Jharkhand Highway Technical Specifications

TECHNICAL SPECIFICATIONS
STATE HIGHWAYS AUTHORITY OF JHARKHAND

TECHNICAL SPECIFICATIONS
1.
PREAMBLE
1.1
The Technical Specifications contained herein shall be

conjunction with the other Bidding Documents as specified.
1.2
SITE INFORMATION
1.2.1
The information given hereunder and provided elsewhere in these

documents are only indicative for general awareness. The Contractor
shall satisfy himself regarding all aspects of site conditions and no claim
whatsoever shall be entertained for insufficiency or incorrectness of
information provided in these documents.
1.2.2
The area in which the works are located is mostly plain terrain, the
approximate longitude and latitude of the region being is Latitude
86.7845 & Longitude 24.4952 and Latitude 87.0787 & Longitude
24.6032 respectively.
1.2.3
General Climatic Conditions
1.2.3.1
The variation in daily temperature in this region is as under:

i)
During summer months, from about 23o C minimum to 43o C
maximum.
ii)
During winter months, from about 8C minimum to 30C
maximum.
1.2.3.2
The average annual rainfall in the area is of the order of 1400 mm, a
good portion of which is concentrated during the months of July to Sept.
each year.
1.2.3.3
The range of relative humidity goes upto maximum of 37%.
1.2.4
Seismic Zone
read
in
The works are located in Seismic Zone II - III as defined in IRC: 6-2000.
2.
GENERAL REQUIREMENTS
The Technical Specifications in accordance with which the entire work
described in Bid Document shall be constructed and completed by the
Contractor shall comprise of the following:
2.1
PART-I: General Technical Specifications

The General Technical Specifications shall be the "SPECIFICATIONS FOR
ROAD AND BRIDGE WORKS (LATEST REVISION) issued by the Ministry
of Road Transport and Highways, and published by the Indian Roads
Congress with all up-to-date amendments issued by Ministry of Road
Transport and Highways (MORT&H).
Draft Detailed Project Report (Volume V: Technical Specifications)
2.2
PART-II: Special Technical Specifications

The Special Technical Specifications, provided in this document, shall
comprise of:
i) Various amendments/modifications/additions to the "General
Technical Specifications" referred to in PART - I above
and
ii) Additional Specifications for particular item of works not covered in
PART-I.
2.2.1
The following Clauses of General Technical Specifications i.e. the

"SPECIFICATIONS FOR ROAD AND BRIDGE WORKS (LATEST REVISION)
have been amended/modified/added to form a part of Special Technical
Specification.
102, 108, 109, 110, 111, 112, 121, 201, 202, 301, 305, 306, 401, 406,
408, 409, 501, 504,507, 509, 511, 521,601, 602, 801, 803, 804, 901,
903, 1006, 1007, 1009, 1014, 1101, 1103, 1104, 1107, 1113, 1115,
1118, 1119, 1202, 1203, 1204, 1205, 1206, 1207, 1208, 1209, 1210,
1214, 1215, 1502, 1503, 1509, 1510, 1703, 1704, 1705, 1706, 1707,
1709, 1713, 1714, 1802, 1806, 2005, 2006, 2009, 2504 and 2706.
2.2.2
The Additional Specifications comprise of specifications for particular

items of works not covered in PART-I
APPENDIX - 1 to APPENDIX - 8 have been added to General Technical
Specifications i.e. the "SPECIFICATIONS FOR ROAD AND BRIDGE WORKS
(LATEST REVISION) to form a part of the Special Technical
Specification.
2.3
Where a particular clause or a part thereof in General Technical

Specifications i.e. "SPECIFICATIONS FOR ROAD AND BRIDGE WORKS
(LATEST
REVISION)
referred
in
PART-I
above
is
amended/modified/added upon by Special Technical Specification
referred in PART-II above, such amendment/modification/addition
supersedes the relevant Clause or part of the Clause.
2.4
When an amended/modified/added Clause supersedes a Clause or part

thereof in the said Specifications, then any reference to the superseded
Clause shall be deemed to refer to the amended/modified/added Clause
or part thereof.
2.5
In case of any conflict or inconsistency between the provisions

amended/modified/added Clause of Special Technical Specification and
that of General Technical Specifications under reference, the
amended/modified/ added Clause of Special Technical Specification shall
always prevail over General Technical Specifications.
2.6
In the absence of any definite provisions on any particular issue in the

aforesaid Specifications, reference may be made to the latest codes and
specifications of IRC, IS, BS and AASHTO in that order. Where even
these are silent, the construction and completion of the works shall
conform to sound engineering practice as approved by the Engineer and
in case of any dispute arising out of the interpretation of the above, the
decision of the Engineer shall be final and binding on the Contractor.
SPECIAL TECHNICAL SPECIFICATIONS

A.
AMENDMENTS/MODIFICATIONS/ADDITIONS TO EXISTING CLAUSES OF

GENERAL TECHNICAL SPECIFICATIONS
Clause 102 DEFINITIONS

The following abbreviations shall be added in this Clause:
"SHAJ" State Highway Authority of Jharkhand
RCD Road Construction Department
GOJ Government of Jharkhand
"MORT&H" Ministry of Road Transport & Highways
Clause 108.4
Delete first two sentences.
Clause 109.9
Delete 2nd and 3rd sentence and add the following Setting out of
the road alignment and measurement of angles shall be done by using
total station.
Clause 110 Encumbrances
Utilities
-
in
Construction
Area,
including
Trees
and
Replace whole of this clause with the following:

Clause 110.1 The contractor shall be responsible to coordinate with service
provider / concerned authorities for cutting of trees, shifting of utilities
and removal of encroachments etc. and making the site unencumbered
from the project construction area required for completion of work. This
will include initial and frequent follow-up meetings / actions /
discussions with each involved service provider / concerned authorities.
The contractor will not be entitled for any additional compensation for
delay in cutting of trees, shifting of utilities and removal of
encroachments by the service provider / concerned authorities.
Payment for cutting of trees and shifting of utilities as required by the
concerned department shall be made by the Employer.
Clause 110.2
Drawings, scheduling the affected encumbrances such as trees
and services like water pipes, oil pipelines, cables, gas/oil pipes,
electricity lines, accessories, telephone poles and OFC cables etc. shall
be verified by the willing bidder in the office of the Employer. Copy of
the drawings, however, will be issued to successful bidder under clause
107 of specification, for verification by him for accuracy, necessary coordination and work.
Clause 110.3
The Employer will make payments to the respective service
provider / authorities for cutting of trees and shifting of utilities,
wherever required. The contractor will obtain necessary approval from
such Authorities after payments by the Employer and also in cases
where payments are not required to be made for such shifting. The
Employer will also write to all concerned departments / service provider
organization for expediting and facilitating cutting of trees, shifting of
utilities and removal of encroachment etc.
Clause 110.4
Any services affected by the Works must be temporarily
supported by the Contractor who must also take all reasonable
measures required by the various bodies to protect their services and

property during the progress of the Works. It shall be deemed to be part
of the Contract and no extra payment shall be made for the same.
Clause 110.5
The Contractor may be required to carry out certain works for
and on behalf of the various bodies and he shall also provide, with the
prior approval of the Engineer, such assistance to the various bodies as
may be authorized by the Engineer.
Clause 110.6
Payment
For coordinating the work of cutting of trees, shifting of utilities and

removal of encroachments etc., the contractor will be paid a lump-sum
amount per km. or part thereof of the section.
Such amount will be deemed to cover all coordination work plus any risk
associated with delay, disruption and the need to adjust the programme
due to delay in tree cutting and shifting of utilities and removal of
encroachments etc.
Clause 111 Precautions for Safeguarding the Environment
This whole clause shall be substituted by following:
Clause 111.1
General
The contractor shall take all precautions for safeguarding the

environment during the course of the construction of works. He shall
abide by all rules, regulations and laws in force governing pollution and
environmental protection that are applicable to the area where the
works are situated.
NOISE:
The Contractor shall mitigate against any sustained increase in base
line ambient sound levels at sensitive receptors during construction of
work.
All construction operations shall be performed in a manner to minimize
noise and vibration. The parameters for noise are detailed below:
70 dB (A) for day and night;
50 dB (A) for day and 45 dB (A) for night for residential and
silence zone areas.
If the noise level are found to be above these standards and it is
determined by the Engineer that these levels are due to the equipment
or plants deployed by the contractor, he shall undertake at his own cost
measures as approved by the Engineer to bring these levels down to
the specified levels. Contractor shall ensure:
Placement of stationery equipment at least 115m away from
inhabitant areas and 200m from sensitive areas to minimize noise
impacts.
Construction activities generally prohibited between 10 p.m. to 6
a.m. near habitation.
Provision of using ear plugs, helmets by workers exposed to high
noise levels.
Erecting sign boards at sensitive and residential locations

prohibiting use of air horns.
Labour shall be warned against the hunting of wild life, if any.
archaeological site shall be disturbed.
Clause 111.2
No
Borrow Pits for Embankment Construction
Borrow pits shall not be dug within the right-of-way of the road.
Contractor will ensure that proper excavation techniques are used to
improve stability and safety of the borrow area. The excavation shall be
carried out in such a way that the area does not inundate during
monsoons generate cesspools of water for breeding site. The area after
excavation shall be properly landscaped. The stipulations in Clause
305.2.2 shall govern.
Clause 111.3
Quarry Operations
The contractor shall obtain material from licensed quarries only after
the consent of the forest department or other concerned authorities.
The quarry operation shall be undertaken within the purview of the
rules and regulations in force. Contractor shall ensure scheduling the
movement of transport carrying material to and from site during nonpeak hours. The trucks carrying dusty material like fly ash shall be
covered with tarpaulin and provided with adequate free board to
prevent spillage. End boards shall be provided in loaders to prevent
spillage. Stockpiling of material shall be properly planned so as to
ensure that no traffic jam takes place on the highway.
Clause 111.4
Control of Soil Erosion & Sedimentation
The contractor shall carry out the works in such a manner that soil
erosion is fully controlled. The stipulations in Clause 306 shall govern
for this purpose.
Clause 111.5
Precautions against Dust
The contractor shall take all reasonable steps to minimize dust nuisance
during the construction of the works. All existing highway and roads
used by vehicles of the contractor or any of his sub-contractor or
suppliers of materials or plant, and similarly any new roads which are
part of the works and which are being used by traffic, shall be kept
clean and clear of all dust/mud or other extraneous material dropped by
the said vehicles or their tyres. Similarly, all dust or mud or other
extraneous material from the works spreading on these highways shall
be immediately cleared by the contractor. Clearances shall be effected
immediately by manual sweeping and removal of debris, or, if so
directed by the Engineer, by mechanical sweeping and clearing
equipment, and all dust, mud and other debris shall be removed
entirely from the road surface. Additionally, the road surface shall be
hosed or watered using suitable equipment to avoid dust pollution.
Special care shall be taken to combat dust problem originating from use
of fly ash.
Clause 111.6 Pollution from Hot Mix Plant, Batching Plant & Other
Construction Machinery
The Contractor shall ensure the use of relatively new, well maintained
hot mix plant (batching plant) so that emission conforms to the CPCB
norms and be fitted with dust extraction unit avoid prolonged engine
powered equipment idleness. Asphalt mixing sites shall be located
more than 500m from any community or residence. The hot mix plant
shall be founded on compacted/paved surface so that the spills do not
affect the aquifer. Properly sizing and maintenance of mufflers, engine
intake, silencers and engine enclosures shall be carried out. The
contractor shall take every precaution to reduce the levels of noise,
vibration, dust and emission from his plant. The contractor shall be
fully responsible for any claims for damages caused to the owner of
property, fields and residence in the vicinity.
All vehicles, equipments and machinery for construction operation will
be regularly maintained to ensure that pollution emission levels
conform to CPCB(Central Pollution Control Board) norms. All vehicles
should be fitted with silencer and dust removal device.
Construction vehicles, machinery & equipment will move or be
stationed in the designated area to avoid Compaction of soil ensuring
the perseverance of the top soil for agriculture.
Clause 111.7
Road Safety
The contractor shall provide adequate circuit for traffic flow around
construction areas, control speed of construction vehicles through road
safety and training of drivers, provide adequate signage, barriers and
flag persons for traffic control.
If there are traffic jams during
construction, measures shall be taken to relieve the congestion with the
assistance of traffic police. Safety of workers undertaking various
operations during construction will be ensured by providing helmets,
masks, safety goggles etc.
Clause 111.8
Sanitation & Waste Disposal in Construction Camp
Contractor shall ensure that construction camps are located at a

distance of minimum 200m from water sources. Special attention shall
be paid to the sanitary conditions of the camps. The contractor shall
ensure that sufficient measures are taken i.e. provision of garbage
tanks and sanitation facility. Waste in septic tanks shall be cleaned
periodically. Garbage shall be collected in four soakage pits at each
construction site and disposed of daily.
Contractor shall provide
adequate measures for the health care of workers and arrange their
regular medical check-up to ensure that they do not suffer from
infectious disease. At every work place, good & sufficient potable water
supply will be maintained to avoid waterborne/water related diseases. If
any pits are dug at construction/camp site, which are not filled and may
turn into mosquito breeding sites during monsoons, either these shall
be filled up properly so that no water gets accumulated or sprayed
frequently with pesticides to prevent mosquito breeding.
Prior
permission of the Engineer and regulatory authority shall have to be

taken by the contractor for discharging or disposing of any material
arising from the execution of workers.
Clause 111.9
Substance Hazardous to Health
The contractor shall not use or generate any material in the work, which
are hazardous to the health of persons, animals or vegetation. Where it
is necessary to use some substance, which can cause injury to the
health of the workers, the contractor shall provide suitable clothing or
appliances to his workers, viz. earplugs, helmets or dust masks.
Clause 111.10 The contractor at his own cost shall make good any structural
damage to the existing roads/structures caused by any action
whatsoever relating to his construction operations his construction
equipment and no claim whatsoever on this account shall be
entertained.
Clause 111.11 Use of Nuclear Gauges
Nuclear gauges shall be used only where permitted by the Engineer.
The contractor shall provide the Engineer with a copy of the regulations
governing the safe use of nuclear gauges he intends to employ and
shall abide by such regulations.
Clause 111.12 Environmental Monitoring
In order to carry out periodic checks environmental monitoring will be
carried out by the Engineer as per schedule and if any parameter is
found above the acceptable standards, mitigation measures/control
measures as decided by the Engineer shall be complied with by the
contractor at his own cost.
Clause 111.13 Protection of Existing Trees
Many of the existing trees within the right of way will be cut for
construction of roadway by Forest Department or any other agency
(Refer clause 110 also). The contractor shall take all necessary
measures to ensure safety and protection of the remaining trees from
any action whatsoever relating to his construction operations in the
adjoining areas.
The contractor shall make his own arrangements of fuel for use of his
labour from outside the forest range as use of forest property or any
other agencys property as firewood or any other domestic use is
strictly prohibited. The contractor shall be fully responsible for any
complain from the Forest Department or any other agency and shall
indemnify the Employer for any damage if so caused by the contractor
on such account.
Clause 111.14 Disposal of Materials outside Work Site
Notwithstanding other relevant provision in the contract, the excess
material generated by dismantling, excavation, waste material and
lubricants, used oil, gasoline and other such substance etc., shall be
removed from site, outside the right of way at regular intervals and site
shall kept clean from all such disposable materials; grease, cotton and
other wastes construction materials will be disposed off in shallow
soakage wells constructed in each construction site. Such intervals
shall not exceed one month under any circumstances. The selection of
the disposal site shall be the responsibility of the contractor and he
shall ensure that the selected site does not result in any claim for
damages to the employer or violation of any existing laws.
Clause. 111.15
Compliance with the foregoing will not relieve the contractor of
any responsibility for complying with the requirement of any Highway
Authority in respect of the roads used by him.
Clause 112.1
General
Delete the last sentence and add the following:

