 mm and -20 mm of
designed level.
h) All relevant QA and QC documents shall be maintained for all stages of Wet Mix Macadam
Construction.
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5. Safety:
a) Suitable barricades shall be erected on the sides / edges of WMM to prevent vehicles from
falling on the stretch in case of widening and entering in to the finished WMM surface.
sections.

c) Gradation report.
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METHODOLOGY FOR PRIME COAT
1. Scope:
The work consists of application of single coat of low viscosity liquid bituminous material to a
granular surface such as Wet Mix Macadam in accordance to clause 502 of the MoRT&H
Specifications.
a) Mechanical Brooms / Power Brooms.
b) Hand Brooms.
c) Air compressor.
d) Bitumen Distributor (Sprayer).
3. Material:
a) The bituminous primer shall be selected according to the porosity characteristics of the
surface to be primed, as classified in IRC: 16. The material to be used for prime coat (as
mentioned in the Technical specifications clause 502) shall be bituminous emulsion complying
with IS 8887 and CSS – I grade confirming to ASTM D 2397/AASHTO M 140 and shall be refinery
produced.
b) The quality of material to be used for priming shall be tested for the physical properties as
per IS 73, IS 217 and IS 8887 as mentioned in table 900.4. The material shall be used at site
after obtaining necessary approval from the engineer.
4. Procedure:
a. The surface to be primed shall be checked for levels and compaction.
b. The surface shall be cleaned by a mechanical broom to remove the dust and other loose
particles over the surface. Hand brooms shall also be used as supplements wherever
necessary. After brooming the surface shall be cleaned with compressed air.
c. Care shall be taken that the compacted granular surface shall not be disturbed.
d. Prime coat shall be applied when the surface is slightly moist, but no free or standing water
shall be present.
e. The viscosity of primer shall be in accordance to the table 500.1 of MORT&H and the rate of
application shall accordance to table 500.3 of MORT&H.
f. The speed of sprayer shall be calibrated at trial stretch to establish the rate of application.
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g. Prime coat material shall be sprayed at a uniform rate by a bitumen distributor. Hand
spraying shall be done in areas inaccessible to the distributor.
h. Frequent tests shall be carried at site to ensure the rate of application of the primer, as
instructed by the Engineer. The frequency of tests shall be carried out as per table 900.4 of
MORT&H.
i. Primed surface shall be allowed to cure for at least 24 hours.
5. Safety:
a) Suitable barricades shall be erected on the sides / edges to prevent vehicles movement on the
primed surface.
sections.
e) Sign board stating “No Smoking” shall be kept at bitumen, emulsion & kerosene storage area
to forewarn all staff & workers.
f) Sand buckets and Fire extingusior shall be kept in strategic location at storage area.

a) Viscosity Test.
b) Rate of Spray.
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METHODOLOGY FOR PREPARATION AND APPLICATION OF TACK COAT
1. Scope:
The work consists of application of single coat of low viscosity bituminous emulsion to an existing
bituminous surface ready to be superimposed by another layer of bituminous mix in accordance
to clause 503 of the MORT&H Specifications.
a) Mechanical Brooms / Power Brooms.
b) Hand Brooms.
c) Air compressor.
d) Bitumen Distributor (Sprayer).
3. Material:
The tack coat shall be bitumen emulsion in accordance to clause 503.2 of the MORTH
Specification. Bitumen emulsion in bulk shall be procured and stored in a suitable place at site.
Emulsion shall be transferred to the bitumen spray tank at atmospheric temperature as per
manufacturer’s recommendation.
4. Procedure:
a) The surface on which the tack coat is to be applied shall be cleaned of dust and any
extraneous material prior to the application using power broom, blowers or manually in
accordance to clause 503.4.2 of the MORTH Specifications.
b) The asphalt distributor shall be calibrated to achieve the required spread rate before the
work is started. The spread rate shall be tested using tray method.
c) Emulsion shall be sprayed uniformly with atmospheric temperature using bitumen sprayer at
the rate as specified in Table no 500-5 of MORTH Specifications.
d) As per manufacturer’s recommendation, the bitumen emulsion shall also be used on the wet
bituminous course during rainy season. However, the same shall not be used in the case of
continuous rain.
e) The following shall be strictly adopted as per the Manufacturer’s instructions:
i. Emulsion shall not be stored in open tank or container.
ii. Care shall be taken that it is not heated above 70°C.
iii. Different type of bitumen emulsions shall not be mixed together.
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iv. Spray tank shall be moved forward and backward for proper mixing of emulsion prior to
application.
f) The spray rate of a sprayer shall be controlled by conducting “tray test” duly witnessed by
Engineer’s field staff.
g) Regular quality control tests of the raw materials and blended material shall be carried out by
our Material Section in accordance to the MORT&H specification section 502,503 and Section
900.
5. Safety:
a) Suitable barricades shall be erected on the sides / edges to prevent vehicles movement on
the tacked surface.
sections.
e) Sign board stating “No Smoking” shall be kept at bitumen, emulsion & kerosene storage area
to forewarn all staff & workers.
f) Sand buckets and Fire extingusior shall be kept in strategic location at storage area.

a) Viscosity Test.
b) Rate of Spray.
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METHODOLOGY FOR BITUMINOUS MACADAM
1. Scope:
This item of work deals with construction of Bituminous Macadam with approved materials as per
the clause 504 of MORT&H Specifications. The construction shall confirm to the specific
alignment, lines and grades given in the drawing.
a) Hot Mix Plant.
b) Loader.
c) Tippers.
d) Paver Finisher (Sensor / Mechanical).
e) Tandem Rollers.
f) Air compressor.
g) Water tanker.
h) Tower Light.
i) Survey Equipment with accessories.
3. Material:
The material used to blend and produce a homogeneous mix of BM shall be in accordance to
clause 504.2 of the MORT&H Specification.
3.1 Bitumen -The bitumen shall be as stated in Table 500-1 and Clause 504.2.1 of the MORT&H
Specification.
3.2 Coarse Aggregates -The coarse aggregate shall be crushed stone or crushed gravel and
comply to physical requirements set forth in Table 500-6 and clause 504.2.2 of the MORT&H
Specification.
3.3 Fine Aggregates -Shall be crushed or natural material with fraction passing 2.36 mm and
retained on 75 micron sieve as stated in Clause 504.2.3 of the MORT&H .
3.4 Aggregate gradation -The combined coarse and fine aggregates shall produce a mixture to
conform to the grading set forth in Table 500-7 of MORT&H Specification.
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4. Procedure:
4.1 Mix Design
The mix design shall be carried out according to the Asphalt Institute Manual MS-2. The optimum
bitumen content and job mix formula shall be arrived. The physical requirements of the
aggregate shall confirm to table 500-6 and job mix shall confirm to the required grading-I/II of
table 500-7 of MORT&H Specifications.
4.2 Preparation and Transportation of Mix:

The individual bins of hot mix plant shall be calibrated for the particular size of material.
Material shall be fed to the mixing plant bins provided for individual sizes of aggregates to meet
the required mix gradation. The temperature of binder at the time of mixing shall be in the
range of 150°C-165°C and the aggregate in the range 150°C to 170°C. The difference between
binder and the aggregate temperature shall not exceed 14°C at any time. The mix shall be
transported to the site with tippers properly covered with tarpaulins.