Two weeks before undertaking work that would involve any obstruction
whatsoever to traffic, the Contractor shall submit a Traffic Control Plan
to the Engineer for approval.
The plan shall include:
i.
Typical drawings for temporary diversions in accordance with

Sub-Clause 112.3
ii.
Typical details of arrangements for construction under traffic

including details of traffic arrangements proposed to be in place
after the cessation of work each day.
Special consideration shall be given in the preparation of the Traffic

Control Plan to the safety of pedestrians and workers and delineation of
the roadway at night.
Temporary diversions will be constructed only with the approval of the
Engineer and will generally be constructed only at bridge sites where
new bridges are to be located on the existing road alignment. Road
works shall generally be constructed under traffic.
Clause 112.2
2nd para of this clause shall read as under:
In case of eccentric widening of existing two lane to four lane, the

additional two lanes shall be constructed first up to the stage of Dense
Bituminous Macadam for a minimum length of 2 km. and traffic diverted
to it, and only thereafter the required treatment to the existing
carriageway including construction of median shall be taken up.
Clause 121 FIELD LABORATORY
Clause 121.1
Scope
Delete this Clause and replace with:

The work under this Clause covers the provision and maintenance of a
fully equipped laboratory.
Clause 121.2
Description
Add the following at the end of this Clause:

Within 14 (fourteen) days from date of Start, the Contractor shall prepare
detail working drawing of the pucca laboratory building and list of
manufacturer/supplier of the equipment and submit the same to the
Engineer for his approval.
The Contractor shall construct a fully furnished and adequately
equipped field laboratory to the satisfaction of the Engineer. The
laboratory will be located at a site approved by the Engineer and must
be of adequate size to perform the tests safely as required under the
contract including sufficient lights, electricity and water supply. The
Contractor shall provide working drawings incorporating all the services
based on the information given in the drawings for the approval of the
Engineer prior to commencement of construction. An office must be
provided in the laboratory for the exclusive use of the Engineer,
Engineers representative and Materials Engineer. Adequate toilet and
washing facilities must be provided.
The Contractor shall provide the field laboratory within 2 months from
the date of the commencement of the work. Prior to this, the contractor
must make suitable alternative arrangements as acceptable to the
Engineer for testing of materials.
The field laboratory and test records shall be open for use and
inspection by the Engineer and/or Employer at any time. All pressure
gauges and other machines, equipments and measuring instruments of
the laboratory shall be got checked and calibrated regularly as directed
by the Engineer by an independent agency and the adjustment
certificate shall be furnished to the Engineer. The contractor shall
render all reasonable assistance and help in making such checks and
tests etc. The cost of all checks and calibrations shall be borne by the
contractor. The cost of tests for materials and cubes shall be borne by
the contractor.
Clause 121.3
Laboratory Equipment
This Clause shall read as under:

The following items of laboratory equipment shall be provided in the field
laboratory.
A: General
(i) Balance
(a) 7 kg to 10 kg capacity semi-self indication Type- 2 Nos
Accuracy 1 gm Electronic
(b) 500 gm capacity semi-self- indicating Electronic 2 Nos.
Type- Accuracy 0.01 gm.
(c) Pan balance 5 kg capacity Accuracy 0.5 gm.
3 Nos.
(d) Platform Scale - 300 kg capacity

(e)
Chemical Balance 100 gm. capacity - accuracy
0.001
(ii)
Ovens-Electrically
operated,
thermostatically
controlled
(a) From 100oC to 220oC Sensitivity 1oC
(iii)
Sieves: as per I.S. 460-1962
(a) I.S. Sieves 450 mm internal dia of sieve sets as per
ISI of required sieve sizes complete with lid and pan
(b) I.S. sieve 200 mm internal dia (brass frame and steel
or brass wire cloth mesh) consisting of sieve sets of
required sieve sizes complete with lid and pan
(iv)
Sieve shaker capable of taking 200 mm and 450 mm
dia sieves electrically operated with time switch
assembly (As per IS)
(v) Stop watches 1/5 sec. Accuracy
(vi)Glassware comprising of Beakers, Pipettes, dishes,
measuring cylinders (100 to 1000 cc capacity) glass
rods and funnels, glass thermometers range 0oC to
100oC and metallic thermometers range upto300oC
(vii)Hot plates 200 mm dia (1500 watt)
(viii) Enamel trays
(a) 600 mm x 450 mm x 50 mm
(b) 450 mm x 300 mm x 40 mm
(c) 300 mm x 250 mm x 40 mm
(d) Circular plates of 250 mm dia
(x) Water Testing kit
B: For Soils testing
(i) Water still
(ii) Liquid limit device with and A.S.T.M grooving tools as
per ISI-2720
(iii) Sampling pipettes fitted with pressure and suction
inlets, 10 capacity
(iv)
Compaction apparatus(Proctor)as per ISI 2720 (Part
8) complete with collar, base plate and hammer
(v) Modified AASHTO Compaction apparatus as per I.S.
2720 (Part 7) 1974 or Heavy Compaction Apparatus as
per IS complete with collar, base plate hammer
(vi)
Sand pouring cylinder with conical funnel and tap
and complete as per I.S. 2720 (Part 28) 1974 including
modified equipment.
(vii) Sampling tins with lids 100 mm dia x 75 mm ht 1/2
kg capacity and miscellaneous items like moisture, tins
with lid(50 grams)etc.
(viii)Lab C.B.R. testing equipment for conducting CBR
testing, load frame with 5 Tonne capacity, electrically
operated with speed control as per I.S. 2720 (Part 16),
and consisting of following:
(a) CBR moulds 150 mm dia - 175 mm ht. complete
1 No.
1 No.
1 No.
2 Sets
2 Sets
1 No
2 Nos.
1 Doz
each
2 Nos.
6 Nos.
6 Nos.
6 Nos.
6 Nos
1 No.
1 No.
2 Nos.
1 set
2 Nos.
2 Nos.
6 Nos.
24 Nos.
1 set
8
10
with collar, base plate etc.

(b) Tripod stands for holding dial gauge holder
(c) CBR plunger with settlement dial gauge holder
(d) Surcharge weight 147 mm dia 2.5 kg. wt with
central hole
(e) Spacers disc 148 mm dia. 47.7 mm ht. with handle
(f) Perforated plate (Brass)
(g) Soaking tank for accommodating 6 CBR moulds
(h) Proving rings of 1000 kg, 2500 kg and 5000 kg
capacity
(i) Dial gauges, 25 mm travel - 0.01 mm/division
(ix)
Standard Penetration Test equipment
(x) Nuclear Moisture Density meter or equivalent
(xi)
Speedy moisture meter complete with chemicals
(xii) Unconfined Compression Test Apparatus
C:
For Bitumen and Bituminous Mixes
(i) Constant temperature bath for accommodating bitumen
test specimen, electrically operated and thermostatically controlled.
(ii) Penetrometer automatic type, adjustable weight
arrangement and needles as per I.S. 1203- 1958
(iii)
Soxhlet extraction or centrifuge type apparatus
complete with extraction thimbles with solvent and
filter paper
(iv)
Laboratory mixer including required accessories
(v)
Marshall Compaction apparatus automatically
operated as per ASTM 1559-62 T complete with
accessories
(vi)
Distant reading thermometer.
(vii) Rifle Box
(viii) Automatic Asphalt Content Meter
D
For Cement, Cement Concrete and related
Materials
(i)
Water still
(ii)
Vicat needle apparatus for setting time with
plungers, as per I.S. 269-1967
(iii)
Moulds
a) 150 mm x 300 mm ht cylinder with capping
component
b) Cubicals150mm, 50cm2 (each size)
(iv)
Concrete permeability apparatus
(v)
High frequency mortar cube vibrator for cement
testing
(vi)
Concrete mixer power driven, 1 cu ft capacity
(vii) Variable frequency and amplitude vibrating table
size 1 metre x 1 metre, as per the relevant British
Standard
(viii) Flakiness index test apparatus
12
2
12
3
12
1 each
10
1 No.
1 No.
2 Nos.
1 Set
1 No.
1 No.
1 No.
1 No.
1 set
1 No.
1 No.
1 No.
1 No.
1 No.
As reqd.
As reqd
1 No.
1 No.
1 No.
1 No.
1 No.
11
(ix)
Aggregate impact test apparatus as per IS 2386
(Part 4) 1963.
(x) Los Angeles abrasion apparatus as per IS. 2386 (Part 4)
1963
(xi)
Flow table as per IS 712-1973
(xii) Apparatus for slump test
Apparatus for compacting factor test
(xiii) Equipment for determination of specific gravity for fine
and coarse aggregate as per IS : 2386 (Part 3) 1963.
(xiv) 2000 KN capacity compression testing machine for
concrete testing
1000 KN capacity compression testing machine for
cement testing with additional dial for flexural testing
(xv) Core cutting machine with 10 cm dia diamond cutting
edge
(xvi) Needle vibrator
(xvii) Air entrainment meter
(xviii) 0.5 Cft, 1 Cft cylinder for checking bulk density of
aggregate with tamping rod
(xix) Soundness testing apparatus for cement
E. For Control of Profile and Surface Evenness
(i) Total Station
(ii) Precision automatic level with micrometer attachment
(iii)
Precision staff
(iv)
3 metre straight edge and measuring wedge
(v) Camber templates 2 lane
(a) Crown type cross-section
(b) Straight run cross-section
(vi) Steel tape
(a) 5 m long
(b) 10 m long
(c) 20 m long
Clause 121.4
1 No.
1 No.
1 No.
4 Nos.
1 No.
4 Nos.
1 No.
1 No.
2 Nos.
4 Nos.
1 No.
As reqd
1 set
1 No.
2 sets
3 sets
3 sets
1 set
2 sets
2 sets
2 sets
2 sets
Ownership

The field laboratory building along with the equipment provided for tests
shall be and remain the property of the Contractor. However, the Engineer
shall have the right to inspect and use them as and when required. The
contractor shall have to remove the equipment at his own cost after
issuance of taking over certificate.
Clause 121.5
Maintenance

The Contractor shall arrange to maintain the field laboratory including
sample store yards in a satisfactory manner until the issue of Taking over
Certificate for the complete work. Maintenance includes all activities
12
described in Clause 120.4 and maintenance of equipment including

periodical calibration and running of the same including chemicals and
consumables.
Clause 121.6
Measurement for Payment
This Clause shall be deleted.

Clause 121.7
This clause shall be read as under:
The cost of provision of field laboratory including supply of laboratory

equipment and also provision of adequate number of qualified personnel,
erection, maintenance and running of laboratory including all consumable
like chemicals and reagents shall be deemed to have been included in the
contract price.
Clause 201 CLEARING AND GRUBBING
Clause 201.1
Scope
Delete the last sentence and replace with as under:

Clearing and grubbing shall be performed less than one month in
advance of earthwork operations and in accordance with the
requirements of these specifications. If any vegetation grows after
clearing and grubbing and before earthwork, the Contractor shall repeat
the work to the satisfaction of the Engineer without any extra cost. Areas
requiring clearing and grubbing shall be determined by the Engineer. "
Clause 201.5 Measurements for payment
Delete the last two sentences in first paragraph and the whole of second
and third paragraph. Add the following sentence in first paragraph
Removal of stumps and roots of any trees shall not be measured
separately. It shall be considered as incidental to Clearing and Grubbing
work.
Clause 201.6
Rates
Clause 201.6.1 this clause may be read as under;

The Contract unit rates for the clearings 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 include removal of stumps and roots of
trees less than 300 mm in girth. Also include removal of stumps and roots
of trees of any girth size left over after cutting of trees carried out by
another agency. The excavation and back filling to required density,
where necessary, and handling, salvaging, piling and disposing of the
cleared materials with all lifts and up to a lead of 1000 m shall also be
deemed to be included in the Contract unit rate.
13
The removal from site and disposal of all materials obtained from clearing
and grubbing operations, which, in the opinion of the Engineer cannot be
used or auctioned, shall be included in the Contract unit rate"
Clause 202.6
Add the following items after item (vi):

(vii) Removal of existing drainage spouts
(viii) Removal of wearing course
(ix)
Removal of Sign boards/Bill boards, Km stones
Nos.
Sqm.
Sqm.
Nos.
(x)
Clause 202.7
and Guard posts

Pavement edge cutting
Rates
Delete the last sentence of the paragraph and replace with:

These will also include excavation and back filling where necessary to
the required compaction and for handling, piling and disposal of the
dismantled materials with all lifts and leads as specified in Sub-Clause
202.5.
Clause 301 EXCAVATIONS FOR ROADWAY AND DRAINS
Clause 301.1
Scope
Insert the following between the words roadway and side in the
second line:
road shoulders, verge, medians.
Clause 301.3.3
Excavation - General
Delete the last two sentences of para 5 beginning and ending with:
"If trees were removed by the Engineer", and
"The cost of planting to the work".
Clause 301.3.7
"In works involving widening of existing pavements or providing paved

shoulders and hard shoulders, the existing shoulders/verge/median shall
be removed to its full width. The subgrade material within 0.5m from the
lowest level of the pavement shall be checked for density that should not
be less than 97% as per table 300-2. In case the density is found to be
less than 97%, then the subgrade shall be loosened, watered and recompacted as per Clause 305 to a density not less than 97% of maximum
dry density determined according to IS:2720 (Part 8). Any unsuitable
material encountered in this portion of subgrade shall be removed and
replaced with suitable material and compacted in accordance with Clause
305.
While removing the existing shoulders/verge/median, care shall be taken
to see that no portion of the existing pavement designated for retention is
14
loosened or disturbed. If the existing pavement gets disturbed or

loosened, it shall be dismantled and cut to a regular shape with sides
vertical and the disturbed/loosened portion removed completely and relaid as directed by the Engineer, at the cost of the Contractor.
Clause 301.3.11 Disposal of Excavated Materials
Delete this sub-clause and replace with:
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)
ii)
iii)
Filling for roadway embankments.

Filling existing pits in the right of way as directed by the Engineer,
including leveling and spreading, with all lifts and lead up to
1000m.
For landscaping of the road as directed by the Engineer, including
levelling and spreading, with all lifts and lead up to 1000m.
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.
Clause 301.8
Read item (i) of the last para as loosening, excavating and
recompacting the loosened material at subgrade.
Read item (v) of the last para as disposal of surplus material beyond
initial 1000m lead.
Read unit of item (v) of the last para as cum km in place of cum.
Clause 301.9
Rates
Add the following after item (vi):

(vii) The removal from site and disposal of all surplus or unsuitable
materials obtained from excavation operations, which, in the opinion of
the Engineer cannot be used in the Works, shall be included in the
Contract rate.
Clause 301.9.2 This clause shall read as under:
"The contract unit rate for loosening, excavating, spreading 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 305.2.1
Physical requirements
Replace the existing table 300-1 by the following:
Table 300-1
DENSITY REQUIREMENTS OF EMBANKMENT AND SUBGRADE MATERIALS.
15
Engineering properties of samples remoulded

as per IS 2720(part 8)
Sl.
Max
dry
Min. Angle of
No Type of work
Min. Cohesion
density
internal
.
(Kg/Sq cm)
(gm/cc)
friction
(Degree)
1.
Embankments
upto
3m Not less than height, not subjected to 1.52
extensive flooding
2.
Embankments exceeding 3 Not less than m height and upto 6 m 1.60
height
3.
Subgrade
and
earthen Not less than shoulders / verge / backfill
1.75
4.
High
embankment Not less than 0.10
27
(embankment exceeding 6 1.80
m height)
Notes: Same as those below existing Table
Clause 305.2.1.6 Add new sub clause as given below:
305.2.1.6
Materials to be used as subgrade shall have a 4 day soaked CBR
value minimum 7% (for
Km.134.3 to Km.150) and 10% (for Km.
153 to Km. 204) at the unit weight applicable as per
Table 300-2.
Clause 305.2.2.2 Borrow Materials
Para 1 of this Clause shall read as under:
"No borrow area shall be made available by the Employer for this work.
The arrangement for the source of supply of the material for embankment
and subgrade as well as compliance to the different environmental
requirements in respect of excavation and borrow areas as stipulated,
from time to time, by the Ministry of Environmental and Forest,
Government of India and the local bodies, as applicable shall be the sole
responsibility of the Contractor."
The Table 300-2 shall read as under:
Table 300-2
Compaction requirements for embankment and subgrade
Sl.
No
.
1.
2.
3.
Type of Work / Material
Relative Compaction as
percentage of maximum
laboratory dry density as per
IS:2720 (Part 8)
earthen Not less than 97
Subgrade
and
shoulders
Embankment
a) Up to 6 m height
b) exceeding 6 m height
Expansive clays
a) Subgrade and 500
Not less than 95

Not less than 95
mm Not Allowed
16
Sl.
No
.
Type of Work / Material
portion just below

subgrade
b) Remaining
portion
embankment
Relative Compaction as
percentage of maximum
laboratory dry density as per
IS:2720 (Part 8)
the
Not less than 90
of
Para 8 of this Clause given below Table 300-2 shall read as under:
"The contractor shall at least 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.
ii)
The graphs showing values of density plotted against moisture

content from which each of the values in (i) above of the maximum
dry density and optimum moisture content were determined.
iii)
The dry density-moisture content-CBR relationship for each of the fill

materials he intends to use in the subgrade.
Clause 305.3
Construction Operations
Clause 305.3.4 Compacting Ground Supporting Embankment/Subgrade

Para 1 of this clause shall read as under:Where necessary, the original ground shall be leveled, mixed with water
and then compacted by rolling to facilitate placement of 1 st layer
embankment and its Compaction in accordance with the requirement as
given in table 300.2.
Add the following as para 6 at the end:
Wherever pavement reconstruction is proposed, the state of compaction
of the existing high embankment fill up to at least 500mm below
subgrade bottom level shall be examined by sampling and conducting insitu density test at every 100m interval at both sides of the embankment.
If the degree of compaction of the existing embankment is found to be
less than 95% of maximum dry density, determined in accordance with
IS: 2720 (Part 8), a depth of minimum 500mm 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), provided the loosened soil is found
suitable as per clause 305.2.
Clause 305.3.6 Compaction
Insert in 3rd line of second para of this clause:
15-30 tonne weight having tyre pressure of at least 7 kg./sq.cm in place
of adequate capacity capable of achieving required Compactions.
17
Clause 305.4.3 Earthwork over Existing Road Surface

Replace item (i) with:
If the existing road surface is of a bituminous type and lies more than
500mm below formation level, the same shall be scarified to a depth of
50mm below the underside of the bitumen, or more if specified, so as to
provide an ample bond between the old and new material. Where the
existing road surface is less than 500mm below formation level, the
existing surface shall be prepared for overlay in accordance with Clause
401.4.1
Clause 305.9.1 Insert including removal of top soil after word material appearing
in
first
line
of
item (v).
Clause 306
SOIL EROSION AND SEDIMENTATION CONTROL
Clause 306.4 Measurement for Payment

Substitute Clause 306.4 as under:
"All temporary soil erosion, sedimentation and pollution control works
shall be deemed as incidental to the earthwork and other items of work
and as such no separate payment shall be made for the same."
Clause 401
GRANULAR SUB-BASE
Clause 401.2
Materials
Clause 401.2.1
Para 1 of this clause shall read as under:
The material to be used for the work shall be crushed sand, crushed
stone, natural sand and combination thereof depending upon the
grading required. The material shall be free from organic or other
deleterious constituents and conform to Grading I given in Table 400-1
for sub-base layer. Materials like gravel, moorum, crushed concrete,
brick metal, kantar or crushed slag shall not be used in sub-base layer.
Clause 401.3
The clause shall read as follows:
It shall be ensured prior to actual execution that the material to be used

in the sub-base have a minimum CBR value of 30% when compacted and
finished.
When directed by the Engineer, this shall be verified by performing CBR
tests in the laboratory. The CBR tests shall be conducted on specimen
when compacted to 98% of the maximum dry density as per IS: 2720
(Part 8) and soaked for 4 days in water.
Clause 406 WET MIX MACADAM SUB-BASE/BASE COURSE
Clause 406.2.1.1 Add at the end of 1st paragraph.
18
The fraction of material passing through 4.75mm sieve shall be crusher

run screening only.
Clause 406.3.3 Preparation of Mix
Delete last sentence of paragraph 1 of Clause 406.3.3.
Clause 406.3.4 Spreading of mix
Substitute first sentence of para 2 of this clause by
The mix shall be spread by a paver finisher.
Clause 408.5.6
Add new sub-clause :
408.5.6 After erection, kerbs shall be painted with one coat primer
and two coats of colour paint (yellow and black). All paints shall be
ready mix oil bound and shall be approved by the Engineer.
Clause 408.7
Rates
The clause shall read as under:

The contract unit rates for cement concrete kerb/kerb with channel and
foundation for kerb/kerb with channel shall be paid in full compensation
for furnishing all materials, labour, tools, equipment for construction,
painting and other incidental cost necessary to complete the work.
Clause 409 Footpaths and Separators
Delete this clause in its entirety and substitute:
Clause 409 Footpaths, Medians, Separators and other Paved Areas
Clause 409.1
Scope
The work shall consist of constructing and finishing footpaths, medians

and/or separators and landscaped areas at locations specified in the
drawings in conformity with the lines and levels and dimensions as
specified in the drawings and/or as directed by the Engineer. The scope
of the work shall also include provision of all drainage arrangements
within the footpaths as shown on the drawings and/or as directed by the
Engineer.
Clause 409.2
Paved Areas
Surfacing for Footpaths, Medians, Separators and other
Clause 409.2.1 Surfacing Type

The footpaths, medians, separators and other paved areas shall be
constructed with the following type, in accordance with the drawings:
(a)
Concrete interlocking paving blocks.
Clause 409.2.2 Materials: General

All materials shall comply with Section 1000 and Section 1700 of the
Specifications and as specified here below.
19
Clause 409.2.3 Sand/Cement Mortar

Sand/cement mortar shall comply with clause 1304 of the Specification,
except as described below:
Class 1 mortar shall be mixed in the proportions 1 volume cement to 3
volumes fine aggregate. Water added shall be the least amount, which
will yield a mix of suitable consistency suitable for either masonry work
or tile bedding.
Clause 409.2.4 Construction Operation: General
All utility diversions within the footpath and/or median and/or other
paved areas shall be completed to the satisfaction of the Engineer prior
to commencing footpath and other pavement finishing.
All drainage works crossing the footpath and/or median shall be laid to
the required slope and connected to the drains/sumps/storm water
drain/drainage chutes/gullies etc. as indicated in Drawings and
Specifications prior to commencing footpath and other pavement
finishing.
Installation of all street lighting traffic sign, traffic signal posts, and
other utility appurtenances and roadside barriers shall be completed
prior to commencing the footpath and other pavement finishing.
All permanent obstacles within the footpath area, such as manhole
covers, shall be adjusted to the correct finished levels prior to
commencing footpath and other pavement finishing.
If footpath and/or median finishing is undertaken prior to completion of
the adjacent carriageway construction, the contractor shall protect the
footpath and/or median finishing from damage from road works
operations, and shall take whatever measures as deemed necessary by
the Engineer to protect the finished works.
The Contractor shall provide and maintain a temporary surface of
compacted granular sub-base material for pedestrians until such time
as the permanent finishes are constructed.
Clause 409.3
Paved Area
Construction of Footpaths, Medians, Separators and Other
Clause 409.3.1 Hydraulically Pressed Pre-Cast Cement Concrete Chequered

Paving Tiles
Clause 409.3.1.1 Materials
Pre-cast concrete paving tiles shall be manufactured and tested in
accordance with IS: 13801, except as described here below, to the
approval of the Engineer.
Pre-cast concrete paving tiles shall be manufactured to the dimensions,
patterns and colours indicated in the drawings. The tiles are to be either
250mm or 300mm x 100mm rectangular or any other size and/or shape
as shown in the drawings or instructed by the Engineer and shall be
20
hydraulically pressed using a coloured concrete topping not less than

8mm thickness. The pre-cast concrete paving tiles shall have a
minimum thickness of 38 mm and shall be laid to the pattern indicated
in the drawings.
The tiles shall be manufactured using a minimum of 350 kg cement per
cubic metre of mix.
The paving tiles shall be manufactured using approved pigments to the
colour indicated on the drawings.
All tiles shall be free from segregation, honey-combing, broken or
damaged corners and imperfect plane surface. Correction of any
defects by a method of polishing or grouting will not be allowed.
Clause 409.3.1.2 Construction Operation
The tiles shall be laid to the required cross falls on granular sub-base
(minimum 150mm thick) laid and compacted in accordance with Clause
401 of the Specification and 25 mm thick concrete of grade M20
The tiles shall be bedded on a layer of Class 1 sand cement mortar of
average thickness 12 mm. The tiles shall be immersed in water
immediately prior to laying on the mortar bed.
The joints between adjacent tiles, other than expansion joints, shall be
of uniform width and not greater than 4mm. All transverse and
longitudinal joints shall be in a true line and the finish shall be of a neat
and professional appearance. On circular work, tiles shall be radially cut
on both edges where necessary to maintain the required line and joint
width.
Expansion joints shall be provided through the tiles, tile bedding and
concrete foundation at 9 metre spacing along the footpath or median.
The joints shall be 6mm wide and filled with bitumen-impregnated
fibreboard complying with IS: 1838 (Part1).
The finished footpath shall be lightly vibrated within half an hour of
placing the tiles using an approved hand tamper or similar approved
method to ensure that the tiles are well bedded with no rocking.
After consolidation, the joints between the tiles shall be filled with Class
1 sand cement mortar to within 3mm of the top surface of the tiles
ensuring the minimum of grout comes in contact with the tile face. The
joints between the tiles and the adjacent kerbs shall be filled with Class
1 sand/cement mortar.
All foreign matter shall be removed from the pavement areas
immediately following the completion of each days work.
Clause 409.4
Finishing to footpaths, medians, separators and other paved areas shall

be measured in plan in square metres between the inside edge of kerbs,
walls and edgings for the complete items of work. No separate items
will be made for base concrete or bedding materials or jointing or
21
dividing strips of Alkathene sheets. Separate measurements shall be

made for risers of steps, skirting, walls or dado where specified. No
deduction shall be made nor any extra payment will be made for any
opening in the paving upto 0.1 square meter. Nothing extra shall be
paid for paving the area at different levels in the same work area.
Clause 409.5
Rates
The contract unit rates for finishing to footpaths, medians, separators

and other paved areas and vertical finishing shall be payment in full
compensation for furnishing all materials, labour, tools, equipment for
construction and other incidental cost necessary to construction of the
item of work. Cost of GSB layer, providing pipes and arrangement for
their discharge into appropriate drainage channels shall be incidental to
the construction of footpaths.
Clause 501.3
Mixing
The first sentence of para 1 shall read as under:

Pre-mixed bituminous materials, including bituminous macadam, dense
bituminous macadam, semi-dense bituminous concrete and bituminous
concrete, shall be prepared in a hot mix plant of batch type of minimum
capacity of 100 tonne per hour and capable of yielding a mix of proper
and uniform quality with thoroughly coated aggregates.
Clause 501.5.3 Add at the beginning of the 4th para:
The temperature of mix at the time of laying shall be in the range 120 oC
-145oC.
Clause 501.6
Compaction
Replace the eighth sentence of second para beginning "The intermediate

rolling.5.6 kg/sq.cm by "The intermediate rolling shall be done with a
pneumatic tyred roller of 12-15 tonnes weight having nine wheels, with a
tyre pressure of at least 5.6 kg/sq.cm".
Add at the end of 6th para:
"Rolling shall be continued till the density achieved satisfies the
requirements of Clause 903.4.2 and all roller marks are eliminated.
Clause 501.8
PREPARATION OF SURFACE
Clause 501.8.3.4 Laying the Profile Corrective Course

Clause 501.8.3.4.1 This Clause shall read as under:
"The surface on which profile corrective course is to be laid shall be
thoroughly swept clean of dust and any other extraneous material using
mechanical broom and dust collected removed or blown off using
compressed air except in places where mechanical means cannot reach.
22
After preparing the granular surface as in Clauses 501.8.3.1, 501.8.3.2

and 501.8.3.3, the profile corrective course with materials as per Clause
501.8.2.3/501.8.2.4 shall be laid and compacted to the requirement of
particular specification Clause. Where a bituminous profile corrective
course is to be laid over primed granular surface, a tack coat conforming
to Clause 503 shall be applied prior to laying profile corrective course.
Where the profile corrective course is to be laid with Granular sub base
and Wet mix macadam, the existing bituminous layer shall be scarified
completely with out disturbing the existing granular base. The scarified
surface shall be free of loose materials and compacted before laying the
profile corrective course. The laying of profile corrective course with
granular sub-base and Wet Mix Macadam shall be as per clause 401 and
406 and as per drawing.
Clause 501.8.3.4.2 This Clause shall read as under:
"An existing bituminous surface shall be prepared as per Clauses
501.8.3.3 and 501.8.3.4.1. The bituminous profile corrective course shall
be laid after applying tack coat conforming to Clause 503, and compacted
to the requirement of specification Clause."
Clause 503 TACK COAT
Clause 503.8
Rate
This clause shall read as under.
The contract unit rate for tack coat shall be in full for carrying out
the required operations including for all components listed in clause 401.8
(i) to (v) and as applicable to the work specified in these specifications.
The rate shall cover the provision of tack coat at 0.2kg per square metre
for tack coat applied over normal bituminous surface and 0.25 kg per
square metre for tack coat applied over dry/ hungry surface or granular
surface treated with primer, with the provision that the variance in actual
quantity of bitumen used will be assessed and the payment adjusted
accordingly.
Clause 504 BITUMINOUS MACADAM
Clause 504.2
Materials

The Bitumen shall be paving bitumen of Penetration Grade 60/70 as per
Indian Standard Specifications for Paving Bitumen IS: 73
Clause 504.2.2
Coarse Aggregates
i)
Delete the words crushed gravel or other hard material retained

on the 2.36 mm sieve from 2nd line of 1st para.
ii)
Delete the entire para 3 of Clause 504.2.2
23
iii)
From the table 500-3 delete at the bottom of the table *

Aggregate may satisfy requirements of either of these two tests
and modify as under:
* Aggregate shall satisfy both the tests values of Los Angeles
Abrasion Value and Aggregate Impact Value.
Clause 504. 8
Rate
Add the words except for the item of tack coat after the words required
operations as specified in second line.
Add at the end of para The rate shall include the provision of bitumen,
at 3.25 per cent by weight of the total mixture.
Clause 507 DENSE GRADED BITUMINOUS MACADAM
Clause 507.2
Materials

The Bitumen shall be paving bitumen of Penetration Grade 60/70 as per
Indian Standard Specifications for Paving Bitumen IS: 73
Clause 507.2.2
Coarse Aggregates
iv)
Delete the words from 2nd line of 1st para crushed gravel or other
hard material retained on the 2.36 mm sieve.
v)
Delete the entire para 2 of Clause 507.2.2
vi)
From the table 500-8 delete at the bottom of the table *

Aggregate may satisfy requirements of either of these two tests
and modify as under:
* Aggregate should satisfy both the tests values of Los Angeles
Abrasion Value and Aggregate Impact Value.
Clause 507.3.3 Insert the following paragraph between existing paragraph 3 and 4.
Mix design shall be carried out in accordance with the modified Marshall
method described in Asphalt Institute Manual MS-2.
Clause 507.9
Rate
Add the words except for the item of tack coat after the words required
operations as specified in second line.
Clause 509
BITUMINOUS CONCRETE
Clause 509.2.1
This clause shall be read as under:
Bitumen shall be paving bitumen of penetration grade 60/70 as per IS

Specification for paving bitumen IS-73 and bitumen modifier using crumb
rubber (CRMB 55 grade) as per clause 521.
24
Clause 509.2.4
This clause shall read as follows: -
Filler shall consist of finely divided hydrated lime or cement as approved

by the Engineer.
Clause 509.2.5 Aggregate Gradation
Add the note below Table 500-18:
"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 509.9
Rate
This clause shall read as follows: -
The contract unit rate shall be as specified in clause 507.9, except that
the rate shall include the provision of bitumen or modified bitumen at 5.0
percent, by weight of total mixture. The variance in actual percentage of
bitumen or modified bitumen used will be assessed and the payment
adjusted up or down, accordingly.
Clause 511 OPEN-GRADED PREMIX SURFACING
Clause 511.1
Open
Cutback Bitumen
graded
Premix
Surfacing
using
Penetration
or
Clause 511.1.2.1 the clause shall read as under:

The binder shall be paving bitumen of penetration grade 60/70 as per
Indian Standard Specifications for paving bitumen IS: 73.
Clause 521 MODIFIED BINDER
Clause 521.6

This clause read as under
Modified binder supplied in the contract shall not be measured

separately. Bitumen layer using modified bitumen shall be included in the
particular item of works.
Clause 600 CONCRETE PAVEMENT
Clause 601.4
Subgrade
Replace the word subgrade by Wet mix macadam sub-base in the

entire Clause.
Clause 601.5.7
Add the following Clause:
Method 'a' shall be adopted. Wet curing shall be done as soon as the
curing compound has lost its tackiness. This is mainly done to reduce the
temperature of the concrete and avoid temperature induced curling of
slabs.
25
Clause 602.2.3 To be added at the end of the Clause.