The sub base shall be checked for proper lines and levels. The surface shall be kept free from
dust with proper equipment. The tack coat shall be laid if the WMM surface was primed and left
for quite some time.
4.4 Laying of Bituminous Macadam:

a) The mix shall be laid with paver finisher. The paver shall have suitable loading hoppers and
distribution mechanism. The paver shall have electronic sensors and string wire shall be run
on steel pegs driven on both sides at 10 m interval in straight portions and 5 m intervals in
curve portions. Mechanical Paver can also be used in special cases like narrow width and
profile corrective course. The mix shall be laid manually in places where the paver movement
is not possible.
b) The compaction of BM shall be done as per clause 501.6 and 501.7. The rolling shall be done
with 80-100 KN smooth wheeled tandem roller. The rolling pattern shall be established in the
trial stretch.
c) The BM shall be laid in one layer / layers not exceeding 100mm compacted thickness.
d) The finished layer shall be checked for compaction. The compaction shall be checked by
taking cores for every 700 sqm area and the %age compaction shall not be less than 98% of lab
Marshall density.
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e) The top shall be checked for level control and the levels shall be within + 6 mm of designed
level.
f) All relevant QA and QC documents shall be maintained for all stages of BM Construction.
5. Safety:
a) Suitable barricades shall be erected on the sides / edges of BM to prevent vehicles falling on
the stretch in case of widening.
sections.
e) Sign board stating “No Smoking” shall be kept at bitumen storage area to forewarn all staff &
workers.
f) Sand buckets and Fire extinguisher shall be kept in strategic location at storage area and hot
mix plant area.

a) Core density.
b) Bitumen content.
c) Top level of finished surface.
d) Gradation.
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METHODOLOGY FOR DENSE BITUMINOUS MACADAM
7. Scope:
This item of work deals with construction of Dense Bituminous Macadam with approved materials
as per the clause 505 of MORT&H Specifications. The construction shall confirm to the specific
a) Hot Mix Plant.
b) Loader.
c) Tippers.
d) Sensor Paver Finisher.
e) Tandem Rollers.
f) Air compressor.
g) Water tanker.
h) Tower Light.
i) Survey Equipment with accessories.
9. Material:
The material used to blend and produce a homogeneous mix of DBM shall be in accordance to
3.1 Bitumen -The bitumen shall be as stated in Table 500-1 and Clause 507.2.1 of the MORT&H
Specification.
3.2 Coarse Aggregates -The coarse aggregate shall be crushed stone or crushed gravel and
comply to physical requirements set forth in Table 500-8 and clause 507.2.2 of MORT&H
Specification.
retained on 75 micron sieve as stated in Clause 507.2.3 of the MORT&H Specification.
3.4 Aggregate gradation -The combined coarse and fine aggregates shall produce a mixture to
conform to the grading set forth in Table 500-10 of MORT&H Specification.
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10. Procedure:
4.1 Mix Design
bitumen content and job mix formula shall be arrived. The physical requirements of the
aggregate shall confirm to table 500-8 and job mix shall confirm to the required grading-I/II of
table 500-10 of MORT&H specifications. The mix properties shall confirm to table 500-11 of
MORT&H Specifications. The permissible variations from the job mix formula shall be according
to table 500-13.

the required mix gradation. The temperature of binder at the time of mixing shall be in the
range of 150°C-165°C and the aggregate in the range 150°C to 170°C. The difference between
binder and the aggregate temperature shall not exceed 14°C at any time. The mix shall be
transported to the site with tippers properly covered with tarpaulins.

The sub base shall be checked for proper lines and levels. The surface shall be kept free from
dust with proper equipment. The tack coat shall be laid if the WMM surface was primed and left
for quite some time.
4.4 Laying of Dense Bituminous Macadam:

g) The mix shall be laid with sensor paver finisher. The paver shall have suitable loading hoppers
and distribution mechanism. The paver shall have electronic sensors and string wire shall be
run on steel pegs driven on both sides at 10 m interval in straight portions and 5 m intervals in
curve portions. The mix shall be laid manually in places where the paver movement is not
possible.
h) The compaction of DBM shall be done as per clause 501.6 and 501.7. The rolling shall be done
with 80-100 KN smooth wheeled tandem roller. The rolling pattern shall be established in the
trial stretch.
i) The DBM shall be laid in one layer / layers not exceeding 100mm compacted thickness.
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j) The finished layer shall be checked for compaction. The compaction shall be checked by
taking cores for every 700 sqm area and the %age compaction shall not be less than 98% of lab
Marshall Density.
k) The top shall be checked for level control and the levels shall be within + 6 mm of designed
level.
l) All relevant QA and QC documents shall be maintained for all stages of DBM Construction.
11. Safety:
g) Suitable barricades shall be erected on the sides / edges of DBM to prevent vehicles falling on
h) Suitable warning signs shall be erected & traffic shall be warned before entering into such
sections.
i) Flagmen shall be stationed on either ends of the section to guide the traffic.
j) Precautionary retro-reflective signs shall be erected & safety cones / bamboos shall be placed
k) Sign board stating “No Smoking” shall be kept at bitumen storage area to forewarn all staff &
workers.
l) Sand buckets and Fire extinguisher shall be kept in strategic location at storage area and hot
mix plant area.