"Admixtures containing calcium chloride shall not be used".
Clause 602.3.3.1 The clause is modified as under:
"The pavement quality concrete shall be of M40 grade with a minimum
28 day compressive strength of 40 MPa and a minimum flexural
characteristic strength of 4.0 MPa. Quality control in the field shall be
exercised on the basis of flexural strength. It may, however, be ensured
that the materials and mix proportions remain substantially unaltered
during the daily concrete production. The water content shall be
minimum required to provide the required workability for full
Compaction of the concrete to the required density as determined by
the trial mixes. The maximum free water cement ratio shall be 0.45.
Clause 602.3.3.2 The Clause is modified as under:
The ratio between 7 and 28 days strengths shall be established for the
mix to be used in the slab in advance from results of the design mix
trials. The average flexural strength of the 7 days cured specimens
shall be divided by the average flexural strength of the 28 days cured
specimens for each batch and the 'R' shall be determined to an
accuracy of three decimal places.
If during the construction of the trial length or during normal working,
the average value of any four consecutive 7 day test results divided by
R falls below (4.0 + 1.65 x standard deviation) MPa, then the Contractor
shall stop paving and propose for the approval of the Engineer
corrections to the mix to improve the flexural strength. The Contractor
shall provide evidence, that the proposed corrections result in the
required flexural strength before paving operations may be resumed
and producing minimum six beams with the proposed corrected mix
and testing these for 7 days flexural strength. No additional payment
will be made for any changes to the mix.
Clause 602.5
The clause is modified as under:
A separation membrane shall be used between the concrete slab

(pavement) and dry lean concrete (DLC), as well as DLC and wet mix
macadam.
Separation membrane shall be impermeable plastic
sheeting 125 micron thick laid flat without creases. It shall be white in
colour and transparent. Before placing the separation membrane, the
surface at which it is laid shall be swept clean of all the extraneous
materials using air compressor. Wherever overlap of plastic sheets is
necessary, the same shall be at least 300 mm and any damaged
sheeting shall be replaced at the Contractor's expense. The separation
membrane may be nailed to the lower layer with nails. There shall be
no standing water on or under the separation membrane when concrete
is placed upon it.
Clause 602.6.2.1 Replace the first para as follows:
"Transverse joints shall be contraction and expansion joints.
Contraction joints shall be provided at 4.5 m intervals, except where the
26
expansion joints are provided. Expansion joints shall be provided at the

junction of the approach slabs and bridges and the rigid pavement.
Furthermore, transverse joints shall be provided at special locations like
transitions to structures, transition to flexible pavements, off
carriageway areas as shown on the drawing. The exact position of
transverse joints shall be coordinated with adjoining construction
packages and shall be proposed by the Contractor in writing for the
approval of the Engineer. Transverse joints shall be straight within the
following tolerances along the intended line, which is the straight line
perpendicular to the longitudinal axis of the carriageway at the position
of the joint".
Clause 602.6.4.3 Add a new sub clause as under:
602.6.4.3 Joints at the junction of rigid and flexible pavements:
Joints shall be provided at the junction of rigid and flexible pavement as
shown in drawing.
Clause 602.9.1 Add new paragraph at the end as follows:
"Paving shall be laid in full lane width.
Clause 602.10.2 Add new paragraph at the end.
"All trials shall be carried out using the same paving width and slab
thickness as used in the permanent works.
Clause 602.10.5.3 The Clause shall read as under:
In-situ density shall be assessed as described in Clause 903.5.2.2 from
at least 3 cores drilled when the concrete is not less than 7 days old.
Should any of the cores show honey-combing in the concrete, the trial
length shall be rejected and further use of the spreading and
compacting unit shall not be permitted until further trials have shown
that modification can be made which will result in adequate
Compaction.
Clause 602.10.5.5 Add a new sub clause as under:
602.10.5.5 Temperature Measurements:
The temperature
development in the concrete slab during the hardening shall be
recorded. The temperature shall be measured in the middle of the slab
(vertically) at a horizontal distance of at least 100 mm from any free
edge.
The temperature shall be recorded every 3 hours and
temperature-age relationship shall be determined.
The maximum
recorded temperature shall not exceed 70C. If the temperature
exceeds 70C the trial length shall be condemned and the Contractor
shall propose methods to reduce the temperature development and
carry out a new trial length at his own expense.
Clause 602.11.3.1 Replace the first sentence with the following:
When sealant are applied, an appropriate primer recommended by the
manufacturer
shall
be
applied
in
accordance
with
their
recommendation.
27
Clause 602.13 The clause shall read as under:

No vehicular traffic (including Contractor's vehicles) shall be allowed
on the finished surface until a field flexural strength of minimum 4.0
MPa has been achieved and until the joints are permanently sealed. It
is the responsibility of the Contractor to produce a sufficient number of
series of test specimens to verify the field flexural strength.
Each series of test specimens for measurement of field flexural strength
shall consist of minimum 3 test specimens. The specimens shall be
cured at conditions similar to the field conditions. The method for
curing and storing of the test specimens in order to simulate field
conditions shall be proposed by the Contractor and approved by the
Engineer. Prior to opening the road to vehicular traffic the areas
adjacent to the pavement shall be completed to a degree that will
ensure traffic safety. Opening to traffic shall not constitute a final
acceptance of the pavement.
Clause 602.16 Add at the end of existing Clause.
This will also include the cost of supplying and laying of separation
membrane as per drawing and technical specification Clause 602.5.
Clause 801
TRAFFIC SIGNS
Clause 801.1.2
This clause shall read as under;
"All road signs shall be of retro-reflectorised type and made of high

intensity grade with encapsulated lens type reflective sheeting vide
Clause 801.3, fixed over aluminum sheeting as per these specifications."
Clause 801.5
Add as well as other informatory / any other types of signs after
the words for direction and place identification signs in the third line.
Clause 803
ROAD MARKINGS
Clause 803.3
Deleted.
Clause 804 HECTOMETRE/KILOMETRE STONES

Clause 804.3
The first sentence of this Clause shall read as under:
"The hectometre/kilometre stones shall be made of concrete of grade as

shown in the drawing".
Clause 901
GENERAL
Clause 901.1 This clause shall read as under:

"All materials to be used, all methods adopted and all works 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
as well as qualified and experienced personnel in order to carry out all
required tests and Quality Control work as per Specifications and/or as per
28
Clause 121 and/or as directed by the Engineer. The list of laboratory

equipment and the facilities to be provided shall be as per Clause 121 and
shall be got approved from the Engineer in advance.
Clause 901.5 This Clause shall read as under:
"The Contractor shall provide necessary cooperation and assistance in
obtaining the samples for tests and carrying out the field tests as required
by the 'Engineer' from time to time. This may include provision of
laboratory, equipment, transport, consumables, personnel, including
labour, attendants, assistance in packing and despatching and any other
assistance considered necessary in connection with the tests."
Clause 903
QUALITY CONTROL TESTS DURING CONSTRUCTION
Clause 903.4
Tests on Bituminous Constructions
In Table 900-4, serial No.6 (xviii) for Density of compacted layer for Dense
Bituminous Macadam/Semi Dense Bituminous Concrete/Bituminous
Concrete add the following at the end in the frequency column:
"10% of the density tests shall be done on edges."
Clause 1006
CEMENT
The existing Clause shall be deleted and replaced with the clause 302.1 of
IRC 21-2000
Clause 1007
COARSE AGGREGATES
(i)
Delete from the first sentence crushed gravel.. insert

material appearing in 4th and 5th line.
(ii)
Add the following at the end of the Clause:
"Primary and secondary stone crusher should be employed for getting

proper size and grading of coarse aggregates."
Clause 1009.2 Steel for Prestressing
This clause shall read as under:
All prestressing steel shall be of uncoated stress relieved low relaxation
seven-ply class 2 strand conforming to IS: 14268
Clause 1009.3 Reinforcement/Un-tensioned steel
Add the following below Table 1000-3:
Note: Thermo Mechanically Treated (TMT) Bars with minimum yield
stress of 415 MPa satisfying requirements of IS: 1786 can also be used
Clause 1014
STORAGE OF MATERIALS
Clause 1014.3 Aggregates

29
The following shall be added to this Clause:

"Aggregates shall be stored or stockpiled in such a manner that
segregation of fine and coarse sizes will be avoided and also that the
various sizes will not become intermixed before proportioning. They shall
be stored, stockpiled and handled in such a manner that will prevent
contamination by foreign materials."
Section 1100
Clause 1101.2
PILE FOUNDATIONS
Add the following at the end of clause 1101.2:
Relevant details of proprietary system of piling shall be included in the

bid documents (Refer Schedule: Proprietary Product and Process
Information of Bid Documents) and shall be subject to the approval of the
Engineer.
The Contractor in his methods statement shall include the procedure for
carrying out initial and routine tests of piles including design calculations
and drawings. The format for reporting test results shall be included in
the methods statement.
Clause 1101.4
Add the following sub-clause
1101.4 Scope of Work

The scope of work shall comprise of the following:
a) Providing all materials including concrete, reinforcing steel, labour,
equipment and other incidentals for installation of cast-in-situ bored
piles.
b) Initial and routine testing of piles.
c) Integrity testing of piles as per additional specifications provided in
Appendix-4 of this Bid Document.
d) Provision of access to movement of Equipment, barricading where
necessary, pollution control measures including measures to control
noise to minimum acceptable levels and site clearance.
Clause 1503
Clause 1503.2
DESIGN OF FORMWORK
The following shall be added to this Clause
"For distribution of load and load transfer to the ground through staging,
an appropriately designed base plate must be provided which shall rest
on firm sub-stratum".
Clause 1509
RE-USE OF FORMWORK
This Clause shall read an under:

30
"After forms are stripped, all materials to be reused shall be thoroughly

cleaned. Holes bored through sheathing for form ties shall be plugged by
driving in common corks or foamed plastics. Patching plaster may also be
used to fill small holes. After cleaning and before refixing, each formwork
shall be got approved from the Engineer.
Formwork and staging shall be so used so as to maintain quality of the
exposed surface. However, if in the opinion of the Engineer, any particular
panel/member has become unsatisfactory for use at any stage, the same
will be rejected.
All bent steel props shall be straightened before reuse. The maximum
deviation from straightness is 1/600 of length. The maximum permissible
axial loads in used props shall be suitably reduced depending upon their
condition.
Clause 1703
GRADES OF CONCRETE
Add the following at the end of this Clause.

The concrete mixes leaner than M15 shall be called as nominal mix
concrete.
Nominal mix concrete is that concrete for which, concrete is not to be
designed by tests and in which the proportions of materials are in
accordance with the drawing and the specification clause mentioned
below:
i)
All the materials for this concrete shall conform to section 1000
of MORT&H
ii)
Minimum cement content and maximum water cement ratio

for above said nominal mix concrete shall conform to clause
1703.2 Table 1700-3(A) of MORT&H
iii) Mixing of above said nominal mix concrete shall conform to

Clause 1708 of MORT&H
iv) Transporting, Placing and Compaction of above said nominal
mix concrete shall conform to clause 1709 of MORT&H.
The Table 1700-1 shall read as under
Grade Designation
M15
M20
M25
M30
M35
M40
M45
M50
M55
M60
Specified
characteristic
compressive
strength
of
150mm cubes at 28 days, in
Mpa
15
20
25
30
35
40
45
50
55
60
31
Clause 1704
PROPORTIONING OF CONCRETE
Add the following at the end of this Clause.
"In proportioning concrete, the quantity of both cement and aggregate

shall be determined by weight. Where the weight of cement is determined
by accepting the manufacturer's weight per bag, a reasonable number of
bags shall be weighed separately to check the net weight. Where cement
is weighed from bulk stock at site and not by bag, it shall be weighed
separately from the aggregates. Water shall either be measured by
volume in calibrated tanks or weighed. All measuring equipment shall be
maintained in a clean, and serviceable condition. Their accuracy shall be
periodically checked".
"It is most important to keep the specified water-cement ratio constant
and at its correct value. To this end, moisture content in both fine and
coarse aggregates shall be determined as frequently as possible,
frequency for a given job being determined by the Engineer according to
the weather conditions. The amount of mixing water shall then be
adjusted to compensate for variations in the moisture content. For the
determination of moisture content in the aggregates, IS: 2386 (Part III)
shall be referred to. Suitable adjustments shall also be made in the weight
of aggregates to allow for the variation in weight of aggregates due to
variation in their moisture content".
The Table 1700-5 shall read as under
Concrete Grade
Current Margin
(MPa)
Target Mean
Strength (MPa)
M15
10
25
M20
10
30
M25
11
36
M30
12
42
M35
12
47
M40
12
52
M45
13
58
M50
13
63
M55
14
69
M60
14
74
Clause 1704.4 Additional Requirement

In para (a) substitute "0.06%" for "0.1%", "0.06%" for "0.2%; and: 0.1%"
for "0.3% for the three items respectively.
Clause 1705
ADMIXTURES

"Duly tested admixtures/additives conforming to IS: 6925 and IS: 9103
(without replacement of cement) may be used subject to satisfactory
proven use, with the approval of the Engineer. Admixtures generating
32
Hydrogen or Nitrogen and containing chlorides, nitrates, sulphides,

sulphates and any other material liable to affect the steel or concrete
shall not be permitted."
"The general requirements, physical and chemical requirements shall be
as per Clause 1012."
Clause 1706
Size of Coarse Aggregate
Table 1700-7 in this clause shall read as under:

__________________________________________________
Components
Maximum Nominal
size of coarse
Aggregate (mm)
_________________________________________________
i) RCC well curb
20
ii) RCC/PCC well steining
40
iii) Well cap or pile cap
40
Solid type piers & abutments
iv)
RCC work in girders, slabs,
20
Kerb, approach slab, piers
And abutments, pier/abutment
caps, piles
v)
PSC work
20
vi)
PCC in bottom plug and top
40
Plug/intermediate plug
vii)
RCC work in wearing coat
12.5
and handrails
viii)
Any other work
As specified or
as directed by
the Engineer
___________________________________________________
Clause 1707
EQUIPMENT
Para 1 of this Clause shall read as under:

"Unless specified otherwise, equipment for production, transportation and
Compaction of concrete shall be as under":
a) For production of concrete.
i)
"Batching and mixing of the concrete shall be done only in a

concrete batching and mixing plant fully automatic with a
minimum capacity of 30 cum. per hour. The plant shall be
approved by the Engineer".
ii)
In special cases, for culverts, the Engineer may allow mixing

of concrete by a diesel or electrically operated mechanical
mixer with integrated weigh batching facility having a
capacity of 500 litres and automatic water measuring
system."
Para 3 of this clause shall read as under:
33
Measurement of cement
+ 3 percent of quantity of cement

in each batch
Measurement of water
+ 3 percent of quantity of water
in each batch
Measurement of aggregate
aggregate in each
+ 3 percent of quantity of
batch
Measurement of admixture
+ 3 percent of quantity of
admixture in each
batch.
Clause 1709
Transporting, Placing and Compaction of Concrete
Add the following paragraph at the end of 2 nd para of clause 1709.
For placing Concrete with Pumps: Pipe Lines from the pump to the
placing area should be laid out with minimum bends. For large concrete
placements standby pumps shall be available. Suitable valves (air
release valves, shutoff valves etc.) shall be provided as per site needs.
The pumping of concrete shall be preceded by a priming mix to
lubricate the pump and pipeline. A rich mix of creamy consistency shall
be required for lubricating the pipelines. Continuous pumping shall be
done to the extent possible. After concrete has been placed, the
pipelines and all related equipment shall be cleaned immediately. A
plug sponge ball shall be inserted in the end near the pump and shall
be forced through the line by either water or air pressure. Pipes for
pumping should not be made from materials which can harm concrete;
aluminium alloy pipelines shall not be used.
Clause 1713
PROTECTION AND CURING
Clause 1713.1
Water Curing
Add the following at the end of para (i).

"Wherever possible, use of water sprinklers or perforated pipes should be
encouraged for curing of concrete. Such arrangement must be
maintained for a minimum period of 14 days after concreting."
"Approved concrete curing compounds shall be preferred where water
curing cannot be done reliably".
Clause 1714
FINISHING
Add the following:
Painting
This work also consists of applying painting to the bridge and retaining
wall surfaces where special formwork has been used as presented in
Section 1510: Specialized Formwork of these supplemental technical
specifications.
Material
Paint for concrete shall consist of a single coat application of epoxy at a
thickness of 80-100m dry, as approved by the Engineer.
Paint for steel railing shall consist of a primer coat of metal primer at a
rate of 35-45m dry; an intermediate coat of exterior latex or alkyd at 35Draft Detailed Project Report (Volume V: Technical Specifications)
34
50m dry; and a finish coat of exterior latex or alkyd at 35-50m dry, as
approved by the Engineer.
Construction Requirements
Refer to Section 1906. Notify the Engineer in writing at least 7 days
before beginning operations. Protect adjacent surfaces hat are not to be
painted by using tarps, screens, paper, cloth, or other suitable means.
Prevent contamination of freshly painted surfaces by dust, oil, grease, or
other harmful or deleterious material.
Immediately before painting, prepare the surface according to the
following:
(a) Clean the surface to the specified cleanliness level.
(b) Remove dirt, dust, and other contaminants from the surface using
methods recommended by the paint manufacturer.
(c) Thoroughly dry the surface.
(d) Determine that the surface temperature is between 10 and 40 C.
(e) Determine that the surface temperature is 3 C or more above the
dew point.
(f) Determine that the humidity is 85 percent less, unless specified
otherwise on the manufacturer's product data sheet.
Paint Application
Use safe handling practices that conform to the manufacturer's safety
data sheet and instructions. Mix and apply paint according to the product
instructions. Mix paint with mechanical mixers for a sufficient length of
time to thoroughly blend the pigment and vehicle together. Continue the
mixing during application. Do not thin paint that is formulated ready for
application.
Paint in a neat and workmanlike manner that does not produce excessive
paint build-up, runs, sags, skips, holidays, or thin areas in the paint film.
Measure the wet film thickness during application and adjust the
application rate such that, after curing, the desired dry film thickness is
obtained. Apply paint by brush, spray, roller, or any combination thereof if
permitted by the manufacturer's product data sheet.
Use brushes that have sufficient bristle body and length to spread the
paint in a uniform film. Use round, oval shaped brushes, or flat brushes no
wider than 120 millimeters. Evenly spread and thoroughly brush out the
paint as it is applied.
Use airless or conventional spray equipment with suitable traps, filters, or
separators to exclude oil and water from the compressed air. Use
compressed air that does not show black or wet spots. Use the spray gun
tip sizes and pressures recommended by the manufacturer.
Use rollers only on flat, even surfaces. Do not use rollers that leave a
stippled texture in the paint film.
Use sheepskin daubers, bottle brushes, or other acceptable methods to
paint surfaces that are inaccessible for painting by regular means.
35
Cure each coat of paint according to the manufacturer's

recommendations. Correct all thin areas, skips, holidays, and other
deficiencies. The Engineer will approve the color before application.
Remove all laitance, dust, foreign material, curing compound, form oil,
grease or other deleterious material from the concrete surface.
Remove form oil, grease, or curing compound by washing with a 5
percent solution of trisodium phosphate and rinsing with clean water.
Allow the surface to dry completely.
Give the cleaned surface a light abrasive sweep to remove mortar wash
or other contaminants. Remove all residue and dust by hand, broom,
compressed air or other approved methods.
Apply the coating. Evenly spread and thoroughly work the paint into all
corners and recesses.
Payment
The accepted quantities will be paid at the contract price per unit of
measurement for pay items listed in the bid schedule. Payment will be full
compensation for the work prescribed in this Section.
Clause 1802
MATERIALS
Clause 1802.2
Sheathing
Clause 1802.2.1 Delete para 1 to 4 of this sub clause and replace as under:
The sheathing ducts shall conform to clause 3.6 of IRC: 18 as per design
consideration & tender drawings drawings.
Clause 1806
TENSIONING EQUIPMENT
Add the following at the end:

"Before initial use and subsequently at suitable intervals, the prestressing
equipment shall be checked to determine any variation from the normal
values during use.
So far as these variations depend upon external influence (e.g.
temperature in the case of oil jacks) they shall be taken into account".
Clause 2006
POT BEARINGS
Clause 2006.1.1
Add the following at the end
Contractor shall furnish the design and the detailed drawings of the
bearing based on the load data provided in the drawing for approval of
the Engineer prior to commencement of the work.
Clause 2009
MEASUREMENTS FOR PAYMENT
Add the following after para 2.

36
"Paper bearings shall be measured in square meters".

Clause 2504
Pitching/Revetment on Slopes
The heading of this clause shall read as under:

Pitching/Revetment on slopes and filter media.
Clause 2706
WEEP HOLE
This clause shall read us under:

"Weep holes shall be provided in solid plain concrete/reinforced concrete,
brick abutments, earth retaining walls, wing walls, return walls, retaining
walls as shown in the drawing or as directed by the Engineer to drive out
moisture from the back filling. Weep holes shall be provided with 100 mm
dia PVC pipe and shall extend through the full width of concrete with
slope of about 1 vertical : 20 horizontal towards the earth face.
The spacing of weep holes shall generally be 1m in either direction or as
shown in the drawing with the lowest at about 150 mm above the low
water level or ground level whichever is higher or as directed by the
Engineer".
37
SPECIAL TECHNICAL SPECIFICATIONS

B.
ADDITIONAL SPECIFICATIONS FOR PARTICULAR ITEM OF WORKS NOT

COVERED IN GENERAL TECHNICAL SPECIFICATIONS I.E. THE
"SPECIFICATIONS FOR ROAD AND BRIDGE WORKS (LATEST REVISION,)
Appendix - 1
ADDITIONAL SPECIFICATION FOR RECYCLING OF BITUMINIOUS PAVEMENT
S-1.0 GENERAL
This work shall consist of processing, laying and compaction of the blended
materials of reclaimed asphalt pavement (RAP) and virgin aggregate on
prepared subgrade in accordance with the requirements of these
Specifications.
This work will include removal and reprocessing of existing asphalt pavement,
blending with conventional granular aggregate, spreading, shaping,
compacting and maintaining the blended sub-base course material to the
proper grade, line and cross-sections as shown on the Plans and as provided
herein, unless otherwise directed by the Engineer.
S-1.1 MATERIALS
The blended material shall meet the following gradation:
Sieve Size
Percent Passing (by
weight)
75 mm
100%
45 mm
90-100%
26.5 mm
55-75%
4.75 mm
10-30%
0.075mm
<10%
CBR Value (Minimum %)
30
If it is necessary to add conventional aggregates in order to meet the
established gradation, CBR, gradeline and cross-section, the aggregate
material shall consist of either 100 percent salvage bituminous material or
reclaimed asphalt pavement mixed with conventional aggregate (which meets
the above gradation requirements and is approved by the Engineer)
S-1.2 CONSTRUCTION REQUIREMENTS
A.
EQUIPMENT REQUIREMENTS
A1
Reclaiming Machine
The removal of asphalt pavements involves ripping and breaking the
pavement using scarifiers, grid rollers, rippers, rhino horn on a bulldozer
and/or pneumatic pavement breakers or any other suitable equipment. The
machine shall be approved by the Engineer prior to the start of the operation.
38
A2
Stationary Plants
To produce a homogeneous mix of reclaimed asphalt pavement and
conventional aggregate to use as a granular sub-base, it requires crushers,
screening units, conveyors and a batch, drum, or continuous type mixing plant
attached with the water pumps.
A3
Rollers
As per Clause 401.4.2 of MORT&H .
(B)
PROCESSING OF RECLAIMED MATERIALS

Reclaimed materials for central plant should be obtained by ripping and
crushing operations. The scarifiers or rippers or grid rollers or any other
approved machine shall be used to break up the existing asphalt pavement.
The removed materials shall be loaded and hauled for crushing to the required
size .The reclaimed bituminous pavement material shall be stockpiled with the
height of stockpiles not exceeding 3 m. The reclaimed untreated aggregate
base/sub-base material shall be stockpiled in the same manner as new
aggregate. The number and location of stockpiles shall be carefully planned
for efficient operation of the central plant.
The Contractor shall take care to avoid disturbing or damaging any existing
drainage or utility structures on the Project. Any damage resulting from the
Contractors operation shall be repaired by the Contractor at no expense to
the Department.
(C)
GRADING AND SPREADING

The reclaimed material shall be spread and compacted to the grade, width
and slope shown on the Plans and typical cross-sections or as directed by the
Engineer.
(D)
COMPACTION
Compaction of each layer of the reclaimed mixture shall be by the Quality
Compaction Method as mentioned in Clause 401.4.2 of MORT&H.
Water shall be added prior to and during compaction as required.
A minimum 200 to 300 kN weight pneumatic-tired roller with 0.7 MN/m2 tire
pressure or 80 to 100kN pads foot vibratory roller shall be used for the initial
rolling and a vibratory or static smooth steel-wheeled roller for intermediate
and/or finished rolling.
The maximum layer thickness for compaction shall be 150 millimeters
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).
(E)
SURFACE FINISH AND QUALITY CONTROL OF WORK
39
As per Clause 401.5 of MORT&H.

S- 1.3ARRANGMENTS FOR TRAFFIC
S-1.4 MEASUREMENT FOR PAYMENT
S-1.5 RATE
The Contract unit rate for granular sub-base shall be payment in full for
carrying out the required operations including full compensation for
(i)
Making arrangements for traffic to Clause 112 except for initial

treatment to verges, shoulders 'and construction of diversions;
(ii)
Furnishing all materials to be incorporated in the work including all

royalties, fees, rents where necessary and all leads and lifts;
(iii)
(iv)
All labour, tools, equipment and incidentals to complete the work to the
Specifications including the dismantling of existing pavement making
stockpiles and reclaim the materials at plant as per specification: Carrying out the work in pan widths of road where directed-, and
(v)
Carrying out the required tests for quality control.
40
Appendix - 2
ADDITIONAL SPECIFICATION FOR COHESIVE-NON-SWELLING SOIL LAYER (CNS)
1.0
GENERAL
A cohesive-non-swelling soil layer (CNS) of varying thickness shall be
provided, based on swelling pressure, all round the open foundation, to
counteract shrinkswell characteristics and to retain the shear strength of the
expansive soils. This layer shall also serves as an impervious blanket and a
surface grading around the foundation to prevent infiltration of surface water.
2.0
MATERIALS AND GENERAL REQUIREMENTS

The basic requirement of CNS soil is that it should be clayey soil, with certain
cohesion but having no expansive characteristics. The properties of the CNS
material should generally conform to the following:
Sl.
No.
1.
2.
3.
4.
5.
Property
Grain size analysis
(i)
Clay
(ii)
Silt
(iii)
Sand
(iv)
Gravel
Consistency limits
(i)
Liquid limit
(ii)
Plastic limit
(iii)
Plasticity index
(iv)
Shrinkage limit
(a) Swelling pressure, when compacted to maximum
dry density, corresponding to standard Proctor
compaction and zero initial compaction moisture
content, for no volume change condition.
(b) Swelling pressure, when compacted to maximum
dry density, corresponding to standard Proctor
compaction
and
initial
compaction
moisture
corresponding to optimum moisture content, for no
volume change condition.
Clay minerals
Shear strength of compacted sample, compacted to
maximum dry density corresponding to modified
Proctor compaction and initial moisture content
corresponding to optimum moisture content, but
sample tested on saturation.
(a) From unconfined compression (UCS).
0.5*UCS
(b) From consolidated undrained direct shear test Ccu
Specifications
Range
15-25%
35-50%
30-40%
<=10%
30-50%
20-25%
10-25%
15% and above
Less than 0.1
kg/cm2 (10 kN/m2)
Less than 0.05

kg/cm2 (5 kN/m2)
Preferably Kaolinite
and illite
> 0.45 kg/cm2 (45

kN/m2)
> 0.4 kg/cm2 (40
kN/m2)
41
cu
> 10
The suitability of the soil from the identified borrow areas shall be examined
based on laboratory tests to ascertain its properties. In case suitable material
are not available from natural resources, CNS may be prepared on site by
mixing natural expansive clays with (river) sand or lime or (river) sand and
lime both. Excavated soil within enclosed boundaries, preferably from depths
beyond 30cm, should be used for synthesized CNS material.
The degree of severity and expansion of the top layer is summarized in Table
3.0. The table also illustrates the minimum thickness of CNS layer shall be
provided along with its minimum shear strength for each structure. The type
of treatment for structures, not covered in Table 3.0, shall be similar to that of
adjacent structure or as decided by Engineer depending on the specific site
condition.
3.0
QUALITY CONTROL AND ASSURANCE