a) Core density.
b) Bitumen content.
d) Surface regularity.
e) Gradation.
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METHODOLOGY FOR BITUMINOUS CONCRETE
1. Scope:
This item of work deals with construction of bituminous concrete with approved materials as per
the clause 507 of MORT&H Specifications. The construction shall confirm to the specific
a) Hot Mix Plant.
b) Loader.
c) Tippers.
d) Sensor Paver Finisher.
e) Tandem Rollers.
f) PTR.
g) Air compressor.
h) Water tanker.
i) Tower Light.
j) Survey Equipment with accessories.
3. Materials:
The material used to blend and produce a homogeneous mix of BC shall be in accordance to
3.1 Bitumen - The bitumen shall be as stated in Table 500-1 and Clause 509.2.1 of the MORT&H
Specification.
3.2 Coarse Aggregates - The coarse aggregate shall be crushed stones or crushed gravel and
comply with physical requirements set forth in Table 500-16 and clause 507.2.2 of the MORT&H
Specification.
retained on 75-micron sieve as stated in Clause 507.2.3 of the MORT&H Specification.
3.4 Filler - shall be finely divided mineral matter in compliance with the requirements of Clause
505.2.4 & Table 500-9 of MORT&H Specification.
3.5 Aggregate gradation -The combined, coarse, fine aggregates and filler shall produce a
mixture to conform to the Table 500-17 and bitumen content as per Table 500-17 and clause
507.3.2 of MORT&H Specification.
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4. Procedure:
4.1 Mix Design
bitumen content and job mix formula are arrived. The physical requirements of the aggregate
shall confirm to table 500-16 and job mix shall confirm to Clause 505.3.3 of MORT&H
Specifications. The mix properties shall confirm to table 500-11 of MORT&H Specifications. The
permissible variations from the job mix formula shall be according to table 500-18.

the required gradation. The temperature of binder at the time of mixing shall be in the range of
150°C-165°C and the aggregate in the range 150°C to 170°C. The difference between binder and
the aggregate temperature shall not exceed 14°C any time. The mix shall be transported to the
site with tippers properly covered with tarpaulins.

The base shall be checked for proper lines and levels. The surface shall be kept free from dust
with air compressor. The tack coat shall be laid before laying Bituminous Concrete layer.
4.4 Laying of Bituminous Concrete:

a) The mix shall be laid with paver finisher. The paver shall have suitable loading hoppers and
distribution mechanism. The paver shall have electronic sensors and string wire shall be run
on steel pegs driven on both sides at 10 m interval in straight portions and 5 m interval in
curved portions. The mix shall be laid manually in places where the paver movement is not
possible.
b) The compaction of BC shall be done as per clause 501.6 and 501.7. The rolling shall be done
with 80-100 KN smooth wheeled tandem roller and 12-15 tonnes pneumatic tyred roller. The
rolling pattern shall be established in the trial stretch.
c) The finished layer shall be checked for compaction. The compaction shall be checked by
taking cores for every 700 sqm. area and the % age compaction shall not be less than 98% of
lab Marshall Density.
d) The top shall be checked for level control and the levels shall be within ± 6 mm of designed
level.
e) All relevant QA and QC documents shall be maintained for all stages of BC Construction.
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5. Safety:
a) Suitable barricades shall be erected on the sides / edges of BC to prevent vehicles falling on
sections.
e) Sign board stating “No Smoking” shall be kept at bitumen storage area to forewarn all staff &
workers.
f) Sand buckets and Fire extinguisher shall be kept in strategic location at storage area and hot
mix plant area.

a) Core density.
b) Bitumen content.
d) Surface regularity.
e) Gradation.
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METHDOLOGY FOR FORM WORK/ REINFORCEMENT/ CONCRETE
1. Scope:
This item of work deals with construction of formwork, reinforcement and placement of
concrete for all structures with approved materials as per contract conditions and Sections 1500,
1600 and 1700 of MORT&H Specifications. The materials shall confirm to section 1000 of MORT&H
Specifications.
1.1 Form work:

This work shall consists of furnishing and fixing of form work (shuttering) of approved quality for
cast-in-situ / precast/ prestressed plain or reinforced concrete with necessary props, staging,
centering, scaffolding and any temporary construction required for their support and ensure no
grout leakage and as per line/ level of drawings.
1.2 Reinforcement:
This work shall consist of furnishing and placing of high yield strength deformed bars of the
shape and dimensions as shown in approved drawings. Each lot shall be tested as stipulated in
MORT&H/ IS: 1786.
1.3 Concrete:
This work shall consist of furnishing and placing of plain or reinforced concrete of all grades with
40 mm downgraded aggregates as defined in Technical Specifications, machine mixed and
mechanically vibrated to the required level, slope, etc. as per approved drawings and approved
design mix.
2. Major Equipments and Machinery

1. Measuring tape
2. Concrete Batching plant
3. Concrete pump/ Boom Placer / Crane & Bucket as required
4. Transit Mixers as required
5. Needle Vibrators
6. Cube Moulds
7. Plumb bob.
8. Bar bending machine.
9. Slum Cone
10. Lighting when required
11. Dewatering pump when required.
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12. Water Tanker
13. Tipper
3. Materials:
The source of materials (for cement, coarse aggregates, fine aggregates, water, admixture,
reinforcement steel, expansion joints, bearings and compressible fiber board etc.) shall be
identified and the sources shall be approved by the Engineer.
3.1 Cement:
The cement to be used in the works shall be Ordinary Portland Cement of 43 / 53 grade
confirming to IS 8112,IS 12269. PPC confirming to IS 1489, PSC confirming to IS 455. The
manufacturer’s test certificate shall be furnished, and cement shall be stored as per IS 4082. All
the lots received shall be tested in site laboratory and independent laboratory as and when
required.
3.2 Water:
The water to be used shall be free from oils, acids, alkalis, salts, sugar, organic materials or
other substances that may be deleterious to concrete and steel. Potable water generally
considered satisfactory. The water to be used shall satisfy the requirements as per clause 1010
of MORT&H Specifications.
3.3 Coarse Aggregate:

Coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable pieces of
crushed stone. All coarse aggregates shall confirm to clause 1007 of MORT&H Specifications and
IS 383, when tested in accordance to IS 2386 parts 1 to 8.
3.4 Fine Aggregate:

Fine aggregate shall consist of clean, hard, strong, dense and durable pieces of crushed stone or
natural sand or a combination of both. All fine aggregates shall confirm to IS 383, when tested in
accordance to IS 2386 parts 1 to 8. The fineness modulus of fine aggregate shall not be less than
2.0 nor greater than 3.5. The grading shall confirm to table 1000-2 of MORT&H specification.
3.5 Admixtures:
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Admixtures shall confirm to the requirements of IS 9103. The manufacturer test certificate shall
be furnished for each consignment.
3.6 Reinforcement:
For plain or reinforced cement concrete or pre-stressed concrete the reinforcement shall be of
grade Fe-500 confirming to IS 1786 – HYSD bars. The steel supplied with test certificate shall be
assembled in accordance with approved drawings and shall ensure storing to avoid deterioration
and corrosion. Each lots shall be tested as stipulated in MORT&H / IS:1786. All steel shall be
procured from original source.
4. Procedure:
3.1 Formwork:
a) The formwork shall provide a smooth finish of uniform texture and appearance. This material
shall leave no stains on the concrete and so fixed to its backing as not to impart any
blemishes.
b) Necessary care shall be taken to see that the formwork is true to line, levels, plumb, etc.,
rigid, adequately braced both horizontally and vertically. Form joints shall be as much as
minimized, tight and not permit any leakage of slurry from concrete. All vertical and
horizontal joints shall be tightened with 6mm thick foam when ever required.
c) Required formwork shall be made out of plywood (Marine Ply, 12x7mm) / steel shutters to
suit the site conditions. Formwork materials shall be rigid, even surface, and sufficiently
strong to prevent deformation during concrete.
d) Releasing agents shall be applied before fixing formwork, and shall not be allowed to come in
contact with any reinforcement or prestressing tendons and anchorages.
e) The formwork shall be cleaned carefully; dried and releasing agents shall be applied before
reuse.
f) The formwork shall be so removed as not to cause any damage to the concrete. Centering
shall be gradually and uniformly lowered so as to enable the concrete to take stresses due to
its own weight uniformly and gradually to avoid any shock or vibration.
g) Before reuse all components of formwork shall be examined for damage and damaged pieces
shall be rectified. Before reuse all components shall be cleaned of deposits of soils, concrete
or other unwanted materials. Threaded parts shall be oiled after cleaning.
h) Formwork shall be checked and if shows excessive wraping, re-use shall not be allowed.
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3.2 Reinforcement Steel:
a) Bar bending schedule shall be strictly as per approved drawings and reinforcement steel shall
be cut and bend as per approved bar bending schedule. Bars shall be bent cold to the
specified shape and dimensions, using a proper bar bender, operated by hand or power to
obtain correct radii of bends and shape.
b) Reinforcement bars shall be placed accurately in position as shown in the drawings. The bars,
crossing one another shall be tied together at every intersection with binding wire (dia. of
binding wire shall not be less than 1 mm), to make the skeleton of reinforcement rigid such
that it does not get displaced during placing of concrete or any other operation.
c) Spacer bars at suitable intervals shall separate layers of reinforcement. The minimum dia. of
spacer bar shall be 12 mm to a maximum of main reinforcement or maximum size of
aggregate. Cover blocks of thickness equal to the specified cover shall be placed between
formwork and bars made of concrete/ cement mortar of specified grade of concrete/ strength
as those of the member.
d) Necessary stays, blocks, chairs, spacers, hangers etc. or other subsidiary reinforcement shall
be provided as approved by the Engineer, to fix the reinforcement firmly in its correct
position. Laps shall be staggered.
3.3 Concrete:
The grades of concrete shall be as specified in the drawings/ contract. Necessary mix designs
shall be carried out well in advance and got approved by the Engineer as per clause 1700 of
MORT&H specifications.
4.3.1 Mixing:
a) The mixing of concrete shall be done in automatic batch type concrete mixer or by concrete
batching and mixing plant. All measuring devices shall be maintained in a clean and
serviceable condition. Its accuracy shall be checked periodically. Batching plant shall be
calibrated prior to production of concrete.
b) Mixing of concrete shall be continued till the individual particles of coarse aggregate shows
complete coating of mortar containing its proportionate amount of cement. In no case the
mixing done for less than 2 minutes. Corrections in water and aggregate with respect to
moisture present in the aggregates shall be done on day-to-day basis.
4.3.2 Transportation and placing:

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a) Concrete shall be transported and placed as near as practicable to its final position, so that
no contamination, segregation or loss of its constituent materials takes place. Concrete from
batching plants shall be transported by transit mixers. Concrete shall not free fall in to place
from a height exceed 1.5 meter.
b) Concrete shall be placed in horizontal layers to a compacted layer not exceeding 450 mm.
Fresh concrete shall not be placed against concrete, which has been in position for more than
30 minutes unless proper construction joint is formed. Concrete when deposited shall have a
temperature not less than 50C and not more than 400C.
c) All formwork and reinforcement contained in it shall be cleaned and made free from standing
water, dust, etc. immediately before placing concrete.
d) Concrete shall contain 10% more cement required for the same mix placed in dry in the case
of concreting under water.
4.3.3 Compaction:
a) The concrete shall be compacted within 30 minutes of its discharge from the mixer, unless
carried by properly designed agitators, operating continuously. When trials show that the
periods stated above are unacceptable, it is necessary to add retarding/ plasticizing
admixtures. This shall be controlled by taking slump at batching plant and site.
b) Concrete shall be thoroughly compacted with vibrators or other means during placing and
worked around reinforcement, tendons, and embedded figures and into corners of formwork
to produce a dense homogeneous void-free mass having a required surface finish.
c) When vibrators are used, vibration shall be done continuously during the placing of each
batch of concrete until expulsion of air has practically ceased and in a manner does not
promote segregation. Where immersion vibrators are used contact with reinforcement and all
inserts shall be avoided. Standby vibrators in serviceable conditions shall be kept at site so
that they can be used in the event of breakdowns.
4.3.4 Construction joints:

a) Construction joints shall be avoided as far as possible, when unavoidable shall be provided in
a direction perpendicular to the axis of the member. The old surface shall be thoroughly
cleaned and soaked with water. Standing water shall be removed and surface shall be wetted
with neat cement slurry shortly before placing of fresh concrete and shall be thoroughly
compacted. Concreting shall be carried out continuously up to the construction joints.
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b) For a vertical construction joint, a supporting board shall be fixed previously at
predetermined position and shall be properly stayed to prevent displacement or bulging when
concrete is compacted against it. Concreting shall be continued right up to the board.
4.3.5 Curing:
a) Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by
ponding or by covering with a layer of sacks, canvas, Hessian or by similar materials and shall
be kept constantly wet at least for a period of 14 days.
b) Curing compounds shall be permitted in special circumstances like PQC, etc. Curing
compounds shall be continuously agitated before use. All concrete cured by this method shall
receive two applications; the first coat immediately after acceptance of surface finish, and
the second coat shall be after first coat has set, on the saturated surface before the surface
water film disappears.
4.3.6 Finishing:
a) Immediately after removal of forms, exposed bars or bolts, if any, as far as possible shall
be removed, or if necessary, shall be cut inside the concrete member to a depth at least
50 mm below surface of concrete and the resulting hole shall be filled by fresh cement
mortar.
b) All fins caused by form joints, all cavities produced by removal of form ties all other holes
and depressions, honeycomb spots, broken edges or corners, and other defects, shall be
thoroughly cleaned, saturated with water, and carefully pointed and rendered true with
mortar of cement and fine aggregate mixed in the proportions used in the grade of
concrete.
c) A surface, which has been thus rendered, shall be kept moist for a period of 24 hours.
5. Quality control tests: (As per section 1700 of MORT&H)

a) Physical tests on cement at a frequency of 1 test per lot (manufacturing week) MTC
(manufacturer's test certificate) shall be maintained.
b) Tests on water shall be at a frequency of once per source.
c) Physical and chemical requirements of admixtures – MTC (manufacturer's test certificate)
shall be maintained.
d) Tests on reinforcement at a frequency of once per source per dia. - test certificate to be
maintained.
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e) Workability of concrete shall be checked by slump cone test at a frequency of once per
session at concrete batching plant as well as at placing area.
f) The natural origin materials of construction (Aggregate & Sand) and purchased material like
cement, admixture shall be tested by site laboratory as per routine frequencies as mentioned
in MORT&H.
g) The concrete shall be prepared by batching plant / mixer machine. In case the mixer machine
is used the required quantity of material as per the design mix shall be established by
calibrated weigh batcher on the site of mixing.
h) The weigh batcher shall be checked prior to concreting, to establish that it is in order and is
ready for concreting.
i) After completing of above said process the concrete shall be started. To establish the pour
height level pegs shall be driven.
j) During the concreting the samples of concrete shall be taken and cubes shall be cast. The
cubes shall be marked with date of pour, grade and identification of structure. The cast cubes
shall be cured in curing tank.
k) After demoulding the cubes shall be shifted to the main project lab for curing and testing of
cubes for strength.
6. Safety Measures
a) All personnel shall be provided with required PPE’s.
b) All personnel shall be provided with safety belt while working on height.
c) Proper ladder and platform shall be provided while working at height.
d) Flagmen shall be stationed on either ends of the approach road to guide the traffic during
movement of all required mechanical equipments.
e) Proper approach road / diversion road shall be provided.
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METHODOLOGY FOR OPEN FOUNDATIONS
1. Scope:
This item of work deals with open foundations with approved materials as per approved Drawings
and Sections 2100 of MORT&H Specifications. The materials used shall adhere to the section 1000
of technical specifications. The concrete used shall be of approved design mix.
2. Major Equipment and Machinery:

a) Excavator / Back Hoe.
b) Total Station/ Theodolite with accessories.
c) Auto level with accessories.
d) Measuring tape.
e) Concrete pump/ Boom placer / Crane & Bucket as required.
f) Transit Mixers as required.
g) Needle Vibrators.
h) Cube Moulds.
i) Dewatering pump
j) Tipper
k) Slump cone
l) Genset
3. Material:
As described in methodology for form work/ reinforcement/ concrete.
4. Procedure:
4.1 Survey:
a) The location points are to be fixed by Total station or a theodolite from the established
survey interfacing points.
b) The reference pillars shall be fixed in such a way that they are not disturbed during the
course of excavation and construction.
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4.2 Excavation:
a) Excavation shall be done to the size of the foundation plus safe working area including
necessary slopes as per site condition.
b) At locations where the surface is below sub soil water level requiring dewatering, the same
shall be done by installing adequate capacity pumps.
c) If hard rock is encountered while excavation, suitable procedures shall be adapted like
i. Pneumatic breaking using compressor and pavement breakers.
ii. Wedge and hammer method i.e. drilling and splitting of rock.
iii. Control blasting and de-mucking.
Any one of the procedures shall be adapted to suit the site conditions.
d) Excavation shall be carried out to the required depth as per the foundation details given in
the drawings and if there are any obstructions / hindrances are there in the course of the
work then they shall be immediately brought to the notice of the engineer for their necessary
instruction/ actions.
e) Surface dressing shall be done before doing the PCC.
4.3 Plain Cement Concrete (PCC):

PCC of required thickness and grade as per approved working drawings and mix design shall be
laid on the dressed surface.
4.4 Reinforcement & Form Work:

Reinforcement shall be tied over the PCC as per the drawings and proper formwork shall be fixed
to suit the requirement and as per drawings.
4.5 Concreting:
Concreting shall be done either by crane/ bucket or by a concrete pump or manually whichever
suits the situation and grade of concrete shall be maintained as per the drawings. The concrete
cubes shall be cast in site and they shall be checked at the intervals specified.
5. Safety Measures
b) Proper ladder shall be provided while working in deep excavation.
c) Suitable barricades shall be erected on the sides / edges of excavation to prevent vehicles
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d) Suitable warning signs shall be erected & traffic shall be warned before entering into such
sections.
e) Flagmen shall be stationed on either ends of the approach road to guide the traffic during
movement of transit mixer for concreting.
f) Precautionary retro-reflective signs shall be erected & safety cones / bamboos shall be
placed in areas where this activity is being carried out by obstructing existing traffic lane.
g) Proper approach road / diversion road shall be provided.
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METHODOLOGY FOR PILE FOUNDATIONS
1. Scope:
This method statement outlines the method proposed for the bored cast in pile accordance to
clause 1107 of the MORT&H Technical Specifications. This methodology shall have the following
main sequences of activities:-
a) Pile points marking
b) Rig placing and bore preparation
c) Reinforcement Cage lowering after bore flushing
d) Concreting
e) Pile head preparation
2. Details of Equipment / machinery:

The plant and machinery list involved in this activity is as follows:
a. Batching plant.
b. Transit mixers.
c. Piling rig.
d. Welding machine for rebar cage welding.
e. Bentonite pump.
f. Air Compressor.
g. Water pump.
h. Hydra Crane.
i. Power generator.
j. Cube Moulds.
k. Trimme pipe.
l. Slump cone.
m. Excavator.
n. Concrete pump / boom placer.
o. Water tank.
p.
3. Material:
As described in methodology for form work/ reinforcement/ concrete and bentonite.
4. Procedure:
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4.1 Piling points marking:
Piling points shall be fixed by driving survey pegs into the ground. The Lay out of the pile points
shall be checked before start of each pile.
4.2 Rig placing and bore preparation:

a) We shall following the DMC method or hydraulic rotating rig for boring to suit the site. The rig
consists of tripod and winch. Tripod has one main leg supported by side legs. Since the length
is more than 4m it is joined by splice plate & welded as per drawing. The tripod leg shall be
adjusted by the crane/ hydra to match the centerline to the pile point.
b) The bailer shall be lowered on the ground covered within sand layer from a height to get an
impression for verifying the survey points after the tripod final adjustment.
c) The pile point shall be controlled by three established control points which shall be
established at distance of 2 to 3 m from pile point. This pile point shall be checked with
respect to control points.
d) The winch shall be fixed to the ground by proper anchoring & counter weights.
e) The guide casing shall be driven keeping the top edge 15-20 cm above ground level while
driving the guide casing the verticality shall be stage wise checked, as this shall be the
template for the entire bore.
f) The Bentonite shall be mixed in tanks with partition so that the recirculation continues.
g) The top 4 -6m soil shall be extracted from bore by bailing system by bailer.
h) After bailing, chisel with DMC rods shall be introduced into the bore for further boring.
i) During the process of chiseling by DMC rods, the Bentonite solution shall be circulated from
Bentonite tank to the bore and same bentonite solution shall be coming out from the bore to
the sedimentation tanks which shall be interconnected with bentonite tanks.
j) During the boring, the specific gravity of Bentonite shall be controlled to the required
consistency.
k) The samples shall be collected from bailer at each metre depth & also at the end of the bore
termination for future record.
l) The fall of the hammer shall be controlled as per the requirement depending upon the chisel
dead weight.
m) All operation during boring of the pile shall be noted in the register.
4.3 Rebar gauge lowering:

a) The bore shall be terminated as per the levels indicated in the drawing with approval from the
Engineer.
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b) The bore just before the lowering of rebar cage shall be flushed out with bentonite water to
remove all loose materials from the bore.
c) The rebar cage shall be tied as per the approved drawing & bar bending schedule and it shall
be checked by the Engineer before lowering into the bore. The laps shall be welded and
adequate cover blocks shall be tied.
d) Lowering the rebar cage with the help of winch pulley/ crane without any damage.
4.4 Concreting:
a) Pile concrete shall be done using tremie pipes of diameter not less than 150mm. Pipes shall be
neat, clean and watertight. The tremie length is measured during fixing for calculating the
depth of tremie in concreting.
b) The bottom of the pipe shall be ensured to be 200mm above from the bottom of the bore for
first pour and always inside the concrete after first pour of concrete.
c) The first charge of concreting shall be done using a stopper at the bottom of the funnel. The
stopper shall be fixed such that it shall be removed with least resistance.
d) The tremie pipe shall be removed in stages and the set concrete should not be disturbed.
e) The method of concreting shall not be changed in the middle in any case.
f) All tremie pipe shall be scrupulously cleaned after use.
g) After the concrete initial setting is over, the guide casing shall be extracted without damaging
the concrete & reinforcement.
h) The top of concrete shall be brought above the cut off level to permit removal of laitance and
weak concrete before capping.
i) Concreting shall be done as per clause 1107.
4.5 Pile head preparation:

a) On the completion of the piles in a group, excavation shall be carried out for the pile cap as
per the dimensions mentioned in the drawing with necessary clearance.
b) PCC shall be laid as per the drawing as leveling course.
c) The excess hardened concrete in the pile stem above cut off level shall be chipped & broken
using hand chisel/jack hammer etc. Thereby the pile stem shall be keying into the pile cap
above the PCC level as per the drawing.
d) The projecting reinforcement bars shall be bent and accommodated into the pile cap.
5. Safety Measures
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b) Suitable barricades shall be erected on the sides of work area.
c) Flagmen shall be stationed on either ends of the approach road to guide the traffic during
d) Precautionary retro-reflective signs shall be erected & safety cones / bamboos shall be
e) Proper approach road / diversion road shall be provided.
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METHODOLOGY FOR SUB-STRUCTURE
1. Scope:
This item of work deals with construction of substructure with approved materials as per
approved Drawings and Sections 2200 of MORT&H Specifications. The construction shall confirm
to the specific alignment, lines and grades given in the drawing. The materials used shall adhere
to the section 1000 of technical specifications. The concrete used shall be of approved design
mix.
a) Auto level with accessories.
b) Measuring tape.
c) Concrete pump/ Boom placer / Crane & Bucket as required.
d) Transit Mixers.
e) Needle Vibrators.
f) Cube Moulds.
g) Plumb bob.
h) Lighting when required.
i) Slump cone.
3. Material:
As described in methodology for form work/ reinforcement/ concrete or as per drawing and
technical specifications.
4. Procedure:
Construction shall be carried out in lifts. The activities for each lift shall be as follows:
4.1 Reinforcement & Formwork:
Reinforcement shall be provided as per the drawings. The formwork used shall be robust strong
and shall be leak proof. Formwork and staging shall be in compliance with section 1500 of
technical specification.
4.2 Weep Holes:

The spacing of the weep holes shall be maintained as specified in the drawing.
4.3 Concreting:
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Concreting shall be done either by crane/bucket or by a concrete pump, boom placer or
manually whichever suits the situation and grade of concrete shall be maintained as per
drawings. The concrete cubes shall be cast in site and they shall be checked at the intervals
specified.
The above activities shall be repeated till the substructure reaches the level mentioned in the
drawings.
5. Safety Measures
d) Suitable barricades shall be erected on the sides / edges of excavation to prevent vehicles
e) Suitable warning signs shall be erected & traffic shall be warned before entering into such
sections.
f) Flagmen shall be stationed on either ends of the approach road to guide the traffic during
g) Precautionary retro-reflective signs shall be erected & safety cones / bamboos shall be
h) Proper approach road / diversion road shall be provided.
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METHODOLOGY FOR PIPE CULVERTS
1. Scope:
This work shall consist of installing pre cast spun concrete pipes, of the type, diameter and
length at the required locations shown in the construction drawings and Sections 2900 of MORT&H
Specifications. The construction shall confirm to the specific alignment, lines and grades given in
the drawing.
2. Major Equipment and Machinery :

1. Excavator / Back Hoe.
2. Auto level with accessories.
3. Measuring tape.
4. Batching Plant / Batch Mixer.
5. Transit Mixers.
6. Needle Vibrators.
7. Cube Moulds / Slump cone.
8. Mini compactors / plate compactor / vibratory compactor.
9. Hydra / Crane
3. Material:
As described in methodology for form work/ reinforcement/ concrete as per drawing and
technical specifications. All materials used in construction of pipe culvert shall confirm to the
requirements of section 1000 of MORTH specifications. All pipes shall be inspected, tested &
approved by Engineer prior to placing on site. Bedding material shall be well graded sand or other
granular material passing 22.4 mm sieve & retained on 5.6mm sieve & shall be suitably
compacted. The concrete used shall be of required grade as per drawing / technical specification
and shall be as per approved design mix.
4. Procedure:
a) Prior to start of the work TBM shall be established jointly with the Engineer’s
representative in a location, which shall not be disturbed during the course of work.
b) Setting out of the location of culvert shall be carried out jointly with consultant as per the
approved construction drawings.
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c) In the case of widening of culvert, the existing wing wall(s) shall be demolished. Prior to
dismantling of wing wall(s), the measurement of wing walls shall be taken jointly with the
Engineer’s representative.
The further execution procedure shall be followed as defined below:-
4.1 Excavation:
The foundation bed for pipe culverts shall be excavated true to the lines, grades and to the
levels shown on the drawings. During the excavation, any soft, spongy, or any other unsuitable
materials encountered shall be removed to depths and widths as specified by the Engineer.
4.2 Bedding for Pipe:

a) The bedding surface which forms a firm foundation throughout the length of the culverts shall
be laid with approved granular material which shall be properly shaped and thoroughly
compacted up to the specified level.
b) The PCC for the head wall shall be laid to the specified thickness mentioned in the drawing.
The head wall shall be constructed to the level of bottom of the pipe.
4.3 Laying and Jointing of Pipe:

a) The laying of pre-cast reinforced spun pipes NP 4 shall be done on prepared bedding. The
laying shall start from the outlet and proceed towards the inlet and shall be done to the
specified levels and grades. The pipes shall be fitted and matched in such a way that they
form a culvert with a smooth invert. The jointing shall be done in such a way it is smooth and
consistent joint with the interior surface of the pipe. The joints shall be kept covered and
damp for at least 4 days.
b) The head wall 2nd lift shall be carried out to the level mentioned in the drawings.
4.4 Backfilling:
a) The backfilling shall be done after the jointing material has hardened. The backfill soil shall
be clean, free from boulders. Backfilling shall be carried in layers not exceeding 150mm to
the level 300 mm above the top of the pipe shall be done. Material shall be imported if
required & compacted using mini compactors, plate compactor or vibratory compactors as per
site conditions.
b) The aprons shall be constructed as per clause 2500 of the MORTH Specification.
5. Safety Measures
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b) Suitable barricades shall be erected on the sides / edges of excavation to prevent vehicles
c) Suitable warning signs shall be erected & traffic shall be warned before entering into such
sections.
d) Flagmen shall be stationed on either ends of the approach road to guide the traffic during
e) Precautionary retro-reflective signs shall be erected & safety cones / painted bamboos shall
be placed in areas where this activity is being carried out by obstructing existing traffic lane.
f) Proper approach road / diversion road shall be provided.
g) Provide a safe means of access for all excavations.
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METHODOLOGY FOR BOX CULVERTS
1. Scope:
The work shall consist of placing concrete in the formwork and vibrating the concrete to produce
the required structural elements of culverts (Box culverts) with approved materials as per
approved Drawings and as per relevant sections of MORT&H. The construction shall confirm to the
specific alignment, lines and grades given in the drawing.
2. Major Equipment and Machinery:

a) Excavator / Back Hoe with breaker.
b) Auto level with accessories.
c) Batching Plant / Batch Mixer.
d) Transit Mixers.
e) Needle Vibrators.
f) Cube Moulds.
g) Tippers.
h) Concrete pump / boom placer.
i) Gen-set or tower light.
j) Dewatering pump.
k) Water Tank.
3. Material:
As described in methodology for form work/ reinforcement/ concrete or as per drawing and
technical specifications. All materials used in construction of box culvert shall confirm to the
requirements of section 1000 of MORTH specifications. The concrete used shall be of required
grade as per drawing / technical specification and shall be as per approved design mix and shall
confirm to section 1700 of Technical specifications. Concrete shall be produced by batching plant
of suitable capacity & transported to site by transit mixers or by concrete mixers fitted with
weigh batchers.
4. Procedure:
a) Prior to start of the work TBM shall be established jointly with the Engineer’s
representative in a location, which shall not be disturbed during the course of work.
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b) Setting out of the culvert location shall be done jointly with the Engineer’s
representative as per the working drawings.
c) In case of a reconstruction or widening of the culvert, part or the whole existing
structure shall be demolished. Joint measurement with the Engineer’s representative shall be
recorded before taking up this work.
The further execution procedure shall be followed as defined below:-
4.1 Diversion of Water:

Requisite efficient methods shall be adapted to suit the particular need of diverting the water.
4.2 Excavation / PCC:

The excavation shall be carried out true to the lines, grades and to the levels shown on the
drawings. Bed shall be duly compacted and leveling course concrete shall be laid.
4.3 Concreting:
4.3.1 Base Slab:
The reinforcement shall be placed in position and shuttering shall be erected to exact
dimensions of base slab and after due checks, base slab shall be concreted to the top of
bottom chamfer and joints shall be maintained as detailed in drawing.
4.3.2 Walls:
The walls shall be cast to bottom level of upper chamber. The procedure adopted shall be
same as for base slab.
4.3.3 Top Slab:

a) Proper Scaffolding arrangement to support the shuttering for top slab shall be made with
suitable material.
b) The shuttering shall be made to support the top slab and necessary care is taken to seal the
joints to avoid slurry loss from concrete through joints. The steel shall be positioned and
concreted.
c) The formwork shall be removed after due time as per norms and blemishes, if found are
made good.
d) The inlet & outlet structures, the aprons and floor protection works shall be constructed in
similar progression.
e) The surroundings shall be cleared of all surplus stocks, waste materials etc. and cleaned.
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f) The structure shall be finished as per specifications including necessary markings, paints
etc. and completed.
5. Safety Measures
d) Suitable barricades shall be erected on the sides / edges of excavation to prevent vehicles
e) Suitable warning signs shall be erected & traffic shall be warned before entering into such
sections.
f) Flagmen shall be stationed on either ends of the approach road to guide the traffic during
g) Precautionary retro-reflective signs shall be erected & safety cones / bamboos shall be
h) Proper approach road / diversion road shall be provided.
i) Prior to start of any excavation complete information on the underground structures (such as
pipelines, electrical cable etc.) shall be obtained.
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METHODOLOGY FOR FIXING OF DRAINAGE SPOUTS
1. Scope:
This item of work deals with fixing of Drainage Spouts and Drainage pipes in bridge decks as per
terms of contract agreement, approved Drawings and clause 2705 of the MORT&H specifications.
2. Major Equipment:
a) Measuring tape.
b) Auto level with accessories.
c) Welding Machine / Gas cutter.
3. Material:
The drainage spouts shall be of not less than 100 mm in diameter and shall be of corrosive
resistant material.
4. Procedure:
4.1 Fabrication:
The drainage assembly shall be fabricated to the dimensions shown on the drawings, the
components shall be of mild steel confirming to IS 226. The drainage assembly then shall be
seam welded for water tightness and then hot-dip galvanized.
4.2 Placement:
The galvanized assembly shall be placed in the provision made in the deck slab by using dummy,
which is removed in the appropriate time to leave a slot exactly fitting the galvanized assembly.
The galvanized assembly shall be given two coats of bituminous painting before placement. The
whole assembly shall be placed in true position, lines and levels as shown in the drawing and
held in place firmly.
4.3 Finishing:
The gap between the galvanized assembly and the slot are sealed by using bituminous sealant and
the excess sealant trimmed to receive the wearing coat. After the wearing coat is completed,
similar sealant shall be finished to cover at least 50 mm on the wearing coat surface all around
the drainage assembly.
5. Safety Measures
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d) Safety cones / bamboos shall be placed in areas where this activity is being carried out by
obstructing existing traffic lane.
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METHODOLOGY FOR FILTER MEDIA, BACKFILLING BEHIND ABUTMENT
1. Scope:
This method statement is for the placement of the drainage filter media, backfilling and
Embankment behind bridge and culvert abutments with approved materials as per the terms of
contract conditions and approved Drawings. This item of work shall confirm to the clause
2504.2.2 and 309.3.2.2 of the MORT&H specifications.
1.1 Filter Media