A detailed laboratory-testing programme shall be undertaken to design such
proportions and to confirm that the engineered material meets the required
specifications for use of CNS material. The above confirmatory tests as listed
in clause 2.0 shall be conducted in every 1000 cum of CNS material whether it
is obtained naturally or by artificial synthesizing. In any case, the end product
must conform to the specifications. It should be ensured that the CNS material
does not contain deleterious materials, sulphates and chloride beyond
permissible limit as specified in clause 305.2 of MORT&H. Plate load test may
be conducted as directed by the Engineer as per IS: 1888 at the proposed
founding depth on the laid CNS layer at locations of open foundations to
confirm the load bearing capacity. If plate load test results do not fulfill the
structural requirement, either lime stabilization or mechanically stabilized mix,
can be adopted to strengthen the founding layer.
4.0
CONSTRUCTION REQUIREMENTS
The compaction of CNS layer shall be in accordance with MORT&H
specification. The CNS layer should be firmly bonded at the interface of the
CNS and expansive soil through provision of serrations in the expansive soil
base and through compaction of the interface layers. Before placement of the
CNS material, the surfaces of the excavation to receive CNS should be
thoroughly wetted to a depth of 150mm. CNS of 25cm loose thickness shall
preferably be compacted at its optimum moisture content or slightly on the
drier side of optimum, but not lower than 1% to at least 95% of the maximum
dry density as determined by the Modified Proctor Test (IS: 2720, Part 8).
In case, in-place expansive soil is used, the excavated soils of around 15cm
loose thickness should be dried and pulverized on the drying bed. The soil has
to be scarified uniformly and continuously prior to measuring the loose density
of air-dried pulverized soil. Five trials should be carried out to determine the
42
average loose density by raindrop method or any other suitable method of the
air-dried pulverized soil. Similarly the sand should be spread loosely on the
drying bed to a thickness of 20cm and allowed to dry and continue to scarify
uniformly and thoroughly. The loose density of the air-dried sand should be
evaluated as explained above. The lime, if required to be mixed should also be
dried and sieved to remove clods. The sand of uniform thickness shall be
stacked at working place corresponding to its mix design weight, using the
weight: volume relationship. Required amount of lime to the total weight of
mix shall be added to sand (if mix design includes sand) or to excavated soil.
The quantity of water to be added to the soil-lime mix should be slightly more
than the optimum to account for curing of lime and evaporation losses. Airdried pulverized soil corresponding to its proportion by weight, using weight:
volume relationship shall be placed uniformly on top of the sand lime. The
overall thickness of the composite shall be limited to 15cm. Before
commencing the compaction by vibratory rollers or any other suitable
compactor, the entire mix shall be thoroughly and uniformly scarified
alternately along longitudinal and transverse directions to the satisfaction of
the Engineer.
Before placing the second layer of CNS the top surface of the earlier layer
should be scraped. In-situ density shall be checked for CNS, at least, at two
places, as identified by the Engineer in each foundation location.
If any part of the road is running through cut section where subgrade is in
contact or in the vicinity of expansive soil, either complete removal of such
soil or minimum 0.75m removal and replacement with compacted CNS layer is
recommended depending on the specific site condition.
To minimize the effect of expansion in general, construction of foundation can
be scheduled to take up during or immediately after prolonged rainy period
when there will be less potential of volume change in the future.
5.0
MEASUREMENT FOR PAYMENTS AND RATES

Measurement for payment of CNS layer shall be made in cubic meter. Plate
load test shall be measured in number.
6.0
RATES
The contract unit rate for CNS layer includes the cost of providing specified
material, transporting, laying, compacting, quality control and assurance etc.
all complete to the satisfaction of Engineer. The rate shall be in accordance
with clause 305.9 of MORT&H Specification wherever relevant.
43
Appendix 3
ADDITIONAL SPECIFICATION FOR TREATMENTS TO COUNTERACT CHEMICAL
ATTACKS ON STRUCTURES
1.0
Introduction
In order to ward off the damaging effects of chemically aggressive ground
water and sub-soil on the foundations, sub-structures etc., various treatments
shall be undertaken based on the presence of pH, chloride and sulphate
content. This additional specification provides a broad guideline about the
treatment methods to counteract the chemical attacks on foundation.
2.0
General Requirement
In general, impermeable and dense non-porous concrete is the best protection
and pre-requisite against any chloride and sulphate attack and therefore a
quality workmanship during construction should be maintained at all stages.
The treatments that need to be assigned against chemical attacks are
specified below:
1. Preferably, Portland Slag Cement conforming to IS: 455 having more than
50% slag should be used in cases where ground water is found to exist in
the vicinity of foundation and chloride content in water is more than
2000mg/ lit. Ordinary Portland cement with C 3A content 5 8% can also
be used as an alternative. Barring this condition, ordinary Portland
cement is recommended for foundations and pile caps.
2. Concrete should contain a minimum cement content of 350 kg/cum with a
maximum free water cement ratio of 0.45 where moderate chloride
exposure along with class 2 or 3 sulphate exposure is expected. For only
class 2 sulphate-attack minimum cement content and maximum free
water cement ratio shall be 330 kg/ cum and 0.5 respectively. However,
provisions in IRC: 21- 2000 and IRC: 78- 2000 regarding minimum cement
content and water cement ration for specific structural part shall be
referred and whichever is more conservative shall be adopted.
3. Wherever chloride content in water is more than 3000 mg/ lit, CRS
reinforcement bar shall be used. TMT bar/ fusion-bonded epoxy coated
HYSD reinforcing bar should be considered at locations where chloride is
within 2000 3000 mg/ lit. Otherwise, HYSD reinforcement bar is
suitable. In general, the reinforcement bar should be clean, free from rust
or chloride.
4. A clear concrete cover over the reinforcement steel of at least 75mm
should be provided for all foundations irrespective of chloride and
sulphate exposure.
5. Adequate and timely curing should be arranged in order to minimize
cracking and consequent ingress of moisture.
44
6. A good mix design should be formulated thereby avoiding harsh mixes,

those leading to bleeding, or those lacking in fines. It is essential to limit
total chloride in the mix (i.e. aggregates, cement, mixing water and
admixtures) to a value less than the value that promotes corrosion at the
initial stage itself.
7. Thorough and adequate vibration using vibrator should be ensured while
placing the concrete for proper densification.
8. Air-entraining agents or other mineral admixtures (plasticisers) may be
introduced to increase workability within a period of time and thereby
permit reducing the water content, which can lead to higher strength and
denser and less permeable concrete. Calcium carbonate should never be
used in prestressed / reinforced concrete and in embedded concrete.
9. Excavation of soil of at least 500mm shall be done all-round the open
foundation/ pile cap where ground water was encountered within 10.0m
depth and backfilled with proper compaction in layers by approved soil
(same used for CNS layer) having permissible chloride content.
10.For open foundation/ pile cap, overlay of watertight concrete of 50mm thick
shall be provided. Portland cement mortars containing styrene
butadiene latex shall be used for this purpose. Typically, concrete
mixtures used for overlay should be of low slump, very low water/ cement
ratio (made possible by adding superplasticizing admixture), and high
cement content.
The specific measures against each structure are indicated in Table 3.0 based
on foundation type and depth, position of ground water table, concentration of
chloride and sulphates, sensitivity of the structure etc and the numbers (1, 2,
3 etc.) indicated in the column for measures against chemical attack in the
said table correspond to those given above in this section. The type and
quantum of cement, w/c ratio, slump requirement, extent of cover etc. are all
enumerated in the table and the treatment shall therefore be selected
referring to the structure member. The structures, which are not covered in
the above table or whose results are not furnished, the more conservative
treatment proposed in the vicinity, shall be considered.
3.0
Construction Requirements
The Contractor shall submit a detailed methodology for each structure as
regards to protection works against chemically active water and soil for the
approval of Engineer. The type of measures as listed in Table 3.0, shall be
followed unless otherwise directed by Engineer. The Contractor shall depute a
Specialist in Concrete Technology for designing an appropriate concrete mix
commensurate to the project requirement. The quality control and assurance
for concrete and reinforcement shall generally be in accordance with the
relevant clause of MORT&H Specification.
4.0
Measurements & Payments
45
The all Precautions or measures taken to avoid Chemical attack are incidental
to the work of respective items except for Sl. No 3 of subheading 2.0 General
Requirement, for this measurement will be taken separately and paid as extra.
The mode of measurement as per MORT&H clause no 1608.
46
APPENDIX-4
Special Specification for Fabrication and Erection of Steel Portion of
Foot Over Bridge (FOB)
This additional specification replaces whole section 1900 of MORT&H
General
This Specification is intended mainly to cover technical provisions relating to
fabrication and erection of steel girder portion of composite girder bridges
including supply of related materials.
2.
Responsibility for Completeness
2.1
The Contractor shall be entirely responsible for the execution of the

contract in all respects in accordance with the terms of this Specification
and the conditions of contract, notwithstanding any approval, which the
Engineer may have given to the detailed drawings prepared by the
Contractor or Sub-Contractor for materials or other parts of the work
involved in the contract or for tests carried out, either by the Contractor or
by the Engineer.
2.2
Any fitting, accessory or apparatus which may not have been mentioned in
this Specification, but which are usual or necessary in the execution of
such work, are to be provided by the Contractor without any extra charge
whatsoever. The whole work must be completed in all details, whether
mentioned in this Specification or not.
3.
Execution of work through other agencies
3.1
Before ordering of work to other agency, the Contractor shall submit the
names and credentials of the proposed Sub-Contractors for the approval of
the Engineer. The Contractor shall be responsible for all the work executed
by his agency. Such work shall be inspected and verified by the Engineer
or his authorized representative.
4.
Stacking Materials
On receipt of materials, these shall be carefully unloaded, examined for
defects, checked, sorted and stacked securely on a level bed out of danger
from flood or tide and out of contact with water or ground moisture. All
material shall be available for inspection by the Engineer.
4.2
Any material found damaged during transit or while unloading should be

stacked separately and damaged portions shall be indicated by paint with
distinctive colour. If any component after receipt at site, has in the opinion
of the Engineer, been damaged in transit, such component shall be
replaced or repaired to the satisfaction of the Engineer free of cost.
4.3
All such damaged material shall be dealt with as per the orders of the
Engineer without any delay. Badly damaged portions may require
replacement. Slightly distorted parts may be straightened by gradual
47
pressure without heat or annealing. Badly distorted or broken parts must

be dealt with as the case demands and as directed by the Engineer.
4.5
4.6
The Contractor shall unload the material promptly on delivery; otherwise

he shall be responsible for demurrage charges.
On receipt of rolled steel at workshop or fabrication yard they shall be
carefully unloaded and stacked properly to avoid bending, twisting,
corrosion etc.
5.
Leading to Site
Care must be taken by the Contractor to see that the parts at site are available
in proper sequence.
6.
Lines and Levels
All lines and levels should be given by the Engineer and all stakes and marks so
given shall be carefully preserved by the Contractor who shall give all
necessary assistance and facilities to establish or check the lines and
levels and to measure the work.
7.
Steel
7.1
IS: 2062 Grade "B" fully killed and normalized/controlled-cooled shall be

used for steel girder portion of the composite girders. Plates less than 12
mm thick need not be normalized/controlled-cooled.
NOTE: Rolled sections like angles, channels, I-sections etc., conforming to
IS: 2062 Grade "A", may be used in structures till such time rolled sections
conforming to IS: 2062 Grade B are not available in the market. The
contractor shall have to submit a certificate from SAIL regarding the nonavailability particular rolled sections conforming to IS: 2062 Grade B
7.2
Materials and fabrication for all High Strength Friction Grip bolts, nuts and
washers shall conform to IS: 4000, IS: 3757, IS: 6623 and IS: 6649.
7.3
All High Strength Friction Grip bolts, nuts and washers shall conform to
property class 8.85 Hot Dip Galvanized as specified in IS: IS: 3757.
7.4
Steel for drifts shall be in accordance with IS: 1875 for forged quality steel
or IS: 7283 for hot rolled bars.
7.5
Steel for rivets shall comply with the requirement of IS: 1148 for hot rolled
rivet bars for general structural purposes and IS: 1149 for high tensile
steel rivet bars for high strength structural purposes.
7.6
The dimensions of all rolled sections must be as per approved drawings.
7.7
The rolling and cutting tolerances shall be in accordance with IS: 1852 or
as approved by the Engineer.
7.8
All the steel sections used in the fabrication must have mill test certificate
clearly indicating the specification to which the steel conforms and
48
whether steel is killed and normalized. All the cast mark numbers/heat
mark numbers shall be recorded along with the number of plates in a
register as soon as the plates are received in the workshop. Whenever the
steel is received without any test certificate, 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 plates are of required specification, these
shall be processed for cutting.
7.9
Use of steel of any quality other than those mentioned above would
require the prior approval of the Engineer.
8.
Maintenance of Records by Fabricators

The records of fabrication shall be maintained in the registers as per the
formats given in the Annexure I.
9.
Manufacture
9.1
The whole work shall be representative of the highest class of

workmanship. The greatest accuracy shall be observed in the design,
manufacture and erection of every part of the work to ensure that all parts
will fit accurately together on erection. The tolerances in manufacture
shall be in accordance with as shown in Annexure II.
9.2
The Contractor shall maintain a master steel tape of approved make for
which he has obtained a certificate of accuracy from National Test House
or any Government recognised institutions competent to do so.
10.
Templates
The templates through out the work shall be of steel. The template shall
be used for marking of cutting material as well as profile machining for
girders.
11.
Flattening and Straightening
11.1 All steel materials, plates, bars and structurals shall have straight edges,
flat surfaces and be free from twist. If necessary, they shall be cold
straightened or flattened by pressure before being worked or assembled.
Pressure applied for straightening or flattening shall be such as it would
not injure the material. Adjacent surfaces or edges shall be in close
contact or at uniform distance throughout.
11.2 Flattening and straightening under hot condition shall not be carried out
unless authorized and approved by the Engineer.
12.
Planning and Shearing
12.1 Except where otherwise indicated, cutting of all plates and sections shall
be affected by shearing or sawing. All edges shall be clean, reasonably
square and true. Wherever possible the edges shall be cut in a shearing
machine, which will take the whole length of the plate in one cut.
49
12.2 If the Engineer finds it necessary, the cut edges shall be ground
afterwards.
12.3 Planning or machining of the edges or surface shall be carried out when so
specified in the drawings or where specifically ordered by the Engineer.
Where machining is specified, the plates or all sections shall be cut in the
first instance to such a size so as to permit not less than 3mm of metal
being removed from each sheared edge or end, in the case of plates or
sections of 12mm or less in thickness and not less than 6mm of metal
being removed in the case of plates and sections exceeding 12mm in
thickness.
12.4 The butting ends of all booms and struts where spliced shall be faced in an
end-milling machine after members have been completely fabricated. In
the case of compression members the face shall be machined so that the
faces are at right angle to the axis of the members and the joint when
made, will be in close contact throughout.
13.
Drilling and Sub-punching
13.1 All holes for High Strength Friction Grip bolts and erection bolts shall be
drilled. Diameter of holes for HSFG bolts shall be 2mm larger than the
nominal diameter of bolts. For erection bolts, hole diameter shall be
1.5mm larger than the nominal bolt diameter up to 25mm and 2mm larger
for bolts having nominal diameter more than 25mm.
13.2 Holes for turned bolts, should be 1mm under drilled in shop and should be
reamed at site to suit the diameter of turned bolt.
13.3 Where the number of thicknesses to be riveted exceeds three or the total
thickness is 90mm or more, the rivet holes, unless they have been drilled
through steel-bushed jigs, shall be drilled out in place 3mm all round, after
assembling. In such cases the work shall be thoroughly bolted together.
13.4 The steel bushes shall be case hardened by an approved process and
checked for diameter after the heat-treatment. The bores of bushes shall
initially have a tolerance of - 0mm, 0.1mm. The tolerance shall be checked
from time to time and when the bores exceed a tolerance of, -0mm,
+0.4mm, the bushes shall be rejected. For this purpose, go and no-go
gauges are to be used. Tolerances for checking jigs from master plates
shall be +0mm-0.13mm.
13.5 The work shall be taken apart after drilling and all burrs left by the drill
and the sharp edges of all the rivet holes completely removed.
14.
Parts in Contact
14.1 All steel work intended to be riveted or bolted together shall be in contact
over the whole surface.
14.2 Drifts as shown in Fig. 2 may be used for drawing light members into
position but their use on heavy members should be restricted to securing
them in their correct positions. In no case, shall drifting be allowed to such
an extent that holes are distorted.
50
14.3 Drifting to enlarge un-faired holes is prohibited. The holes that will have to
be enlarged to admit rivets should be reamed provided the Engineer
permits such reaming after satisfying himself about the extent of
inaccuracy and the effect of reaming on the soundness of the structure.
The Purchaser retains the right to reject all steel work if the holes are not
properly matched.
15.
Making of Joints
15.1 Cleaning of permanent contact surfaces:- Surfaces which will have

permanent contact shall be removed of paints and mill scale down to bare
metal, clean and dried and immediately a coating of red lead to IS: 102
shall be applied. Care shall be taken to see that all burrs are removed and
no surface defects exist before the parts are assembled.
15.2 Surface preparation for connections using HSFG bolt must conform to IS:
4000 to attain a slip factor of 0.35.
15.3 Bolting and Drifting: - Only barrel drifts as per Fig. 2 shall be used in
erection. They may be used for drawing light members into position; but
their use on heavy members shall be restricted to securing them in their
correct position. Any apparent error in shop work, which prevents the
assembling and fitting up of the parts by the proper use of these drifts,
shall be investigated immediately. As all work is rigidly inspected in the
manufacturers work before dispatch, these difficulties should not arise and
the cause should be first sought in the use of incorrect components or the
transposition of a correct part. It is usually important that parts should be
correctly handled. Should error still persist, the matter shall be
immediately reported to the Engineer who will decide what action is to be
taken. No reaming shall be undertaken without the written authority of the
Engineer, except for the under drilled holes meant for turned bolts. If
approved, the Contractor shall supply, at his own expense, any special
rivets that may be required. Copies of all correspondence relative to the
recourse to reaming and the use of over-size rivets shall invariably be sent
by the Engineer for information to the inspectorate concerned.
15.4 Joints shall normally be made by filling not less than 70% of the holes with
service bolts and barrel drifts in the ratio of four to one. The service bolts
are to be fully tightened up as soon as the joint is assembled.
15.5 In cases where the joints have to withstand stresses arising from special
method of erection, provision is to be made to take the whole stress that
will or may occur. Cylindrical drifts and turned bolts shall be used to
withstand such stresses and no reliance is to be placed on the service
bolts for this purpose. Upto maximum of 40% of the holes of each member
of the joint are to be filled with drifts and balance of strength required is to
be attained with turn bolts. The position and number of the drifts and bolts
will be intimated by the Engineer. The condition of clause 20.1 must be
observed and the bolt fully tightened up as soon as the joint is made.
15.6 It shall be ensured that when in position, the girder has the camber as per
drawing.
51
15.7 Emergency Jointing:- In the event of an emergency arising such as the

staging is in danger of being carried away by floods before the riveting can
be completed, the joints shall be made secure by filling 40% of the holes
with cylindrical drifts and equal number with service bolts fully tightened .
(Ref. Clause 14 & 15)

16.
Erection and Equipment
16.1 The Contractor shall provide at his own cost all tools, machinery,
equipment and erection material necessary for the expeditious execution
of the work and shall erect the structural steel and iron work, in every
respect as covered by the contract and in accordance with the drawings
and specifications.
16.3 Before starting the work, the Contractor shall advise the Engineer fully as
to the method he proposes to follow and the amount and character of
equipment he proposes to use, which shall be subjected to the approval of
the Engineer. The approval of the Engineer shall not be considered as
relieving the Contractor of the responsibility for the safety of his method or
equipment or from carrying the work in full accordance with the drawings
and specifications.
16.4 All temporary work shall be properly designed and substantially
constructed for the loads, which it will be called upon to support. Adequate
allowance and provision of a lateral forces and wind loads shall be made
according to local conditions and ensure that support shall not settle
during erection.
16.5 Careful and periodical inspection of plants shall be made by the Contractor
to ensure that all tackle, ropes, chains and other important lifting gear and
machinery are in good order and fit for service and well upto the capacity
for which they are required.
16.6
When chains are used for lashing, care must be taken to protect the
edges of members to avoid the marking and distortion otherwise caused.
16.7 Span erected upon staging shall be supported upon suitable blocks, which
shall ensure that the girders shall be at the correct elevation and
52
alignment when completed. If other methods of erection be adopted

where staging in situ is not employed, special means shall be used to
ensure this.
16.8 The method used for lifting and slinging flexible members shall be brought
to the notice of the Engineer and shall be subject to his approval.
16.9 Temporary bracing shall be provided to take care of stresses from erection
equipment or other loads carried during erection.
16.10 All holes necessary for erection bolts shall be plugged fully after successful
completion of erection.
17.
Bed Plates
Bed plates shall be set to required level and fixed accurately in position by giving
full and even bearing by setting them on a layer of cement sand and cast
iron chips as approved and directed by the Engineer.
18.
Rivets and Riveting
18.1 The dimensions on the drawings referred to the diameters of the rivet
holes and their finished rivets. The rivet holes shall be 1.5 mm greater
than the diameter of the rivet bars used. The rivets shall be made to IS:
1929. The shanks of the undriven rivets shall be made of a length
sufficient to fill the holes thoroughly and form the head. The clearance i.e.
the difference in diameter between the rivets measured under head before
being heated and the rivet hole shall not be less than 0.75mm. Before
riveting is commenced, all works shall be properly bolted so that the
sections riveted are in close contact throughout. Rivets shall completely fill
the holes and shall be machine driven by means of pressure or percussion
riveters of approved design.
18.2 All rivets shall be properly heated to straw heat for the full length of the
shank, firmly backed and closed. The head of the rivet, particularly in long
rivets, shall be heated more than the point and in no case shall the point
be heated, more than the head. Sparking or burnt rivets shall not be used.
Where it is impossible to back up by normal method of holding up, double
gunning may be resorted to. Alternatively pneumatic holding device may
be used.
18.3 Gauges for rivet dimensions and contours shall be provided by the
Contractor for the use of the Inspecting Officer.
18.4 Rivets when driven shall completely fill the holes, have the heads
concentric with the shanks and shall be in full contact with the surface.
Driven rivets when struck sharply on the head with the 110-gm. rivet
testing hammer, shall be free from movement or vibration.
18.5 While riveting built-up members great care should be exercised to ensure
that the set of holes for field rivets in each flange of the built-up member,
is aligned dead-square in relation to that in the other flange and not
aborrated. Use of assembly fixtures shall be made to ensure this.
53
18.6 All loose and burnt rivets and rivets with cracks, badly formed, eccentric or
deficient heads shall be cut out and replaced. Permissible deviation of
driven rivets shall be as per Annexure III. Rivets shall also be cut out
when required for the examination of the work. Actual method of cutting
out shall be approved by the Engineer. Recapping and caulking shall in no
circumstances be resorted to.
18.7 Riveting shall not be started until such time as the Engineer has personally
satisfied himself that the alignment of the girders is correct, the verticals
plumb laterally, the camber according to that shown on the camber
diagram with camber jacks screwed tight, all the joints and cover plates
well up, service bolts tight and field rivet holes coinciding. Special care
should be taken that service bolts are frequently re-tightened as the
riveting proceeds.
18.8 All field rivets shall be tested as directed by the Engineer.
18.9 Where practicable all riveting shall be done by pneumatic or hydraulic
riveting machine. The working pressure to be employed when using
pneumatic or hydraulic tools shall be approved by the Engineer. Hand
riveting shall only be done when sanctioned by the Engineer. In such
cases, means shall be adopted to ensure the rivets being used in their
entire length so as to fill the rivet holes completely, the snap being used
only to give the correct form of head.
18.10
When all the rivets of joints have been finally passed, they shall be
painted as under:
a) One coat of ready mixed zinc chrome primer to IS: 104 followed by one
coat of ready mixed paint red oxide zinc chrome primer to IS:1874
b) Finishing coat as per clause 39
19.
Field Rivets, Bolts, Nuts and Service Accessories
19.1 The work is to include supply of all units bolts, nuts, washers etc. required
to complete erection at site with an allowance for wastage etc. of 12.5% of
the net number of field rivets, bolts and washers required subject to a
minimum number of five in each item.
19.2 The Contractor shall be responsible for supplying site rivets of approved
length. The length of such rivets shall be verified by snapping a few rivets
of each length in the presence of the Inspecting Officer. In the case of
rivets with long grips (with grip exceeding 6 times the diameter) specimen
rivets on the test piece shall be cut to see if the holes are totally filled
even though the rivets are tight under the usual hammer tests.
19.3 Black hexagonal bolts (Service bolts) with nuts and ordinary platters
washers and drifts for use in the erection of the work shall also be supplied
at 60% (45% bolts and 15% drifts) of the number of field rivets per span in
each size (this includes wastage). The Purchaser may however, specify a
reduction in the quantities of service bolts etc. if more than one span of
each type is ordered.
54
20.
Smithed Work
20.1 All joggles shall be performed by pressure. Craned sections or knees can
be formed by forging or by gas cutting and welding by any approved
electric arc process. Any bending, forging, cutting or welding shall be
carried out in such a manner as not to impair the strength in the metal.
Forging shall be annealed as indicated in the drawing.
20.2 If drop forging through dies is resorted to, excessive forging in one
operation shall be avoided. Where necessary, a series of intermediate
stage dies shall be manufactured and used.
21.
Welding
21.1 Welded construction work shall be carried out generally in accordance with
the specifications given in the following paragraphs.
21.2 All welds should be done by submerged-arc welding process either fully
automatic or semi-automatic. Carbon dioxide welding or manual metal-arc
welding may be done only for welds where access of the locations of weld
do not permit automatic or semi-automatic welding.
21.3 Except for special types of edge preparation, such as single and double U
single and double J the fusion edges of all the plates which are to be
joined by welding may be prepared by using mechanically controlled
automatic flame cutting equipment and then ground to a smooth finish.
Special edge preparation should be made by machining or gouging.
21.4 Welding procedures: - The welding procedure shall be such as to avoid
distortion and minimize residual shrinkage stresses. Properly designed jigs
should be used for assembly. The welding techniques and sequence,
quality, size of electrodes, voltage and current required shall be as
prescribed by manufacturers of the material and welding equipment. The
Contractor should submit full details of welding procedure in proforma
given at Annexure V.
21.5 All welding shall be continuous fillet except where otherwise shown and of
thickness as specified in the approved drawing
21.5 Site welding should not be undertaken except in special circumstances
with the approval of the Engineer. Site welding should be confined to
connections having low stresses, secondary members, bracings etc.
22.
Sequence of Welding and Weld Pass
22.1 For fabrication of welded composite girders, channel shear connectors

shall be welded on top flange plate prior to assembly of I-section. This
facilitates correction of any distortion of flange plate developed during the
welding of channel shear connectors.
22.2 In making a typical I-section four fillet welds are to be made. The welding
sequence to be followed is indicated by number 1 to 4 as shown in the
Fig. 3.
55
22.3 Whenever a square butt weld in a 10 or 12mm thick plate is required to be

made, the sequence to be adopted is shown in Fig. 3.
23.
(Ref. Clause 22)

Erection in Contractors Works
The work shall be temporarily erected complete at the Contractors Works
for inspection by the Engineer, with the exception of such riveting as has
to be done at site, so that accuracy of fit and perfection of workmanship
may be assured. The work shall be put together with sufficient numbers of
parallel drifts or turned bolts or both to bring the pieces into place. When
so erected all holes left to be filled at site shall be so fair that a parallel
gauge turned to a diameter 0.8mm less than that of the hole, of a length
equal to the depth of the hole, can be passed through them without
difficulty. No drift shall be used anywhere in the work larger in any part
than the hole in which it is to be driven. Holes for turned bolts, which have
been 1 mm under drilled in shop, should be reamed at site by the erecting
agency.
24.
Camber
24.1 In order to ensure that the fabrication and erection of main girders shall be
such as to eliminate secondary stresses in the loaded span, the amount
camber shall be as specified in the approved drawing.
24.8 Frequent checks shall be made of the camber of girders during erection
and care taken to see that the camber as per drawing is obtained when
the girder is completely assembled. When span is supported on ends and
intermediate supports are removed the dead load camber shall be
56
recorded. This will provide the reference to compare the camber checked
during technical inspection to ascertain the loss of camber.
25.
Testing
25.1 The Engineer shall be empowered, at his discretion to make or have made
under the supervision, any of the tests specified in the specifications
mentioned herein in addition to such other tests as he may consider
necessary, at any time upto the completion of the contract and to such an
extent as he may think necessary to determine the quality of all materials
used therein. In doing so, he shall be at liberty under any reasonable
procedure, he may think fit to select, identify, have cut-off and take
possession of test pieces from the material either before, during or after
its being worked up into the finished product.
25.2 He shall also be empowered to call for a duly authenticated series of
mechanical tests to be obtained from the maker for this materials used in
the work and to accept the same in lieu of other tests to the extent he
deems fit. The Contractor shall supply the material required for the test
pieces and shall also prepare the test pieces necessary.
25.3 The test shall be carried out by the Contractor, for which Contractor shall
provide all facilities including supply of labour and plant. Engineer may at
his discretion direct the Contractor to despatch such tests pieces as he
may require to the National Test House or elsewhere as he may think fit for
such testing purposes.
26.
Check on Tests Made at Contractors Work
26.1 The Engineer may at his discretion check test results obtained at
Contractors work by independent tests.
26.2 The Engineer shall at all times be empowered to examine and check the
working of the Contractors plant before and after using it. Should the
Contractors plant be found, in the Engineers opinion, unreliable, he is
empowered to cancel any tests already carried out in this contract and
have these tests carried out at any National Test House or elsewhere, as
he may think fit.
27.
Analysis
The Contractor shall supply authenticated copies of analysis of any
materials used in the contract when required to do so by the Engineer who
shall be empowered to accept them to the extent he thinks fit. In addition
to the above samples may be subjected to complete analysis at the
National Test House or elsewhere as the Engineer may determine; the cost
of the same to be borne by the Contractor.
28.
Inspection - General
The Engineer shall have free access to the works of the Contractor at all
reasonable times and shall be at liberty to inspect the process of
manufacture at any such time and to reject in whole or part, any work or
material that does not conform to the provisions of this Specification and
may order the same to be removed, replaced or altered at the expense of
57
the Contractor. All gauges and templates necessary and required by the
Engineer for proper inspection must be supplied by the Contractor free of
cost.
29.
Oiling, Painting and Metallising
29.1 No part of the work shall be painted or coated, packed or dispatched, until
it has been finally inspected and approved by the Engineer. Dry Film
Thickness shall be measured by elcometer or any other method approved
by the Engineer.
29.2 When so specified by the Engineer, the whole of the work except
machined surfaces shall be given protective coating using one of the
systems of painting or metallising given in clauses 29.2.1 to 29.2.4. Prior
to the application of protective coating, the surface of work shall be
carefully prepared removing mill-scale, rust, etc. using wire brushes, sand
or grit blasting as stipulated and approved by the Engineer.
29.2.1
For locations where the girders are subjected to salt spray such as
in close vicinity of the sea and/or over creeks etc. the protective coating
by metallising with sprayed aluminium as given in the Annexure IV
followed by painting as per painting schedule given below may be applied:
(i) One coat of etch primer to IS: 5666.
(ii)
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.
iii) Two coats of aluminium paint to IS:2329 brushing or spraying as
required. One coat shall be applied before the fabricated steel work
leaves the shop. After the steel work is erected at site, the second
finishing coat shall be applied after touching up the primer and the
finishing coat if damaged in transit.
29.2.2
For locations where girders are exposed to corrosive environment,
protective coating by metallising followed by painting as mentioned in
clause 29.2.1 or by painting using epoxy based paints as per the following
painting schedule may be applied:
i) Surface Preparation
a) Remove oil/grease from the metal surface by using petroleum
hydrocarbon solvent to IS: 1745.
b) Prepare the surface by sand or grit blasting to Sa 2-1/2 to IS: 9954
i.e. near white metallic surface.
(ii)
Painting
(a)
Primer Coat
Apply by brush/airless spray two coats of Epoxy Zinc Phosphate to
minimum 60 microns dry film thickness (DFT) giving sufficient time
gap between two coats to enable the first coat of primer to hard dry.
(b) Intermediate Coat
Apply by brush/ airless spray one coat of Epoxy Micaceous Iron
Oxide to minimum 100 microns DFT and allow it to hard dry.
58
(c) Finishing Coat

Apply by brush/airless spray two coats of polyurethane aluminium
finishing to polyurethane red oxide (red oxide to ISO 446 as per IS:5
to minimum 40 microns DFT giving sufficient time gap between two
coats to enable the first coat to hard dry. The finishing coats to be
applied in shop and touched after erection if necessary.
29.2.3
For other locations protective coating by painting as per painting
schedule given below may be applied:
a) Primer coat
One heavy coat of ready mixed paint red lead priming to IS: 102.
or
One coat of ready mixed paint zinc chrome priming to IS: 104 followed
by one coat of ready mixed paint red oxide zinc chrome priming to
IS:2074.
or
Two coats of zinc chromate red oxide primer to IRS:P-31.
b) Finishing coat
Two finishing coats of red oxide paint to IS: 123 or of any other
approved paint shall be applied over the primer coats. One coat shall
be applied before the fabricated steel work leaves the shop. After the
steel work is erected at site, the second finishing coat shall be applied
after touching up the primer and the finishing coat if damaged in
transit
29.3 Surfaces which are inaccessible for cleaning and painting after fabrication
shall be applied one heavy coat of red lead primer to IS: 102 before being
assembled for riveting/welding.
29.4 All rivets, bolts, nuts, washers etc. are to be thoroughly cleaned and
dipped into boiled linseed oil to IS: 77
29.5 All machined surfaces are to be well coated with a mixture of white lead to
IS: 34 and Mutton tallow to IS: 887.
29.6 For site painting the whole of the steel work shall be given the second
finishing coat after finally passing and after touching up the primer and
finishing coats if damaged in transit.
30.
Name Plate
A neat casting bearing the name of the Contractor, the place and year of
manufacture, drawing number and the standard of loading to be specified
by the Engineer shall be bolted conspicuously on each span. The drawing
of the nameplate shall be approved by the Engineer.
31.
Erection Mark
Every portion of the work shall be distinctly stenciled with paint with letter
size not less than 10 mm for guidance in the erection in the field, and
stamped with the letters specified in the drawings. In the case of non-
59
interchangeable work, the system of marking shall be in accordance with

the drawings prepared by the tenderer and approved by the Purchaser.
32.
Packing
32.1 All projecting plates or bars shall be kept in shape by timber or angle bars
spiked or bolted to them, and the ends of the chord lengths, end posts and
plate girders at their shipping joints shall be protected and stiffened so as
to prevent damage or distortion in transit as the Engineer may direct.
32.2 All threaded ends and machined surfaces are to be efficiently protected
against damage in transit. The parts shall be sent out in lengths
convenient for transport.
32.3 All straight bars and plates except small pieces are to be sent out in
convenient bundles temporarily riveted or bolted together or bound with
wrought iron or suitable wire as the Engineer may direct. All rivets, bolts,
nuts, washers, plates under 300 mm square and small articles generally
are to be packed separately for each span in cases each weighing, when
full, not more than 320 kg, or in strong petroleum casks, or in barrels
approved by the Engineer. If not entirely filled by the contents the space
left shall be closely packed with wood shaving or other suitable material.
Bolts and rivets of different sizes shall be separately packed in bags, each
bag having a label indicating its contents. A list of the contents shall be
placed in the top of each case or cask.
33.
Dispatch or Shipping Marks

Each package, case or bundle is to have clearly stenciled on it in good oil
paint the address as stated in the order of contract, gross and net weight
description of contents and such marks as may be required by the
Purchaser must be shown against each item in the invoice. The Contractor
is to provide necessary stencil plates for marking. Every piece of bundle
shall be marked and in the case of material (shipped to India) all cases or
casks shall be clearly cut or branded, not merely painted, with their net
and gross weights and with such shipping marks and other particulars as
the Engineer may direct and each bundle shall also have a metal label
securely attached with wire stamped with similar marks. The marking shall
be done with thick oil paint and in such a manner that it cannot be washed
off or obliterated.
34.
Loading
34.1 All trucks or wagons are to be loaded to as near their full capacity as is
consistent with safe transport. While loading the material in wagon, truck
or trailer, care should be taken that heavier material is loaded first and
lighter material is kept on top so that lighter material is not damaged due
to heavy weight. While transporting the material by road, adequate safety
precautions shall be taken as per extant instructions.
34.2 The Contractor shall apply all dunnage and lashing required to hold the
material securely in position free of charge.
60
34.3 While handling any girder or girder component it shall be ensured no

damage to material takes place in the form of dent/cut mark etc. Wooden
blocks, rubber pads shall be used to avoid direct contact between
materials to be handled and handling equipment.
35.
Rivets and Bolts Lists

The Contractor shall also supply, without charge, three complete lists of
the rivets, bolts, service bolts, washers and drifts required for erecting the
work at site, showing the parts of the work to which the various rivets and
bolts belong and having each item marked so as to indicate the particular
case in which it will be found.
36.
36.1 Any steel work the weight of which differs by more than 2.5% from the
calculated weight determined from the nominal weight of the sections
shall be liable to rejection.
36.2 For the purpose of payment the weight shall be calculated in accordance
with the nominal weight of the sections as specified on the approved
drawings. An addition in weight for welds and rivet heads, if not otherwise
specified in the schedule, shall be made as under:
a) 3% in case of purely riveted work; and
b) 1 % in case of purely welded or composite (riveted and welded)
work.
36.3 No separate payment shall be made for the items mentioned in clause 19.
36.5 In the event of a dispute arising as to the weight of a portion of steelwork,
a weighment shall be made in the presence of the Engineer.
37.
RATE
The contract unit rate for the complete steel girder portion of composite
shall include the cost of all material, labour, tools, plant and equipment
required for fabrication, connection, inspection, painting, temporary
erection and tests at the Contractors works, marking, packing and
delivery F.O.R. or C.I.F. and complete final erection as shown in the drawing
and as specified in these specifications.
61
Annexure I
(Ref. Clause 8)
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:
62
4. Drawing No. for the component:

Date of
inspection
Observation/
inspection
notes
2
Compliance
action
Initial of
Supervisor
In-charge
4
In the beginning of Register, a statement of jigs shall also be placed in the

following proforma:
Jig No.
Description
of Jig.
Shipping
mark of
the
component.
Dwg. No. as
per which jig
is
Inspecting
officials
approval
details
made/modifi
ed
4
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:Compone
nt
descriptio
n
Date of
riveting
Riveting
party
Number
and
nature of
defective
rivets
Number
of
defective
rivets
replaced
Initial of
Superviso
r
In-charge
After riveting, component has been inspected and defective rivets have
been replaced, the Supervisor In-charge of riveting 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
No.
Initial
of
Supervisor
offering
material
for
inspection
2
Inspectin
g officials
Remarks
Complian
ce action
Seal &
initial of
Inspectin
g official
Dispatch
and
consignee
details.
63
4)
INSPECTION NOTES AND COMPLIANCE REGISTER

This register shall be maintained for record of compliance action taken on
Inspection notes. In this register one copy of the inspection note received
from the Engineer 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
welding
Girder
component
and its Sl.
No.
Weld joint
description
Name of
welder/Tick
et No.
WPSS No.
followed
Welding
consumable
used
Electrod Flu
e
x
/ wire
6
Welding parameters
Curre
nt
(amp.)
Arc
Voltag
e
(volt)
Travel
Speed
(m/mi
n)
10
Weld
repai
r
detail
s
Run
on/Ru
n
off
tabs.
No.
if any
Radiograp
h
no. if any
Initial of
Supervis
or
Incharge.
11
12
13
14
The welding data record to be submitted to the Engineer while offering the
welded girders for inspection, shall be prepared based on the details recorded in
this register.
6)
Nam
e of
work
RADIOGRAPHIC INSPECTION REGISTER

Record of radiographic inspection of welded girders shall be maintained in
the register in the proforma given below:
Spa
n
No.
Gird
er
Part
Weld
joint
descryiption
Date of
radiographic
inspectio
n.
Radi
ograp
h
No.
Obse
rvatio
n
Resu
lt
Initial of
Supervis
or
Incharge.
7)
STATEMENT OF MATERIAL TEST CERTIFICATES
Name of Work _____________________________
Contract/Order No. ______________________
Span No. ______________________
64
Girder
componen
t
descriptio
n
and
identificati
on
No.
1
Type
and
Size of
rolled
section
Material
Test
Certifica
te
No.
Cast
No.
Steel
quantit
y as per
the test
certifica
te
Steel
Manufactu
rer/
Supplier
Initial of
Supervi
sor
Incharge
One page should be allotted for each span.

Annexure II
(Ref. Clause 9)
Manufacturing Tolerances
1.
Plate girders
Tolerances in mm
(a)
(b)
(c)
Overall length of the girder

Distance between centers of
bearings
Depth over angles
Notation
in the
Figure
No.1
(plus)
6
1
(minus)
3
1
a
b
(d)
Corner of flange angle to edge of

web at any place
(e)
Diagonal at either end of the

assembled span
(f)
Centers of intersection of
diagonals with girder flange
measured along the girder flange
(g)
Butting of compression ends

i)
Throughout
ii)
Locally
Butting edge at web splices
Straightness of girder bottom laid
on the ground and checked with
piano wire:
0
0
0
0.15
0.25
1
g
g
h
0
0
2
3
0
2
j
j
j
(h)
(i)
(i) Vertical plane

Convexity
Concavity
(ii) Horizontal plane
65
2.
Holes
(a) Between any two holes in group
(b)
(c)
(d)
Between holes of one group and

another
Edge distance
Distance of GO gauge open holes
in two or more thickness
0.5
0.5
0.5
0
0.5
0.8
x
Y
(On nominal diameter of hole)

3.
Special Fabrication Tolerances as applicable to Welded Plate
Girder
S. No. Description
Tolerances in mm
1.
Depth at the center of web
+2 to -1
2.
Flange out of square for compression
1/200 or 3 max
member and beams
From edge whichever is less
3.
Displacement of vertical axis of the web
2
with reference to flange
4.
Box width of member
0 to +3
5.
Verticality of stiffener or diaphragm out
2
of plumb
6.
Overall length of girder
-3 to + 6
7.
Depth of the girder at the ends
-1 to + 3
8.
Depth of the girder at the center of span
-1 to + 2
9.
Distance between center of bearings
-1 to + 1
10.
Diagonal at either end of assembled
-3 to+ 3
span
PLATE GIRDERS
66
Manufacturing Tolerances
Figure No. 1
67
Annexure III
(Ref. Clause 18.6)
68
Annexure IV
(Ref.Clause 29.2.1)
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 (microns).The
minimum local thickness, determined in accordance with procedure given
in clause 3.1 below, shall be not less than 110 (microns).
3.
Shop Painting
69
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.
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 gritblasted surface of the base metal prior to its being sprayed. The
thickness of the shim shall be measured by micrometer 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 cm 2,
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
70
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 re-spraying. 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.
71
Annexure IV
(Ref.Clause 29.2.1)
Proforma for Welding Procedure Specification Sheet
1.
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:
Welding Parameters:
:
:
:
Weld
Pass
No.
Electrod
es/
wire
dia.
(mm)
Curren
t
(amp)
Arc
Voltag
e
(volt)
Wire
feed
speed
(m/min
))
Travel
speed
(m/min
)
Electri
cal
stick
out
(mm)
Gas
flow
rate
(litre/mi
n.)
9.2
10.
11.
12.
13
14
15
16
17
18.
Welding sequence and technique:

(Give sketch showing sequence and direction of welding).
Provision of run in and run-off tabs:
Cleaning of weld bead before laying next weld bead:
Root preparation before welding other side of groove weld:
Preheating and inter pass temperature:
Peening
Post weld treatment:
Rectification of weld defects:
Inspection of weld.
Any other relevant details
Prepared by
Signature_____________________________
Designation __________________________
Date ________________________________
(for & on behalf of Fabricator).
72
2.
1.
3.
5.
7.
9.
10
11.1
11.3
Proforma for Welding Procedure Qualification Record

NAME AND ADDRESS OF FABRICATOR:
Description of weld joint:
2.
Welding procedure specification no:
Name of welder:
4.
Date of preparation of test piece:
Dimensions of test piece:
6.
Base Metal:
Welding Process:
8.
Welding position:
Welding Current: Type:
Polarity:
Weld joint design details:
11
Welding consumables:
Electrode/wire
Class:
11.2 Flux
Class:
Dia:
Type:
Brand:
Brand:
Shielding gas:
12.
Welding parameters:
Weld
pass
No.
Electro
de
wire
dia
(mm)
Curren
t
(amp)
Arc
voltag
e
(volt)
Wire
feed
speed
(m/min
.)
Travel
speed
(m/min
.)
Electri
cal
stick
out
(mm)
13.
14.
Shieldi
ng gas
flow
rate
(lit/min
.)
8
Preheating and interpass temperature:

Results of Qualification Tests:
Test
1
Non-destructive tests:
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 %
Guided bend test:
Root bend test
Face bend test
Side bend test
vii) Any other tests:
Specimen No.
2
Result
3
Signature _______________________
Designation ___________________
Date _________________________
(for & on behalf of Fabricator).
73

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TECHNICAL SPECIFICATIONS

STATE HIGHWAYS AUTHORITY OF JHARKHAND

The Technical Specifications contained herein shall be

The information given hereunder and provided elsewhere in these

General Climatic Conditions

The variation in daily temperature in this region is as under:

The range of relative humidity goes upto maximum of 37%.

PART-I: General Technical Specifications

Draft Detailed Project Report (Volume V: Technical Specifications)

PART-II: Special Technical Specifications

The following Clauses of General Technical Specifications i.e. the

The Additional Specifications comprise of specifications for particular

Where a particular clause or a part thereof in General Technical

When an amended/modified/added Clause supersedes a Clause or part

In case of any conflict or inconsistency between the provisions

In the absence of any definite provisions on any particular issue in the

Draft Detailed Project Report (Volume V: Technical Specifications)

SPECIAL TECHNICAL SPECIFICATIONS

AMENDMENTS/MODIFICATIONS/ADDITIONS TO EXISTING CLAUSES OF

Clause 102 DEFINITIONS

Delete first two sentences.

Replace whole of this clause with the following:

measures required by the various bodies to protect their services and

For coordinating the work of cutting of trees, shifting of utilities and

The contractor shall take all precautions for safeguarding the

Erecting sign boards at sensitive and residential locations

Borrow Pits for Embankment Construction

Control of Soil Erosion & Sedimentation

Precautions against Dust

Sanitation & Waste Disposal in Construction Camp

Contractor shall ensure that construction camps are located at a

permission of the Engineer and regulatory authority shall have to be

Substance Hazardous to Health

Delete the last sentence and add the following:

Typical drawings for temporary diversions in accordance with

Typical details of arrangements for construction under traffic

Special consideration shall be given in the preparation of the Traffic

2nd para of this clause shall read as under:

In case of eccentric widening of existing two lane to four lane, the

Delete this Clause and replace with:

Add the following at the end of this Clause:

This Clause shall read as under:

(d) Platform Scale - 300 kg capacity

with collar, base plate etc.

This Clause shall read as under:

This Clause shall read as under:

described in Clause 120.4 and maintenance of equipment including

Measurement for Payment

This Clause shall be deleted.

This clause shall be read as under:

The cost of provision of field laboratory including supply of laboratory

Delete the last sentence and replace with as under:

Clause 201.6.1 this clause may be read as under;

Draft Detailed Project Report (Volume V: Technical Specifications)

Measurement for Payment

Add the following items after item (vi):

and Guard posts

Delete the last sentence of the paragraph and replace with:

This Clause shall read as under:

"In works involving widening of existing pavements or providing paved

loosened or disturbed. If the existing pavement gets disturbed or

Filling for roadway embankments.