Filter Media is proposed from the tests conducted in the laboratory and checked for its
suitability as per Clause 2504.2.2 of MORT&H Specification.
1.2 Backfilling
Back filling shall be done with the material from approved borrow areas.
1.3 Embankment
Embankment shall also be done from the suitable borrow area as per drawings and Technical
Specifications Clause 305.
2. Equipment/ Machinery
a) Roller / Plate compactor/ Rammer
3. Material:
As per relevant MORT&H Specifications.
4. Procedure:
a) Excavation of the area to be backfilled shall be done to the required angle and slope stated in
the drawings.
b) Squares of geotextile fabric will be secured over each of the weep holes to prevent the loss of
fines.
c) Initially filter media shall be laid manually with coarse filter towards weep hole of Abutment
and finer material towards earthen side layer by layer as per the technical requirement.
d) After completion of each filter media layer to the required suitable height back filling shall be
done simultaneously in layers matching the height with the filter media layer till it reaches
the existing ground level behind Abutment and compacted as per requirement.
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e) Embankment construction shall also be taken up either separately or simultaneously along
with filter media and back filling layers.
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METHODOLOGY FOR TURFING WITH SODS IN EMBANKMENT SLOPES
1. Scope:
This item of work dealt with turfing embankment side slopes with sods as per the terms of
contract conditions and approved Drawings. This item of work shall confirm to the clause 307 of
the MORT&H Specifications.
a) Tractor with Trolley / Tipper.
b) Wooden Rammer.
a) Water Tanker.
b) Hand Tools.
3. Material:
Sods of grass in the size and quality as specified in clause 307.2 of MORT&H Specifications.
4. Procedure:
a) Embankment slopes shall be prepared by trimming as per the approved drawing. Trimmed
surface shall be loosened and stones having size more than 50mm, stumps or any undesirable
foreign materials shall be removed.
b) Sods to be used shall be cut in suitable sizes with length 50 to 80mm.
c) Prepared embankment slopes shall be moistened and sods shall be laid from bottom of the
slope towards the top. Strips of sods shall be lightly tamped with suitable means.
d) After placing and temping the surface shall be cleaned of loose sods, excess soil or any foreign
materials.
e) The sods shall be watered regularly for a period of 4 weeks.
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METHODOLOGY FOR SLOPES PROTECTION (STONE PITCHING) IN HIGH EMBANKMENTS
1. Scope:
This item of work deals with slopes protection in High embankment location with stone pitching
as per the terms of contract conditions and approved Drawings. This item of work shall be
executed as per the clause 2500 of the MORT&H specifications.
2. Equipment, Tools / Machinery:

c) Hand Tools
d) Water tanker
e) Tipper
f) Wooden Straight edges.
3. Material:
Material shall be approved by the Engineer in accordance to clause 2504 of the MORT&H
specification. The size and weight of stone / concrete blocks shall conform to clause 5.3.5.1 of
IRC:89. No stone, weighing less than 40 kg shall, however, be used. The sizes of spalls shall be a
minimum of 335 mm and shall be suitable to fill the voids in the pitching. The material for the
filter shall consist of sand, gravel, stone, coarse sand or geotextile membrane and should be got
approved from the Engineer.
4. Procedure:
4.1 Slope Preparation:
The compacted layers shall be trimmed to the required slope and profile as per the approved
drawing using line and pegs. Any depression shall be filled up and compacted thoroughly using
wooden rammers.
4.2 Placing of filter layer:

Approved filter material shall be placed manually over prepared base and shall be compacted
maintaining slope and profile as per the approved drawing.
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4.3 Dry rubble pitching:
Over the prepared filter layer dry pitching shall be carried out either with stones of specified
quality or concrete blocks (of M15 grade) having an average weight of 40 Kg maintaining slope
and profile as per the approved drawing. Pitching shall be commenced from bottom of the slope
and continued to the top. In case of rubble pitching care shall be taken to minimize void
between the stones, which however shall be filled up with spalls of suitable size.
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METHODOLOGY FOR SURVEY WORKS

4.2 Establishment of Center Line:

4.3 Establishment of Temporary Bench Marks (TBM):

4.5 Taking O.G.L.’S and cross section data:

4.6 Layout for CD Structures and Junctions:

6. Records and Documents to be maintained:

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6. Records and Documents to be maintained:

Prepared By: Checked By: Approved By:

6. Records and Documents to be maintained:

Prepared By: Checked By: Approved By:

Prepared By: Checked By: Approved By:

6. Records and Documents to be maintained:

Prepared By: Checked By: Approved By:

6. Records and Documents to be maintained:

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6. Records and Documents to be maintained:

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4.2 Preparation of Base:

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4.3 Laying of Wet Mix Macadam:

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6. Records and Documents to be maintained:

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6. Records and Documents to be maintained:

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6. Records and Documents to be maintained:

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Prepared By: Checked By: Approved By:

4.2 Preparation and Transportation of Mix:

4.3 Preparation of Base:

4.4 Laying of Bituminous Macadam:

6. Records and Documents to be maintained:

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Prepared By: Checked By: Approved By:

4.2 Preparation and Transportation of Mix:

4.3 Preparation of Base:

4.4 Laying of Dense Bituminous Macadam:

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12. Records and Documents to be maintained:

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Prepared By: Checked By: Approved By:

4.2 Preparation and Transportation of Mix:

4.3 Preparation of Base:

4.4 Laying of Bituminous Concrete:

6. Records and Documents to be maintained:

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1.1 Form work:

2. Major Equipments and Machinery

3.3 Coarse Aggregate:

3.4 Fine Aggregate:

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Prepared By: Checked By: Approved By:

4.3.2 Transportation and placing:

4.3.4 Construction joints:

5. Quality control tests: (As per section 1700 of MORT&H)

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Prepared By: Checked By: Approved By: